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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority to Korean Patent Application No. 10-2009-0119407 filed in the Korean Intellectual Property Office on Dec. 3, 2009, the entire contents of which is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a steer by wire apparatus. More particularly, the present invention relates to a steer by wire apparatus which controls a steering angle by converting a vertical rotation caused by a motor into a horizontal rotation.
2. Description of Related Art
Generally, a steering apparatus is an apparatus for controlling a moving direction of a vehicle. A driver rotates a steering wheel so as to change the moving direction to his intention. Such a steering apparatus is an important means for the driver to drive and control the vehicle.
According to the steering apparatus, if the driver rotates the steering wheel, torque generated by the rotation of the steering wheel is applied to a wheel.
Recently, a steer by wire (SBW) apparatus is used for steering a front wheel between the steering wheel and the front wheel.
Such a steer by wire apparatus includes a steering wheel which a driver directly handles for steering, a reaction motor mounted at one side of the steering wheel and supplying reaction torque according to a rotation of the steering wheel, an actuator connected to a tie rod and performing a steering operation, a sensing means detecting a change of torque, a steering angle, and a vehicle speed according to the rotation of the steering wheel, and an ECU operating the actuator and the reaction motor according to an electrical signal transmitted from the sensing means.
FIG. 5 is a schematic diagram showing movements of a tie rod according to a conventional steer by wire apparatus. As shown in FIG. 5 , a tie rod 3 is moved by operating L-shape levers 1 pivoted at a point P 1 through an actuator (not shown) according to a conventional steer by wire apparatus.
If the actuator inputs reciprocal motions to the L-shape lever 1 , the L-shape lever 1 pivots about the point P 1 and makes a tie rod inner point T 1 move to the left or to the right. Thereby, a steering angle of the wheel W is controlled.
According to a conventional SBW mechanism different from a conventional rack and pinion mechanism, the tie rod inner point T 1 moves forward or rearward as well as to the left or to the right. Therefore, geometry characteristic of the tie rod may change.
In addition, the L-shape levers 1 and the tie rod 3 are operated only by the actuator when steering the wheel. Therefore, performance on demand of the actuator and cost may increase. In addition, since an external force is transmitted to the actuator through the wheel, load and usage of current may increase.
The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY OF THE INVENTION
Various aspects of the present invention are directed to provide a steer by wire apparatus having advantages of optimizing capacity and size of a motor and preventing geometry characteristic from being changed as a consequence of controlling a steering angle through a coupling unit which converts a vertical rotation caused by a motor into a horizontal rotation.
In an aspect of the present invention, the steer by wire apparatus performing steering operation by turning a wheel to the left or to the right when a vehicle turns, may include a tie rod provided with one end pivotally connected to a knuckle of the wheel, a coupling unit rotatably mounted at a sub-frame of a vehicle body, connected to the other end of the tie rod, and converting rotation direction of torque from a first rotation direction to a second rotation direction which is substantially perpendicular to the first rotation direction so as to slidably move the tie rod from the coupling unit and control a steering angle of the wheel, and a motor unit fixed to the sub-frame and supplying the torque to the coupling unit according to a control signal of a vehicle ECU, the rotation direction of the torque being the same as the first rotation direction or being opposite to the first rotation direction.
The coupling unit may include a first rotation shaft rotatably mounted on the sub-frame through a bearing device, and receiving the torque from the motor unit, a second rotation shaft substantially perpendicularly disposed to the first rotation shaft, rotatably mounted on the sub-frame through a bearing device, wherein the other end of the tie rod is slidably connected to the second rotation shaft, and a plurality of couplers engaging the first rotation shaft with the second rotation shaft.
The first and second rotation shafts may have a cylindrical shape, a plurality of first insert holes is formed at one surface portion of the first rotation shaft with a predetermined depth, and a plurality of second insert holes corresponding to the plurality of first insert holes is formed with a predetermined depth at one surface portion of the second rotation shaft close to the one surface portion of the first rotation shaft
The first insert holes may be formed at the one surface portion of the first rotation shaft with a distance therebetween along a circumferential direction thereof, wherein the first insert holes are formed with an equal distance from a rotation center of the first rotation shaft.
The second insert holes may be formed at the one surface portion of the second rotation shaft close to the one surface portion of the first rotation shaft with a distance therebetween along a circumferential direction thereof, wherein the second insert holes are formed with an equal distance from a rotation center of the second rotation shaft.
Each coupler may have one end slidably and rotatably inserted in each first insert hole and the other end thereof slidably and rotatably inserted in each corresponding second insert hole.
Each coupler may have a shape (right-angle inverted L shape), the one end of each coupler is inserted in each first insert hole with a different depth, and the other end of each coupler is inserted in each corresponding second insert hole with a different depth.
The one end of each coupler may be slid in each first insert hole when each first insert hole is rotated by the first rotation shaft, and each second insert hole is moved by a slide of the other end of each coupler in each second insert hole such that the torque of the first rotation shaft is transmitted to the second rotation shaft by the coupler.
The other end of the second rotation shaft may be connected to the tie rod through a ball screw to move the tie rod slidably.
The motor unit may include a drive motor fixedly mounted at the sub-frame and provided with a rotation shaft, a driving pulley fixedly mounted at the rotation shaft of the drive motor, a driven pulley fixedly mounted at the other end of the first rotation shaft, and a driving belt connecting the driving pulley with the driven pulley, wherein the drive motor is a motor which can control a rotation speed and a rotating direction thereof according to the control signal of the vehicle ECU.
The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a steer by wire apparatus according to an exemplary embodiment of the present invention.
FIG. 2 is a partial enlarged view of FIG. 1 .
FIG. 3 is a top plan view of a steer by wire apparatus according to an exemplary embodiment of the present invention.
FIG. 4 is a schematic diagram showing an operation of a steer by wire apparatus according to an exemplary embodiment of the present invention.
FIG. 5 is a schematic diagram showing movements of a tie rod according to a conventional steer by wire apparatus.
It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
An exemplary embodiment of the present invention will hereinafter be described in detail with reference to the accompanying drawings.
FIG. 1 is a perspective view of a steer by wire apparatus according to an exemplary embodiment of the present invention, FIG. 2 is a partial enlarged view of FIG. 1 , and FIG. 3 is a top plan view of a steer by wire apparatus according to an exemplary embodiment of the present invention.
Referring to the drawings, a steer by wire apparatus 100 according to an exemplary embodiment of the present invention controls a steering angle through a coupling unit 200 which converts a vertical rotation caused by a motor into a horizontal rotation. Thereby, capacity and size of the motor may be optimized and geometry characteristic may not be changed.
For this purposes, the steer by wire apparatus 100 according to an exemplary embodiment of the present invention performs steering operation by turning a wheel to the left or to the right when a vehicle turns. As shown in FIG. 1 , the steer by wire apparatus 100 includes a tie rod 110 , a coupling unit 200 , and a motor unit 300 .
The tie rod 110 is provided with one end connected to a knuckle 101 of the wheel W through a ball joint 103 .
According to the present exemplary embodiment, the coupling unit 200 is rotatably mounted at a sub-frame 105 of a vehicle body and is connected to the other end of the tie rod 110 . The coupling unit 200 changes a direction of torque from the vertical direction to the horizontal direction, and moves the tie rod 110 so as to control the steering angle of the wheel W.
Herein, the coupling unit 200 , as shown in FIG. 2 and FIG. 3 , includes a first rotation shaft 210 , a second rotation shaft 220 , and a coupler 230 , and each component will be described in detail.
According to the present exemplary embodiment, the first rotation shaft 210 is rotatably mounted on the sub-frame 105 through bearing device 120 , and receives the torque from the motor unit 300 .
The second rotation shaft 220 is disposed vertically to the first rotation shaft 210 , is mounted at the sub-frame 105 through bearing device 120 , and is connected to the other end of the tie rod 110 .
The second rotation shaft 220 is connected to the tie rod 110 through a ball screw 111 .
Herein, the first rotation shaft 210 has a cylindrical shape and is provided with a plurality of first insert holes 211 formed at one surface portion thereof. The second rotation shaft 220 is provided with a plurality of second insert holes 221 corresponding to the first insert holes 211 formed at one surface portion thereof close to the one surface portion of the first rotation shaft 210 .
The first insert holes 211 are formed at the one surface portion of the first rotation shaft 210 with distances therebetween along a circumferential direction thereof. The second insert holes 221 corresponding to the first insert holes 211 are formed at the one surface portion of the second rotation shaft 220 with distances therebetween along a circumferential direction thereof.
In this specification, it is exemplarily shown that four first and second insert holes 211 and 221 are formed respectively at the first rotation shaft 210 and the second rotation shaft 220 with a central angle of 90°.
Meanwhile, the bearing device 120 includes a mounting block 121 mounted on the sub-frame 105 and a bearing 123 .
In addition a plurality of couplers 230 is provided and each coupler 230 connects the first rotation shaft 210 with the second rotation shaft 220 .
Herein, one end of each coupler 230 is slidably and rotatably inserted in each first insert hole 211 , and the other end of each coupler 230 is slidably and rotatably inserted in each second insert hole 221 .
Each coupler 230 has a shape, and the one end of each coupler 230 is inserted in each first insert hole 211 with a different depth. In addition, the other end of each coupler 230 is inserted in each second insert hole 221 with a different depth.
According to the present exemplary embodiment, the one end of each coupler 230 is slid in each first insert hole 211 when each first insert hole 211 is moved by a rotation of the first rotation shaft 210 .
Accordingly, the other end of each coupler 230 is slid in each second insert hole 221 and each second insert hole 221 is rotated by a slide of each coupler 230 . Therefore, the torque of the first rotation shaft 210 is transmitted to the second rotation shaft 220 through each coupler 230 .
In addition, the motor unit 300 is mounted at the sub-frame and supplies the torque to the coupling unit 200 according to a control signal of a vehicle ECU 107 . The rotation direction of the torque is positive or negative in the vertical rotation direction.
The motor unit 300 includes a drive motor 310 , a driving pulley 320 , a driven pulley 330 , and a driving belt 340 .
The drive motor 310 is fixedly mounted at the sub-frame 105 .
The drive motor 310 may be a motor which can control a rotation speed and a rotating direction thereof according to the control signal of the vehicle ECU 107 .
According to the present exemplary embodiment, the driving pulley 320 is mounted at a rotation shaft 311 of the drive motor 310 , and the driven pulley 330 is mounted at the other end of the first rotation shaft 210 .
In addition, the driving belt 340 connects the driving pulley 320 with the driven pulley 330 .
That is, the motor unit 300 operates the drive motor 310 according to the control signal of the vehicle ECU 107 and rotates the driving pulley 320 . Then, the torque of the driving pulley 320 is transmitted to the driven pulley 330 through the driving belt 340 , and the first rotation shaft 210 is rotated.
An operation of a steer by wire apparatus according to an exemplary embodiment of the present invention will hereinafter be described in detail.
FIG. 4 is a schematic diagram showing an operation of a steer by wire apparatus according to an exemplary embodiment of the present invention.
When a vehicle turns to the left as shown in S 1 of FIG. 4 , the drive motor 310 rotates counterclockwise according to the control signal of the vehicle ECU 107 .
The driving pulley 320 transmits the torque of the drive motor 310 to the driven pulley 330 through the driving belt 340 , and the first rotation shaft 210 rotates counterclockwise.
If the first rotation shaft 210 rotates counterclockwise, the first insert holes 211 rotates counterclockwise and the one end of each coupler 230 also rotates counterclockwise by the first insert holes 211 . Therefore, the one end of each coupler 230 slides in each first insert hole 211 .
Simultaneously, the other end of each coupler 230 rotates the second insert holes 221 counterclockwise and slides in each second insert hole 221 .
As a result, the second rotation shaft 220 rotates counterclockwise by the first rotation shaft 210 and the couplers 230 .
At this time, the tie rod 110 moves from the second rotation shaft 220 to the wheel W by the ball screw 111 , and the wheel W turns to the left.
On the contrary, when the vehicle turns to the right as shown in S 2 of FIG. 4 , the drive motor 310 rotates clockwise according to the control signal of the vehicle ECU 107 .
The driving pulley 320 transmits the torque of the drive motor 310 to the driven pulley 330 through the driving belt 340 , and the first rotation shaft 210 rotates clockwise.
If the first rotation shaft 210 rotates clockwise, the first insert holes 211 rotates clockwise and the one end of each coupler 230 also rotates clockwise by the first insert holes 211 . Therefore, the one end of each coupler 230 slides in each first insert hole 211 .
Simultaneously, the other end of each coupler 230 rotates the second insert holes 221 clockwise and slides in each second insert hole 221 .
As a result, the second rotation shaft 220 rotates clockwise by the first rotation shaft 210 and the couplers 230 . At this time, the tie rod 110 moves from the wheel W to the second rotation shaft 220 by the ball screw 111 , and the wheel W turns to the right.
That is, the coupling unit 200 transmits the torque of the first rotation shaft 210 to the second rotation shaft 220 through the rotation and the slide of both ends of the coupler 230 .
The tie rod 110 receives the torque of the motor unit 300 and changes the steering angle of the wheel W by moving toward or away from the second rotation shaft 220 .
Therefore, according to an exemplary embodiment of the present invention, capacity and size of a motor may be optimized and changes in geometry characteristic may be prevented by controlling the steering angle through the coupling unit 200 which can convert the vertical rotation caused by the motor into the horizontal rotation.
In addition, the steer by wire apparatus according to an exemplary embodiment of the present invention may have simple structures, may reduce cost by controlling the steering angle through the torque, and may prevent excessive load from being applied to the motor by cancelling the external load through the driving belt.
For convenience in explanation and accurate definition in the appended claims, the terms “upper”, “lower”, “inner” and “outer” are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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A steer by wire apparatus performing steering operation by turning a wheel when a vehicle turns, may include a tie rod provided with one end pivotally connected to a knuckle of the wheel, a coupling unit rotatably mounted at a sub-frame of a vehicle body, connected to the other end of the tie rod, and converting rotation direction of torque from a first rotation direction to a second rotation direction which is substantially perpendicular to the first rotation direction so as to slidably move the tie rod from the coupling unit and control a steering angle of the wheel, and a motor unit fixed to the sub-frame and supplying the torque to the coupling unit according to a control signal of a vehicle ECU, the rotation direction of the torque being the same as the first rotation direction or being opposite to the first rotation direction.
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This application is a continuation-in-part of previously filed application, Ser. No. 941,769, filed Dec. 15, 1986, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to apparatus and methods for suctioning body fluids. More particularly, it relates to apparatus and methods for reducing the likelihood of contamination and infection during the collection of fluids from body cavities of human and animal subjects by suctioning fluids and disposing of or reusing those fluids without exposing the apparatus, the subjects or the collected fluids to potential sources of contamination and infection.
In modern medical practice it is often necessary or desirable to initiate drainage from body cavities in patients and to collect and contain these body fluids. In such situations, it is essential to prevent undesirable microorganisms from gaining access to both the drained cavity and to the collecting reservoir. It is also necessary to prevent undesirable microorganisms from gaining access to the collected fluids when those fluids are to be reused rather than discarded. By enclosing and preventing contamination of the collecting reservoir, the likelihood of retrograde contamination of the patient and cross contamination of the patients and hospital personnel is greatly reduced.
Unfortunately, conventional, commercially available, drainage devices are a prime source of infection in catheterized patients. For example, in the area of bladder drainage, a large proportion of catheterized patients suffer from urinary tract infections attributable to contaminated drainage devices. In most cases, the drainage collection device itself becomes contaminated in use and infection then ascends in a retrograde manner from the drainage collection device to the patient via the drainage catheter. Such retrograde infection from contaminated drainage or infusion devices has been observed, for example, in patients undergoing urinary, wound, biliary, gastro-intestinal drainage, peritoneal dialysis, and hyperalimentation treatment. See, e.g. E. M. Goldberg, et al., "Peritoneal Dialysis", Dialysis and Transplantation, June/July 1975, Vol. 4 #4; J. H. Isaccs, et al., "Foley Catheter Drainage Systems and Bladder Damage", Surgery, Gynecology & Obstetrics, May 1971, p.889; R. E. Desautels, "The Causes of Catheter-Induced Urinary Infections and Their Prevention", J. Urology, 1969, 101:757: R. E. Desautels, et al. "Technical Advances in the Prevention of Urinary Tract Infection", J. Urology, 1962, 87:487; R. E. Desautels, "Aseptic Management of Catheter Drainage", New Eng. J. Med., 1960, 263:189; E. H. Kass, et al., "Prevention of Infection of Urinary Tract in Presence of Indwelling Catheters", J.A.M.A. 1959, 169:1181; and E. H. Kass, et al. "Entry of Bacteria into the Urinary Tracts of Patients with Inlying Catheters" New Eng. J. Med., 1957, 256:556.
Contamination of drainage collection devices often arises from containers or reservoirs designed to be filled repeatedly with drained body fluid and regularly emptied so suction can be resumed. For example, the evacuator described by McElhenny in U.S. Pat. No. 3,115,138 includes a capped fluid outlet. After the evacuator becomes filled it is emptied for reuse by removing the cap and expelling collected fluid via the outlet. During this operation the interior of the evacuator is exposed to the atmosphere and contamination of the evacuator will result.
Efforts have been made to reduce the contamination of drainage devices during periodic emptying. For example, U.S. Pat. Nos. 3,779,243 and 3,774,611 disclose evacuators which employ a special valve over the fluid outlet. This valve operates to close the outlet at all times except for the time when fluid is actually being purged from the evacuator. Such evacuators may succeed in reducing the contamination brought on by purging. However, since these evacuators must be periodically opened for purging, they are exposed to the surrounding atmosphere and will become contaminated and therefore a potential source of infection.
U.S. Pat. No. 4,435,171 for Apparatus to Be Worn And Method For Removing Fluid From A Living Subject, describes a closed, gravity drainage system designed to minimize retrograde introduction of microorganisms into a patient. This system, however, has no provision for suction drainage.
U.S. Pat. No. 4,265,243 describes one very complex liquid collection receptacle assembly in which urine is drained from a patient's bladder under the force of gravity into an intermediate collection chamber from which it is emptied into a larger receptacle either by siphoning or by squeezing the first chamber to force the urine from it. This apparatus, unfortunately, is most complex, and, as a gravity system, lacks the ability to suction fluid from the bladder or any other body cavity.
To the best of the present inventor's knowledge, no commercially available so-called "closed drainage" system is a "truly" closed drainage system. All current commercially available drainage systems were originally developed to avoid open drainage by enclosing the drainage through the catheter into a receptacle. The receptacle in all such systems is periodically emptied, opening the system up to potential contamination.
In modern medical practice, it is often desirable to efficiently collect blood, gastric, biliary, pancreatic, small bowel (succus entericus) and other bodily fluids into safe, economical containers, so that the fluids can be reused and returned if and when needed. In fact, with the widespread concern such diseases as acquired immune deficiency syndrome, which can be transmitted by the transfer of bodily fluids, it is particularly desirable to be able to collect blood from an individual, filter that blood as necessary to remove clots, particles, foreign bodies and microorganisms and then either store or immediately return the blood to that individual. Whether or not the collected fluids are to be administered to the patient from whence they came or to another patient, it remains essential to prevent contamination and infection from reaching the collected fluid.
SUMMARY OF THE INVENTION
The present invention comprises a truly closed drainage apparatus for receiving fluid (liquids and gases) from body and tissue cavities including suctioning means in communication with the cavities for suctioning and receiving the drained body fluids. The present invention also comprises a truly closed drainage apparatus for receiving fluid from body and tissue cavities in which the collected fluids are maintained in an uncontaminated state and reused from the container into which they were originally collected.
In one important embodiment of the invention, the suctioning means comprise a resilient bellow which draws body fluid from the cavities under the inherent spring back suction force produced as it returns to its normal, expanded condition. When the collected fluids are to be reused in the "transfusion" configuration of the invention, the bellows also provides pressure for driving the collected fluid out of apparatus.
The apparatus includes a reservoir into which excess body liquids from the suctioning means are automatically siphoned and into which the suctioning means may be emptied, all without exposure of the system to the ambient atmosphere. In an important embodiment of the invention, the reservoir consists of an impervious, flexible bag in communication with an outlet port of the suctioning means which has a one-way valve at its inlet to prevent liquid from flowing back from the reservoir. When the collected fluids are to be reused, either immediately or after storage for a period of time, an impervious, flexible outer pressure bag is provided for driving the fluids collected in from the secondary reservoir into a patient, as needed.
Yet another important embodiment of the invention, the reservoir is vented to the atmosphere through one or more small pore hydrophobic filters to permit gases in the system to be purged without retrograde introduction of microorganisms into the reservoir.
It is therefore an object of the present invention to provide an improved apparatus and method for draining body fluids from a body cavity under suction in which potential retrograde infection due to contamination of drainage devices from exposure to the ambient atmosphere is eliminated.
It is a further object of the present invention to provide an improved apparatus and method for collecting body fluids including liquids and gases from a body cavity under suction in which collected liquids are siphoned into disposable containers for disposal and collected gases are vented to the atmosphere without exposing the system to the atmosphere and without exposure and contamination of hospital personnel from the container contents.
Yet another object of the invention is to provide a closed drainage system in which gases in the system can be purged without exposing the system to the ambient atmosphere.
A still further object of the present invention is to provide an economical, easy to use, truly closed suction drainage apparatus and method.
Another object of the present invention is to provide an economical, easy to use and safe apparatus for collecting blood and other bodily fluids and administering the blood and other fluids either to the donor or to another party, without requiring additional containers or special apparatus.
A still further object of the present invention is to provide an apparatus for collecting blood and other bodily fluids, filtering those fluids as necesssary, and immediately administering the fluids under pressure to the patient.
These and other objects of the present invention will become apparent to those skilled in the art upon consideration of the accompanying specification, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of this invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with its objects and advantages, may be best understood by reference to the following description, taken in conjunction with the following drawings, in which like reference numerals identify like elements in the several figures and in which:
FIG. 1 is a perspective view of a closed drainage apparatus in accordance with the practice of the present invention;
FIG. 2 is a cross-sectional elevation view of the apparatus of FIG. 1, taken generally along section line 2--2 of that figure;
FIG. 3 is an enlarged cross-sectional view of a one-way valve illustrated in FIG. 1, taken along section 3--3 of FIG. 1;
FIG. 4 is an enlarged cross-sectional view of that portion of the apparatus of FIG. 1 containing a vent hole and filter for purging air from the apparatus, taken along section line 4--4 of FIG. 1;
FIGS. 6A-6E are cross-sectional elevation views of the apparatus of FIG. 1, showing the operation of the apparatus of FIG. 1 in draining and storing body fluids;
FIG. 7 is a perspective view of an apparatus of the invention adapted for receiving fluids and subsequently administering those fluids;
FIG. 8 is an elevation cross-sectional view of FIG. 7; and
FIG. 9 is a side cross-sectional elevation view of a control of the apparatus of FIG. 7 taken along lines 9--9 of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIGS. 1 and 2, an apparatus for collecting body fluids 10 is illustrated including a resilient bellows 12 mounted to a support housing 14 by way of an externally threaded neck 16 which is screwed into an internally threaded integral flange 18 of the housing. In an alternative embodiment, the bellows is permanently and sealingly affixed to the housing to prevent accidental opening of the system at the bellows-to-housing interface.
The bellows, which serves as the suctioning means of the invention as well as, as a pressure source, is preferably constructed of polyethylene, although it may be made of other impervious resilient materials such as polypropylene. In fact, the suctioning may be accomplished using any sort of reservoir capable of producing sufficient negative pressure, when evacuated, to draw blood, bile, serum, pus, gases and other fluids from a wound site. In the illustrated embodiment, resilient bellows 12 has a liquid capacity in its normal extended state of about 150 cc.
A conventional drain 20 of the type placed in body or tissue cavities of patients undergoing urinary, wound, biliary, gastro-intestinal drainage, peritoneal dialysis, and hyperalimentation treatment is connected to a suction port 22 of the apparatus by way of an appropriate length of flexible tubing 24 affixed at one end to the drain and at the other end to the proximal end of the suction port.
Suction port 22 passes through housing 14 and into the area circumscribed by flange 18. A one-way gross reflux valve 24 (FIG. 3) is affixed to the distal end of the suction port, positioned as near as practical to the top of bellows 12. Although it is preferred that a duckbill valve be used as the gross reflux valve, other conventional one-way valves may be used, such as ball, check and diaphragm valves. The primary consideration in the choice of the valve is that it prevent fluid reflux and that it not interfere with the bellows when the bellows is compressed during operation of the apparatus.
In addition to suction port 22, a drainage port 26 passes through housing 14 and into the area circumscribed by flange 18 to communicate with the interior of bellows 12. The distal end of the drainage port is connected to a conduit 28 interconnecting the suctioning means and the reservoir which is supported in the housing (FIG. 2A) to maintain the suctioning and reservoir means in fluid communication at all times. In the illustrated embodiment, reservoir 30 is a clear, flexible polyethylene bag although other impervious containers (flexible or rigid) could be used. The size of the reservoir is a matter of choice, although in typical applications where a polyethylene bag is used, the reservoir will be large enough to the contain 500, 1000, or 2000 cc of liquid. As illustrated in the figures, reservoir 30 has a 500 cc capacity and is marked to indicate its level of fill.
Reservoir 30 is attached and heat sealed to a flange 32 protruding downwardly from housing 14. A rigid tube 29 protrudes from the flange into the top of reservoir 30 where it terminates in a second anti-reflux valve 50.
Anti-reflux valve 50 must be chosen for maximum contact sealing area to prevent blood clots and other solids from causing leakage across the valve. While a conventional Heimlich valve could be used, a film valve 50 particularly useful in this application is illustrated in FIG. 5. In addition to its excellent sealing properties (even in the presence of solids in the sealing area), the film valve is particularly well adapted to the present application since it does not create dead space in reservoir 30.
The film valve is made up of two pieces of virtually any type of plastic film, such as polyethylene, mylar, nylon or PVC, as well as laminates of these materials. The only requirement in choosing the plastic films is that the combination of plastics do not adhere. Also, it has been found to be preferable to use films with a combined thickness in the range of about 3-5 mils. The edges of the two film members of the valve are heat sealed to each other with a tortuous profile 51 at the closed edges of the valve in order to prevent fluid leakage.
Housing 14 includes a vent 34 (FIG. 4) in communication with reservoir 30. Vent 34 permits air from the reservoir to escape as it is filled with liquid during the drainage procedure. The vent also permits gases which may be drawn into the system from the drain site by way of drain 20 to escape. Absent vent 34, reservoir 30 would not be able to be filled to capacity with liquid due to space taken up by gases in the system. Also, by eliminating gases from the system through vent 34, the reservoir may be maintained in a lower and easier to handle profile.
A small pore hydrophobic filter 36 is heat sealed into vent cup 34 which is friction fit onto a flange 40 encircling port 34. Filter 36 prevents the migration of bacteria into the system. It also makes it possible to vent gases without impairing the "closed" nature of the system. The vent cap is positioned at the top of the housing in order to prevent the filter from getting wet, which could cause clogging. Although only a single vent cup and filter are illustrated in order to simplify the figures, two or more cups and filters could be used.
Hydrophobic filter 36 must have a pore size less than or equal to 0.45 microns in order to prevent bacterial migration. One useful filter material is an expanded PTFE membrane available from W. L. Gore & Associates, Inc. of Elkton, Md. under the name "GORE-TEX EXPANDED PTFE". Alternative materials include woven fabric filters such as those available from PALL Bio-Medical Products Corporation of Glencove, N.Y. under the trademark "PALLFLEX".
The operation of the above apparatus of the present invention is illustrated in FIGS. 6A-E. It is to be understood in this discussion of the operation of the apparatus of the invention that the apparatus is affixed to the patient's bed or clothing by way of hook 42 (FIG. 1) or other fastening devices at a position below the wound site.
Looking first to FIG. 6A, the apparatus is shown in an empty condition, with bellows 12 extended. In FIG. 6B the bellows are manually compressed, forcing the air in the bellows through tube 28, past valve 50 and out of the system through hydrophobic filter 34.
In FIG. 6C, the resilient bellows are permitted to expand. Since the system is sealed (film valve 50 is closed due to the suction created by the bellows), liquid and gases are drawn from the wound site through the suction port 22 past gross reflux valve 24 and into the bellows.
One started, the bellows continue filling with fluid (FIG. 6D) until the liquid reaches the bellows top. At that point, due to the siphon effect produced by the positioning of the apparatus below the wound site, surplus liquid automatically enters tube 28 and flows into reservoir 30, as shown in FIG. 6E. The fluid entering the bag displaces any gases therein which exit the system through vent 34 and filter 36.
Turning now to FIGS. 7-9, there is illustrated an apparatus 60 in accordance with the present invention for collecting and administering body fluids, which includes a resilient bellows 62 sealingly mounted to a support housing 64. The bellows, which comprises the source both of suction and pressure for the apparatus, is described above in connection with the embodiment of FIGS. 1-6.
A conventional drain of the type illustrated at 20 in FIG. 1 is connected to the suction port 68 of the apparatus by way of an appropriate length of flexible tubing 70 affixed at one end to the drain and at the other end to the suction port. In addition, in the embodiment illustrated, the apparatus is adapted for collecting blood and an in-line blood clot filter 71 is therefore mounted in tubing 70 ahead of the inlet port. When other materials are collected, appropriate conventional filtering media will be used.
Suction port 68 passes through housing 64 and into the area circumscribed by flange 72. A one-way gross reflex valve 74 is affixed to the suction port and positioned as described above in connection with FIG. 3.
A drainage port 76 passes through housing 64 and into the areas circumscribed by flange 72 to communicate with the interior of the bellows. The distal end of the drainage port is connected to a tube 78, located within the housing, which is routed to the top of a reservoir 80. This reservoir is a flexible bag of the type described above in connection with the discussion of reservoir 30 of FIGS. 1-6. As also described there, reservoir 80 is attached and heat sealed to a flange 82 which protrudes downwardly from the housing.
A rigid tube 84 protrudes from the flange into the top of reservoir 80 where it terminates in a second anti-reflux valve 86. Again, the anti-reflux valve is as described above in connection with the discussion of anti-reflux valve 50 of the device of FIGS. 1-6. In addition, housing 64 includes a vent 88 in communication with reservoir 80. This vent functions in the same fashion as vent 34, discussed above.
The apparatus of FIGS. 7-9 also includes an outer pressure bag, 90, sealingly affixed to flange 92. The pressure bag is larger than the blood bag and completely circumscribes it. This establishes an airtight pressure interface 94 surrounding reservoir 80.
An administration tube 96, which is sealingly affixed to reservoir 80, crosses the pressure interface and protrudes beyond the edge 96 of the pressure bag. The pressure bag is sealed about the administration tube at 96 to maintain the airtight condition of the pressure interface. Another filter 98 is positioned on the administration tube to further filter the blood being administered to the patient. In addition, a conventional bubble trap (not shown) can be placed in line, preferably after the filter, to remove air bubbles from the blood. A clamp 100 or other device closes off the administration tube when not in use.
Finally, the apparatus includes a control 102 which diverts air expelled from bellows 62 either to reservoir 80 (from which it escapes to the atmosphere through hydrophobic filter 88) or to the pressure interface 96. The operation of control 102 can best be understood by an examination of FIGS. 7 and 9.
In FIG. 7, three tubes, 78, 106 and 108 are illustrated, communicating respectively with reservoir 80, bellows 62 and pressure interface 94. Valve 102 is provided with a "Y" shaped passage 110 in which the bellows can be placed in communication through tube 106 respectively with reservoir 80 (by way of tube 78) or pressure interface 94 (by way of tube 108) by simply rotating the control stem 104 to align leg 112 of the passage with either tube 78 or 108.
The apparatus illustrated in FIGS. 7-9 is used in collecting and administering blood as follows:
1. Bellows 62 are manually compressed, forcing the air in the bellows through tube 78, across control 102 and into reservoir 80 from which it escapes to the atmosphere through hydrophobic filter 88;
2. The resilient bellows are permitted to expand, drawing blood from the patient, through filter 71 and into the bellows.
3. The bellows are compressed, driving the blood out of the bellows through tube 78 across control 102 and into reservoir 80. The bellows are allowed to expand again, drawing further blood from the patient through the gross filter and into the bellows.
4. The above process is repeated until the reservoir is filled, or the blood is needed.
5. When it is desired to administer the blood contained in the reservoir, control 102 is turned to divert air from the bellows through tube 108 into pressure interface 94. Bellows 62 are repeatedly compressed, building up the pressure in the pressure interface, creating a "pressure cuff" which squeezes the inner bag (FIG. 9).
6. Administration tube 96 is attached to a cannula or other appropriate device for administration of the blood to a patient, and with the device connected to the patient, clamp 100 is opened to permit the blood in the reservoir to rapidly flow to the patient under the pressure of the air contained in the pressure interface.
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the spirit and scope of the invention and, therefore, it is intended in the appended claims to cover all such changes and modifications which fall within the true spirit and scope of the invention.
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A truly closed drainage apparatus for suctioning, storing and administering fluid from body and tissue cavities including draining means for suctioning and receiving fluid, a reservoir for siphoning and storing excess fluids, a small pore hydrophobic filter for venting air without retrograde introduction of microorganisms, and means for applying pressure to the reservoir to administer the fluid contained therein.
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BACKGROUND OF THE INVENTION
This invention relates to xylene isomerization catalyst mixtures based upon supported AMS-1B crystalline, borosilicate molecular sieve catalyst compositions, and particularly, to isomerization of an unextracted, ethylbenzene-containing xylene stream using such mixtures, which process converts ethylbenzene to benzene and ethane primarily by hydrodeethylation and has improved paraffins and naphthenes conversion. More particularly, it relates to catalyst mixtures comprising an AMS-1B crystalline, borosilicate molecular sieve incorporated into an inorganic matrix and silica-supported molybdenum and to processes for using these catalyst mixtures to isomerize an unextracted, ethylbenzene-containing xylene stream to a mixture rich in paraxylene in a process which shows improved paraffins and naphthenes conversion to light hydrocarbons and converts ethylbenzene primarily by hydrodeethylation to benzene and ethane.
Typically, paraxylene is derived from mixtures of C 8 aromatics separated from such raw materials as petroleum naphthas, particularly reformates, usually by isomerization followed by, for example, lower-temperature crystallization of the paraxylene with recycle of the crystallizer liquid phase to the isomerizer. Principal raw materials are catalytically reformed naphthas and petroleum distillates. The fractions from these sources that contain C 8 aromatics vary quite widely in composition but will usually contain 10 to 35 weight percent ethylbenzene and up to about 10 weight percent primarily C 9 paraffins and naphthenes with the remainder being primarily xylenes divided approximately 50 weight percent meta, and 25 percent each of the ortho and para isomers. The primarily C 9 paraffins and naphthenes can be removed substantially by extraction to produce what are termed "extracted" xylene feeds, however, the extraction step adds to processing costs. Feeds that do not have the primarily C 9 paraffins and naphthenes removed by extraction are termed "unextracted" xylene feeds.
The ethylbenzene in a xylene mixture is very difficult to separate from the other components due to similar volatility, and, if it can be converted during isomerization to products more readily separated from the xylenes, buildup of ethylbenzene in the recycle loop is prevented and process economics are greatly improved. The primarily C 9 paraffins and naphthenes present in unextracted feeds unless removed also build up in the recycle loop and are usually extracted prior to isomerization as most commercial isomerization processes do not provide a catalyst which effectively converts them to easily separable-by-distillation products. Thus, it would be valuable to have a catalyst/process for xylene isomerization which would effectively convert both the ethylbenzene and primarily C 9 paraffins and naphthenes to easily separable products without affecting the isomerization efficiency. In addition, the catalyst should minimize xylene loss via hydrogenation and cracking.
Xylene isomerization catalysts can be classified into three types based upon the manner in which they convert ethylbenzene: (1) naphthene pool catalysts, (2) transalkylation catalysts, and (3) hydrodeethylation catalysts.
Naphthene pool catalysts are capable of converting a portion of the ethylbenzene to xylenes via naphthene intermediates. These catalysts contain a strong hydrogenation function, such as platinum, and an acid function, such as chlorided alumina, amorphous silica-alumina, or a molecular sieve. The role of the hydrogenation function in these catalysts is to hydrogenate the C 8 aromatics to establish essentially equilibrium between the C 8 aromatics and the C 8 cyclohexanes. The acid function interconverts ethylcyclohexane and the dimethylcylohexanes via cyclopentane intermediates. These C 8 cycloparaffins form the so-called naphthene pool.
It is necessary to operate naphthene pool catalysts at conditions that allow the formation of a sizable naphthene pool to allow efficient conversion of ethylbenzene to xylenes. Unfortunately, naphthenes can crack on the acid function of the catalyst, and the rate of cracking increases with the size of the naphthene pool. Naphthene cracking leads to high xylene loss, and the by-products produced by naphthene cracking are low-valued paraffins. Thus, naphthene pool catalysts are generally less economic than the transalkylation-type and hydrodee- thylation-type catalysts.
The transalkylation catalysts generally contain a shape selective molecular sieve. A shape selective catalyst is one that prevents some reactions from occurring based on the size of the reactants, products, or intermediates involved. In the case of common transalkylation catalysts, the molecular sieve contains pores that are apparently large enough to allow ethyl transfer to occur via a dealkylation/realkylation mechanism, but small enough to substantially suppress methyl transfer which requires the formation of a bulky biphenylalkane intermediate. The ability of transalkylation catalysts to catalyze ethyl transfer while suppressing methyl transfer allows these catalysts to convert ethylbenzene while minimizing xylene loss via xylene disproportionation.
When ethyl transfer occurs primarily by dealkylation/realkylation, it is possible to intercept and hydrogenate the ethylene intermediate involved with this mechanism of ethyl transfer by adding a hydrogenation function to the catalyst. The primary route for converting ethylbenzene then becomes hydrodeethylation, which is the conversion of ethylbenzene to benzene and ethane. It is desirable to selectively hydrogenate the ethylene intermediate without hydrogenating aromatics (without establishing a naphthene pool) to prevent the cracking of the naphthenes that occurs over the acid function of the catalyst. Commercial hydrodeethylation catalysts selectively hydrogenate ethylene without substantial hydrogenation of aromatics at reported commercial conditions.
In order to form a hydrodeethylation catalyst, it is essential to use an acidic component that behaves as a shape selective catalyst, i.e., one that suppresses the formation of the bulky biphenylalkane intermediate required for transmethylation, because transethylation can occur via a similar intermediate. For catalysts with pores large enough to allow the formation of these biphenylalkane intermediates, transethylation appears to occur primarily via these intermediates. In this case, ethylene is not an intermediate for transethylation, and the addition of a hydrogenation component cannot produce a hydrodeethylation catalyst
Molecular sieves such as the AMS-1B crystalline, borosilicate molecular sieves have shown great utility in the isomerization of xylenes to make primarily paraxylene Such sieves when supported on an oxide carrier like alumina effectively produce equilibrium amounts of paraxylene and dispose of ethylbenzene largely by transalkylation without serious loss of xylenes. However, such sieves are not very effective in removing paraffins and naphthenes during the isomerization of xylenes and they are generally used with extracted feeds.
Periodic Group VIb elements including molybdenum have shown utility in the past for various hydrocarbon conversions including hydrogenation. In particular, in U.S. Pat. Nos. 4,420,467; 4,532,226; and 4,655,255, molybdenum is said to be incorporated into or on a molecular sieve framework, which sieve is useful for hydrocarbon conversions including isomerization. In U.S. Pat. No. 4,202,996, hydrocarbon isomerization is carried out over a catalytic composite having a nickel component, a molybdenum component, a platinum component in combination with a zeolitic carrier. In other work, the activity of supported molybdenum compounds useful for hydrogenation/dehydrogenation has been found to depend upon the oxidation state of molybdenum with the lower molybdenum oxidation states being more effective.
Now it has been found that by adding molybdenum on silica to an alumina-supported HAMS-1B crystalline, borosilicate molecular sieve catalyst composition, a catalyst mixture is formed which, when used for xylene isomerization of unextracted xylene streams, removes ethylbenzene primarily by the hydrodeethylation mechanism to benzene and ethane and can substantially increase the removal of paraffins and naphthenes by cracking to light hydrocarbons. These results are obtained, moreover, without otherwise substantially affecting the isomerization effectiveness of the supported molecular sieve catalyst composition. Unexpectedly, other common molybdenum supports such as alumina do not produce a supported molybdenum which is as effective in removing paraffins and naphthenes when made into a catalyst mixture with the borosilicate sieve.
SUMMARY OF THE INVENTION
Described herein is a vapor phase process comprising isomerizing in the presence of hydrogen an unextracted xylene stream containing a major amount of xylene and a minor amount of ethylbenzene to a mixture rich in paraxylene over a catalyst mixture containing a HAMS-1B crystalline, borosilicate molecular sieve incorporated into alumina component and a molybdenum on silica component, said molybdenum on silica component containing between about 1 and about 20 weight percent molybdenum calculated as the metal, said catalyst mixture containing between about 5 to about 95 percent by weight of said molybdenum on silica component based upon the total weight of said mixture, and said HAMS-1B crystalline, borosilicate molecular sieve incorporated in alumina component containing between about 40 and about 95 weight percent alumina.
DETAILED DESCRIPTION OF THE INVENTION
Unextracted xylene-containing feeds to this process include one or more of the xylene isomers and between about five and about thirty-five weight percent of ethylbenzene depending upon the source of feed. These feeds also include between about one and about ten percent primarily C 9 paraffins and naphthenes. Such paraffins and naphthenes include materials such as n-nonane, methyl octanes, dimethylheptanes, trimethylcyclohexane, ethylmethylcyclohexane and the like.
The catalyst mixtures used in this invention include an AMS-1B crystalline borosilicate molecular sieve which is described in U.S. Pat. Nos. 4,268,420; 4,269,813; and 4,285,919, and Published European Patent Application 68,796, all of which are incorporated herein by reference. AMS-1B crystalline borosilicate generally can be characterized by the X-ray pattern listed in Table A and by the composition formula:
0.9±0.2M.sub.2/n O:B.sub.2 O.sub.3 :ySiO.sub.2 :zH.sub.2 O
wherein M is at one cation, n is the oxidation state of the cation, y is between 4 and about 600 and z is between 0 and about 160.
TABLE A______________________________________d-Spacing Å (1) Assigned Strength (2)______________________________________11.2 ± 0.2 W-VS10.0 ± 0.2 W-MS5.97 ± 0.07 W-M3.82 ± 0.05 VS3.70 ± 0.05 MS3.62 ± 0.05 M-MS2.97 ± 0.02 W-M1.99 ± 0.02 VW-M______________________________________ (1) Copper K alpha radiation (2) VW = very weak; W = weak; M = medium; MS = medium strong; VS = very strong
The AMS-1B borosilicate molecular sieve useful in this invention can be prepared by crystallizing an aqueous mixture, at a controlled pH, of sources for cations, an oxide of boron, an oxide of silicon, and an organic template compound.
Typically, the mol ratios of the various reactants can be varied to produce the crystalline borosilicates of this invention. Specifically, the mol ratios of the initial reactant concentrations are indicated below:
______________________________________ Most Broad Preferred Preferred______________________________________SiO.sub.2 /B.sub.2 O.sub.3 5-400 10-150 10-80R.sub.2 O.sup.+ /[R.sub.2 O.sup.+ + M.sub.2/n O] 0.1-1.0 0.2-0.97 0.3-0.97OH.sup.- /SiO.sub.2 0.01-11 0.1-2 0.1-1H.sub.2 O/OH.sup.- 10-4000 10-500 10-500______________________________________
wherein R is an organic compound and M is at least one cation having the oxidation state n, such as an alkali or an alkaline earth metal cation or hydrogen. By regulation of the quantity of boron (represented as B 2 O 3 ) in the reaction mixture, it is possible to vary the SiO 2 /B 2 O 3 molar ratio in the final product.
More specifically, the material useful in the present invention is prepared by mixing a base, a boron oxide source, and an organic template compound in water (preferably distilled or deionized). The order of addition usually is not critical, although a typical procedure is to dissolve base and boric acid in water and then add the template compound. Generally, the silicon oxide compound is added with intensive mixing such as that performed in a Waring Blender and the resulting slurry is transferred to a closed crystallization vessel for a suitable time. After crystallization, the resulting crystalline product can be filtered, washed with water, dried, and calcined.
During preparation, acidic conditions should be avoided. When alkali metal hydroxides are used, the values of the ratio of OH - /SiO 2 , shown above, should furnish a pH of the system that broadly falls within the range of about 9 to about 13.5. Advantageously, the pH of the reaction system falls within the range of about 10.5 to about 11.5 and most preferably between about 10.8 and about 11.2.
Examples of materials affording silicon oxide useful in this invention include silicic acid, sodium silicate, tetraalkyl silicates and Ludox, a stabilized polymer of silicic acid manufactured by E. I. DuPont de Nemours & Co. Typically, the oxide of boron source is boric acid although equivalent species can be used such as sodium borate and other boron-containing compounds.
Cations useful in formation of AMS-1B crystalline borosilicate include hydrogen ion, the cationic form of the organic template, alkali metal and alkaline earth metal cations such as sodium, potassium, lithium, calcium, and magnesium. Ammonium cations may be used alone or in conjunction with such metal cations. Since basic conditions are required for crystallization of the molecular sieve of this invention, the source of such cation can be a hydroxide such as sodium hydroxide. Alternatively, AMS-1B can be prepared directly and more preferably in the hydrogen form by replacing such metal cation hydroxides with an organic base such as ethylenediamine as described in Published European Application No. 68,796.
Organic templates useful in preparing AMS-1B crystalline borosilicate include alkylammonium cations or precursors thereof such as tetraalkylammonium compounds, especially tetra-n-propylammonium compounds. A useful organic template is tetra-n-propylammonium bromide. Diamines, such as hexamethylenediamine, can be used.
In a more detailed description of a typical preparation of this invention, suitable quantities of sodium hydroxide and boric acid (H 3 BO 3 ) are dissolved in distilled or deionized water followed by addition of the organic template. The pH may be adjusted between about 11.0 ±0.2 using a compatible acid or base such as sodium bisulfate or sodium hydroxide. After sufficient quantities of a silica source such as a silicic acid polymer (Ludox) are added with intensive mixing, preferably the pH is again checked and adjusted to a range of about 11.0±0.2.
Alternatively and more preferably, AMS-1B crystalline borosilicate molecular sieve can be prepared by crystallizing a mixture of sources for an oxide of silicon, an oxide of boron, an alkylammonium compound and ethylenediamine such that the initial reactant molar ratios of water to silica range from about 5 to about 25, preferably about 5 to about 20 and most preferably from about 10 to about 15. In addition, preferable molar ratios for initial reactant silica to oxide of boron range from about 4 to about 150, more preferably from about 5 to about 80 and most preferably from about 5 to about 20. The molar ratio of ethylenediamine to silicon oxide should be above about 0.05, typically below 5, preferably between about 0.1 and about 1.0, and most preferably between about 0.2 and 0.5. The molar ratio of alkylammonium compound, such as tetra-n-propylammonium bromide, to silicon oxide can range from 0 to about 1 or above, typically above about 0.005, preferably about 0.01 to about 0.1, more preferably about 0.01 to about 0.1, and most preferably about 0.02 to about 0.05.
The resulting slurry is transferred to a closed crystallization vessel and reacted usually at a pressure at least the vapor pressure of water for a time sufficient to permit crystallization which usually is about 0.25 to about 20 days, typically is about one to about ten days and preferably is about one to about seven days, at a temperature ranging from about 100° C. to about 250° C., preferably about 125° C. to about 200° C. The crystallizing material can be stirred or agitated as in a rocker bomb. Preferably, the crystallization temperature is maintained below the decomposition temperature of the organic template compound. Especially preferred conditions are crystallizing at about 165° C. for about five to about seven days. Samples of material can be removed during crystallization to check the degree of crystallization and determine the optimum crystallization time.
The crystalline material formed can be separated and recovered by well-known means such as filtration with aqueous washing. This material can be mildly dried for anywhere from a few hours to a few days at varying temperatures, typically about 50°-225° C., to form a dry cake which can then be crushed to a powder or to small particles and extruded, pelletized, or made into forms suitable for its intended use. Typically, materials prepared after mild drying contain the organic template compound and water of hydration within the solid mass and a subsequent activation or calcination procedure is necessary, if it is desired to remove this material from the final product. Typically, mildly dried product is calcined at temperatures ranging from about 260° C. to about 850° C., and preferably from about 425° C. to about 600° C. Extreme calcination temperatures or prolonged crystallization times may prove detrimental to the crystal structure or may totally destroy it. Generally, there is no need to raise the calcination temperature beyond about 600° C. in order to remove organic material from the originally formed crystalline material. Typically, the molecular sieve material is dried in a forced draft oven at 165° C. for about 16 hours and is then calcined in air in a manner such that the temperature rise does not exceed 125° C. per hour until a temperature of about 540° C. is reached. Calcination at this temperature usually is continued for about 4 to 16 hours.
The original cation in the AMS-1B crystalline borosilicate, if not hydrogen, can be replaced all or in part by ion exchange with other cations including other metal ions and their amine complexes, alkylammonium ions, ammonium ions, hydrogen ions, and mixtures thereof The preferred AMS-1B cation is hydrogen ion to form the HAMS-1B component of the catalyst mixture of this invention.
The HAMS-1B crystalline borosilicate useful in this invention is admixed with or incorporated with an alumina binder. Typically, the borosilicate is incorporated within the binder by blending with a sol of the alumina material and gelling the resulting mixture. These supported compositions are then dried at 100° to 200° C. and thereafter generally calcined at 500°-600° C. The crystalline borosilicate content of the supported compositions can vary anywhere from about 5 to 60 weight percent of the total composition. Preferably they contain about 10 to about 60 weight percent of sieve and more preferably, contain about 10 to about 40 weight percent sieve.
The silica used to support the molybdenum compound which is the second component of the catalyst mixture can be obtained from any one of a number of different sources. Preferably, the silica used has a surface area above about 30 sq m/g.
The amount of molybdenum placed on the silica can vary from about 1 to about 20 weight percent, more preferably about 2 to about 15 weight percent, and most preferably from about 3 to about 10 weight percent molybdenum, calculated as the metal. Soluble compounds of molybdenum such as ammonium molybdate may be used to impregnate the silica, and are generally dissolved in water and used to impregnate the silica by the incipient wetness or other technique as may be understood by one skilled in the art. The resulting molybdenum-containing silica is then dried at about 100° to about 200° C. and calcined at about 500° to about 600° C. before use.
The catalyst mixtures containing alumina-supported HAMS-1B crystalline, borosilicate molecular sieve and molybdenum on silica component can be made by several different methods. The two components can be physically mixed in a mixer with a little distilled water to form a paste which may then be dried at elevated temperature and formulated into catalyst particles of appropriate shape and size. Alternatively, the sieve component and the molybdenum on silica component may be added to an alumina sol and the catalyst mixture gelled with, for example, concentrated ammonia after which it is dried, calcined and formulated into catalyst particles of the appropriate size and shape. The gellation technique of forming the catalyst mixtures is preferred. Preferably, the catalyst mixture contains between about 5 and about 95 weight percent of the molybdenum on silica component based upon the total weight of the mixture, more preferably between about 25 and 75 percent, and most preferably, about 35 and 60 percent.
Isomerization of xylene in the presence of the above-described catalyst mixtures is effected by contact at a temperature between about 300° and about 650° C., and preferably between about 350° and about 600° C. The reaction can take place at atmospheric pressure, but the total pressure is preferably within the approximate range of about 1 atm to about 1000 psig.
Reaction is suitably accomplished utilizing a weight hourly space velocity of between about 0.2 and about 50 and preferably between about 1 and about 25. The space velocity is calculated on the basis of the weight of HAMS-1B sieve on alumina present in the catalyst mixture.
Hydrogen is used in the isomerization process and is generally present in a mol ratio, hydrogen to hydrocarbon, between about 0.5 and about 7, and more preferably between about 1 and about 6.
The following Examples will serve to illustrate certain specific embodiments of the hereindisclosed invention. These Examples should not, however, be construed as limiting the scope of the novel invention as there are many variations which may be made thereon without departing from the spirit of the disclosed invention, as those of skill in the art will recognize.
EXAMPLES
General
Isomerization results were obtained using a 2 ft stainless steel reactor with an i.d. of 0.5 in placed in a salt bath. The catalyst was loosely packed in the reactor with glass beads on either side of the catalyst charge.
EXAMPLE 1
In this Example a physical mixture of molybdenum on silica and alumina-supported HAMS-1B was prepared by physically mixing the two separate portions.
The supported HAMS-1B sieve was prepared as follows. A 120.0 g portion of distilled water was added to 40.0 g of the hydrogen form of AMS-1B. A 1985 g portion of PHF alumina sol from American Cyanamid (8.06 wt % solids) was added and the mixture blended in a homogenizer for approximately 5 min. A 160 ml amount of concentrated ammonium hydroxide was added to gel this mixture, and the gel was blended in a mixmaster for about 5 min. The gelled AMS-1B on alumina was dried at 165° C. for 16 hr. The resulting cake was ground to a powder fine enough to pass through a 100 mesh sieve.
An impregnation solution was prepared by adding 33.13 g of ammonium heptamolybdate to 800.0 g of distilled water. This solution was added to 200.0 g of Cab-O-Sil brand silica in a mixmaster. The impregnated Mo/SiO 2 was dried 8 hr at 165° C. and then calcined 12 hr at 82° C. The resulting cake was ground to a powder fine enough to pass through a 100 mesh sieve. This results in a 9.0% Mo/SiO 2 .
The catalyst mixture was prepared by adding 31.25 g of 9.0% Mo/SiO 2 to 93.75 g of alumina-supported HAMS-1B and mixing in a mixmaster. A 154.0 g portion of distilled water was added slowly to the result while stirring them with the mixer until a thick paste was formed. The result was then dried at 165° C. for 16 hr and calcined at 482° C. for 12 hr.
Isomerization results for a catalyst mixture which is 25% of 9% Mo/SiO 2 , 15% HAMS-1B, and 60% Al 2 O 3 are shown below in Table 1.
TABLE 1______________________________________ Composition in Wt %Component FEED EFFL______________________________________Light P/N's 0.009 2.008C.sub.9 P/N's 6.455 5.080Total P/N's 6.464 7.088Benzene 0.354 1.943Toluene 0.850 1.287Ethylbenzene 9.782 7.635Para-xylene 8.485 19.298Meta-xylene 49.687 42.274Ortho-xylene 22.545 18.537Other 1.833 1.936T (°F.) 759P (PSIG) 200H/HC 2.68WHSV 11.46% EB Conversion 21.95% Xylene Loss 0.71EB Conversion/ 30.88% Xylene Loss% C.sub.9 P/N 21.31Conversion% EB Converted 82.73to Benzeneand Ethane% Para-xylene 104.41EquilibriumApproach______________________________________
EXAMPLE 2
In this Example a physical mixture of molybdenum on silica and alumina-supported HAMS-1B was prepared by physically mixing the two separate portions.
The supported HAMS-1B sieve was prepared as follows. A 120.0 g portion of distilled water was added to 40.0 g of the hydrogen form of AMS-1B. A 1985 g portion of PHF alumina sol (8.06 wt % solids) was added to this mixture and was blended in a homogenizer for approximately 5 min. A 160 ml amount of concentrated ammonium hydroxide was added to gel the mixture, and the gel was blended in a mixmaster for about 5 minutes. The gelled HAMS-1B on alumina was dried at 165° C. for 16 hr and calcined at 510° C. for 12 hr. The resulting cake was ground to a powder fine enough to pass through a 100 mesh sieve.
An impregnation solution was prepared by adding 11.04 g of ammonium heptamolybdate to 800.0 g of distilled water. This solution was added to 200.0 g of silica in a mixmaster. The impregnated Mo/SiO 2 was dried at 165° C. for 8 hr and then calcined at 538° C. for 12 hr. The resulting cake was ground to a powder fine enough to pass through a 100 mesh sieve. This results in a 3% Mo/SiO 2 material
The catalyst mixture was prepared by combining 93.75 g of the 3.0% Mo/SiO 2 and 31.25 g of alumina-supported HAMS-1B and mixing in a mixmaster. A 203.0 g portion of distilled water was added slowly to the powders while stirring them with a mixer until a thick paste was formed. The result dried at 165° C. for 16 hr and calcined at 482° C. for 12 hr.
Isomerization results for a catalyst mixture which is 75% of 3% Mo/SiO 2 , 5% HAMS-1B, and 20% Al 2 O 3 are shown below in Table 2.
TABLE 2______________________________________ Composition in Wt %Component FEED EFFL______________________________________Light P/N 0.008 3.519C.sub.9 P/N's 6.445 3.828Total P/N 6.453 7.347Benzene 0.337 1.828Toluene 0.842 1.512Ethylbenzene 9.778 7.712Para-xylene 8.485 19.136Meta-xylene 49.700 41.912Ortho-xylene 22.568 18.416Other 1.837 2.137T (°F.) 760P (PSIG) 200H/HC 2.76WHSV 5.94% EB Conversion 21.13% Xylene Loss 1.57EB Conversion/ 13.46% Xylene Loss% C.sub.9 P/N 40.61Conversion% of EB Converted 80.93to Benzene andEthane% Para-xylene 104.4EquilibriumApproach______________________________________
EXAMPLE 3
In this Example a co-gelled mixture of molybdenum on silica and HAMS-1B supported on alumina was prepared. An impregnation solution was prepared by adding 73.61 g of ammonium heptamolybdate to 800 g of distilled water. This solution was added to 200.0 g of silica. The impregnated catalyst was dried 8 hr at 165° C. and then calcined at 510° C. for 4 hr. The resulting cake was ground to a powder fine enough to pass through a 100 mesh sieve.
A 40.0 g portion of distilled water was added to 18.8 g of the hydrogen form of AMS-1B. A 915.0 g portion of PHF alumina sol (8.2 wt % solids) was added and the mixture was blended in a homogenizer for approximately 5 minutes. A 31.0 g portion of the Mo/SiO 2 was added to the HAMS-1B/alumina while mixing. A 75 ml amount of concentrated ammonium hydroxide was added to gel this mixture, and the gel was blended in a mixmaster for about 5 minutes. The gelled catalyst was dried at 165° C. for 16 hr, ground to 18/40 mesh, and calcined at 482° C. for 12 hr.
Isomerization results for a catalyst mixture which is 25% of 20% Mo/SiO 2 , 15% HAMS-1B and 60% Al 2 O 3 are set forth in Table 3 below.
TABLE 3______________________________________ Composition in Wt %Component FEED EFFL______________________________________Light P/N 0.009 2.372C.sub.9 P/N's 6.495 4.944Total P/N 6.504 7.316Benzene 0.361 1.874Toluene 0.856 1.303Ethylbenzene 9.746 7.691Para-xylene 8.480 19.252Meta-xylene 49.666 42.185Ortho-xylene 22.565 18.544Other 1.822 1.835T (°F.) 760P (PSIG) 200H/HC 2.75WHSV 20.48% EB Conversion 21.09% Xylene Loss 0.83EB Conversion/ 25.30% Xylene Loss% C.sub.9 P/N 23.88Conversion% of EB Converted 83.49to Benzeneand Ethane% Para-xylene 104.28EquilibriumApproach______________________________________
EXAMPLE 4
In this Example a co-gelled mixture of molybdenum on silica and HAMS-1B supported on alumina was prepared. An impregnation solution was prepared by adding 33.13 g of ammonium heptamolybdate to 800 g of distilled water. This solution was added to 200.0 g of silica. The impregnated catalyst was dried 8 hr at 165° C. and then calcined at 510° C. for 4 hr. The resulting cake was ground to a powder fine enough to pass through a 100 mesh sieve.
A 40.0 g portion of distilled water was added to 18.8 g of the hydrogen form of AMS-1B. A 915.0 g portion of PHF alumina sol (8.2 wt % solids) was added and this mixture was blended in a homogenizer for approximately 5 minutes. A 31.0 g portion of the Mo/SiO 2 component was added to the HAMS-1B on alumina component while mixing. A 75 ml amount of concentrated ammonium hydroxide was added to gel this mixture, and the gel was blended in a mixmaster for about 5 minutes. The gelled catalyst mixture was dried at 165° C. for 16 hr, ground to 18/40 mesh, and calcined at 482° C. for 12 hr.
Isomerization results for a catalyst mixture which is 40% of 9% Mo/SiO 2 , 15% HAMS-1B, and 60% Al 2 O 3 are set forth in Table 4 below.
TABLE 4______________________________________ Composition in Wt. %Component FEED EFFL______________________________________Light P/N 0.015 2.427C.sub.9 P/N's 6.514 4.667Total P/N 6.529 7.094Benzene 0.366 1.735Toluene 0.859 1.358Ethylbenzene 9.743 7.816Para-xylene 8.480 19.260Meta-xylene 49.656 42.187Ortho-xylene 22.551 18.702Other 1.816 1.848T (°F.) 761P (PSIG) 200H/HC 2.70WHSV 15.12% EB Conversion 19.78% Xylene Loss 0.67EB Conversion/ 29.72% Xylene Loss% C.sub.9 P/N 28.35Conversion% of EB Converted 82.17to Benzeneand Ethane% Para-xylene 103.99EquilibriumApproach______________________________________
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Described are catalyst mixtures comprising a HAMS-1B crystalline borosilicate molecular sieve incorporated into an inorganic matrix component and a molybdenum on silica component. These mixtures when used to isomerize unextracted xylene streams containing ethylbenzene to mixtures rich in paraxylene demonstrate improved paraffins and naphthenes conversion to light hydrocarbons and convert most of the ethylbenzene by a hydrodeethylation mechanism to benzene and ethane.
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This application is a continuation-in-part, of application Ser. No. 07/040,531, filed Apr. 17, 1987 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for bleaching cellulose fiber material with hydrogen peroxide. More particularly, the present invention relates to the aforesaid method in which a stabilizer for hydrogen peroxide in an aqueous bleaching solution for bleaching fiber materials.
2. Description of the Related Art
It is known that a bleaching process using hydrogen peroxide as a bleaching agent is carried out under an alkaline condition. However, it is also known that, under the alkaline condition, if the bleaching solution contains a heavy metal, for example, iron, copper or manganese, hydrogen peroxide in the bleaching solution is decomposed to a certain extent, due to the undesirable influence of the heavy metal, in accordance with the following chemical reaction:
2H.sub.2 O.sub.2 →2H.sub.2 O+O.sub.2
the above-mentioned phenomenon hinders the production of perhydroxyl ions (OOH - ), which make a large contribution to the bleaching effect of hydrogen peroxide, in accordance with the following reaction:
H.sub.2 O.sub.2 →H.sup.+ +OOH.sup.-
and results in an undesirable decrease in the bleaching effect of hydrogen peroxide.
Usually, the above-mentioned undesirable decomposition of hydrogen peroxide into molecular oxygen is prevented by adding a stabilizer to the hydrogen peroxide-containing bleaching solution. A well-known conventional stabilizer for the hydrogen peroxide bleach is sodium silicate, which exhibits an excellent stabilizing effect and allows fiber materials having an excellent whiteness to be produced. However, sodium silicate is disadvantageous in that it causes water-insoluble silicate compounds to be produced in the bleaching solution, which are deposited in the form of scales not only on the surface of the bleached fiber material but also on a bleaching apparatus, and thus degrade the touch of the bleached fiber material and the function of the bleaching apparatus. As other stabilizers for the hydrogen peroxide bleach, organic chelating agents, for example, ethylenediamine tetraacetic acid (EDTA) and diethylenetriamine pentaacetic acid (DTPA), and inorganic chelating agents, for example, polyphosphates, are disclosed in "MOL", No. 4, page 42, 1968, and water-soluble protein substances, for example, soybean protein and casein, are disclosed in Japanese Examined Patent Publication No. 50-34675 (1975).
The above-mentioned stabilizers different from sodium silicate exhibit a certain stabilizing intensity and an industrial usefulness when used in a batch type bleaching systems at a large liquor ratio. However, these stabilizers are disadvantageous in that, when used in a continuous bleaching system at a relatively small liquor ratio, the resultant hydrogen peroxide-stabilizing effect, whiteness of the bleached fiber material, prevention of degradation of the bleached fiber material, and process stability are poorer than those of sodium silicate. Accordingly, the above-mentioned conventional stabilizers other than sodium silicate do not satisfy the requirements of the bleach industry.
Japanese Unexamined Patent Publication No. 52-103,386 (1977) discloses that a bleaching stabilizer consisting of a poly(sodium-α-hydroxyacrylate) exhibits an excellent stabilizing effect, whiteness-increasing effect, and other effects, at a very high level, which could not be obtained by the conventional stabilizer. That is the poly(sodium-α-hydroxyacrylate) exhibits an excellent stabilizing effect for the hydrogen peroxide bleach and inhibition of the decomposition of hydrogen peroxide due to the presence of a hydrogen peroxide-decomposing catalyst, for example, heavy metals, at a high level comparable to those of sodium silicate. Also, it has been found that the poly(sodium-α-hydroxyacrylate) provides an excellent protection of the fiber materials from the degradative action of the bleaching agent. However, it has been further found that the stabilizing effect of the poly(sodium-α-hydroxyacrylate) is excessively high, and thus sometimes restricts the bleaching effect and cotton seed-removing effect of the hydrogen peroxide.
Furthermore, the poly(sodium-α-hydroxyacrylate) is very expensive and, therefore, if a stabilizer consisting of this compound alone is used in a necessary amount for exhibiting a desired bleaching effect, the bleaching process becomes extremely costly, and thus cannot be industrially utilized. In order to avoid the above-mentioned disadvantages, Japanese Unexamined Patent Publication No. 55-76161 (1980) discloses an improved hydrogen peroxide bleaching process in which a composite stabilizer consisting of a poly(sodium-α-hydroxyacrylate) combined with a polyphosphate is used. However, this type of composite stabilizer is disadvantageous in that the resultant bleached fiber material exhibits an unsatisfactory touch and is not preferable for industrial use.
Also, attempts have been made to use a composite stabilizer consisting of a poly(sodium-α-hydroxyacrylate) combined with sodium silicate. However, the results obtained by usage of the composite stabilizer were not satisfactory.
SUMMARY OF THE INVENTION
The invention primarily consists in a method of bleaching a cellulosic fiber materialwith hydrogen peroxide, comprising:
(a) impregnating a cellulosic fiber material with an aqueous bleaching solution containing hydrogen peroxide and a stabilizer comprising:
(i) 1 to 100 parts by weight of at least one hydroxyacrylic acid polymer selected from the group consisting of poly-α-hydroxyacrylic acids, and salts thereof and polylactone corresponding thereto; and
(ii) 1 to 50 parts by weight of at least one organic phosphate acid compound selected from the group consisting of methylene,1,1-diphoshonic acid, ethylidene-1,1-diphosphonic acid, butylidene-1,1-disphosphonic acid, 1-hydroxyethylidene-1,1-diphosphonic acid, 1-hydroxypropyl-idene-1,1-diphosphonic acid, amino-tri(methylenephosphonic acid), hexamethylene diamine tetra(methylenephosphonic acid), triethylenetetramine hexa(methylenephosphonic acid), and salts of the above-mentioned organic phosphonic acids, and
(b) heating the impregnated cellulosic fiber material with steam.
An object of the present invention is to provide a stabilizer for hydrogen peroxide bleach which exhibits an excellent bleaching effect superior to that obtained when using a conventional bleaching agent consisting of a poly(sodium-α-hydroxyacrylate) alone or sodium silicate alone, even when used in a continuous bleaching process at a small liquor ratio.
Another object of the present invention is to provide a stabilizer for hydrogen peroxide bleach which does not cause an undesirable formation of scales on the bleached fiber material and on the bleaching apparatus.
Still another object of the present invention is to provide a stabilizer for hydrogen peroxide bleach which makes a large contribution to the industrial production of a bleached fiber material having an enhanced high whiteness and a satisfactory touch, at a reduced cost.
A further object of the present invention is to provide a stabilizer for hydrogen peroxide bleach which exhibits an excellent restriction of the decomposition of hydrogen peroxide due to a decomposition catalyst, for example, heavy metals, a superior cotton seed-eliminating effect, and enhanced protection of the fiber material.
The aforesaid objects are attained by providing a method for bleaching a cellulosic fiber material with hydrogen peroxide, comprising:
(a) impregnating a cellulosic fiber material with an aqueous bleaching solution containing hydrogen peroxide and a stabilizer, comprising:
(i) at least one hydroxyacrylic acid polymer selected from the group consisting of poly-α-hydroxyacrylic acid, and salts thereof and polylactone corresponding thereto; and
(ii) at least one organic phosphonic acid selected from the group consisting of methylene-1,1-diphosphonic acid, ethylidene-1,1-diphosphonic acid, butylidene-1,1-diphosphonic acid, 1-hydroxyethylidene-1,1-diphosphonic acid, 1-hydroxypropylidene-1,1-diphosphonic acid, and compounds of the formula (I): ##STR1## wherein X 1 , X 2 and X 3 respectively represent, independently from each other, a member selected from the group consisting of a hydrogen atom and a methylene phosphonic acid radical, when one of X 1 and X 2 represents a hydrogen atom, the other one of X 1 and X 2 representing a methylenephosphonic acid radical, m represents an integer of from 1 to 15 and n represents zero or an integer of from 1 to 4, and salts of the above-mentioned organic phosphonic acids, and
(b) heating the impregnated cellulosic fiber material with steam.
A feature of the invention is to provide the stabilizer in the aqueous bleaching solution is in an amount of 0.25 to 15 g/l.
A further feature of the invention is to provide the poly-α-hydroxyacrylic acids in the stabilizer have a molecular weight of from 1,000 to 1,000,000.
Another feature of the invention is to provide that the poly-α-hydroxyacrylic acid salts in the stabilizer are selected from monovalent metal salts and ammonium salts thereof.
A further feature of the invention is to provide that the salts of organic phosphonic acids in the stabilizer are selected from monovalent metal salts and ammonium salts thereof.
Another feature of the method is to provide that the organic phosphonic acids of the formula (I) in the stabilizer are selected from amino-tri(methylenephosphonic acid), ethylene-diaminetetra(methyklenephosphonic acid), diethylenetriaminepenta-(methylenephosphonic acid, and triethylenetetraminehexa(methylenephosphonic acid.
Yet another feature of the invention is to provide that the hydroxyacrylic polymer component (i) and the organic phoshonic acid component (ii) in the stabilizer are in a mixing weight ratio of 100:1 to 1:50.
Also within the scope of the invention is the use of a stabilizer of hydrogen peroxide bleach, which comprises:
(A) at least one hydroxyacrylic polymer
selected from the group consisting of poly-α-hydroxyacrylic acids, and salts thereof and corresponding polylactones thereto; and
(B) at least one organic phosphonic acid compound selected from the group consisting of those of the formulae (1) and (2): ##STR2## wherein A and Y respectively represent, independently from each other, a member selected from the group consisting of a hydrogen atom and alkyl radicals having 1 to 3 carbon atoms, D, E and F respectively represent, independently from each other, a member selected from the group consisting of a hydrogen atom and a methylenephosphonic acid radical, when one of D and E represents a hydrogen atom, the other one of D and E representing a methylenephosphonic acid radical, m represents an integer of from 1 to 15 and n represents zero or an integer of from 1 to 4, and salts of the above-mentioned organic phosphonic acids.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The inventors of the present invention discovered that, when a hydroxyacrylic acid polymer component (A) consisting of at least one hydroxyacrylic acid polymer selected from poly-α-hydroxyacrylic acids and salts thereof and corresponding polylactones thereto was combined with an organic phosphonic acid component (Y) consisting of at least one organic phosphonic acid compound selected from those of the formulae (1) and (2) and salts thereof, the resultant stabilizer exhibited an enhanced hydrogen peroxide-stabilizing effect, bleach-promoting effect, cotton seed-removing effect, and fiber material-protecting effect without forming undesirable scales on the fiber material, and is useful for producing bleached fiber materials having an enhanced whiteness and a satisfactory touch. The grounds for the attainment of the excellent effects of the stabilizer of the present invention are not absolutely clear, but it is presumed by the inventors of the present invention that, since the chelating activity of the poly-α-hydroxyacrylic acid compounds has a different intensity from that of the organic phosphonic acid compounds, the hydrogen peroxide can be allowed to penetrate and reach the inside of the fiber material without decomposition thereof by the strong stabilizing effect of the poly-α-hydroxyacrylic acid compound, and the hydrogen peroxide is activated by the action of the organic phosphonic acid compound.
The above-mentioned effects are exhibited at an unexpectedly high intensity by a synergistic effect of the poly-α-hydroxyacrylic acid compound and the organic phosphonic acid compound of the formula (1) or (2).
In the stabilizer of the present invention, the hydroxyacrylic acid polymer component (A) and the organic phosphonic are acid component (B) preferably contained in a mixing weight ratio of from 100:1 to 1:50, more preferably from 9:1 to 1:4.
The poly-α-hydroxyacrylic acids which are water-soluble, and water-soluble salts thereof and corresponding polylactones thereto, have a chelating activity and can produce complex salts with metal ions. These compounds also exhibit a sequestering effect on various types of metal ions. The poly-α-hydroxyacrylic acid compounds usable for the present invention preferably have a molecular weight of from 1,000 to 1,000,000, more preferably from 2,000 to 800,000.
The water soluble salts of poly-α-hydroxyacrylic acids are preferably selected from monovalent metal salts, for example, alkali metal salts including sodium salts and potassium salts, and ammonium salts thereof. The polylactone (PLAC) corresponding to the poly-α-hydroxyacrylic acids (PLAC) have intramolecular or intermolecular ester groups formed by intramolecular or intermolecular reactions of carboxyl groups with hydroxyl groups in the poly-α-hydroxyacrylic acid compound molecules.
Usually, the hydroxyacrylic acid polymer component (A) is used in an amount of 0.05 g/l or more, preferably, 0.2 g/l or more, in a hydrogen peroxide bleaching solution. Note, although there is no specific upper limit of the concentration of the hydroxyacrylic acid polymer component (A), the hydroxyacrylic acid polymer component (A) is usually used in an amount not exceeding 10 g/l.
The organic phosphonic acids of the formulae (1) and (2), and salts, particularly water-soluble salts, thereof, have a chelating activity and can produce complex salts with metal ions and exhibit a buffering effect.
The salts of organic phosphonic acids usable for the present invention are selected from water-soluble salts thereof, for example, monovalent metal salts, especially alkalic metal salts including sodium salts and potassium salts, and ammonium salts.
The organic phosphonic acids of the formula (1) are preferably selected from methylene-1,1-diphosphonic acid, ethylidene-1,1-diphosphonic acid, butylidene-1,1-diphosphonic acid, 1-hydroxyethylidene-1,1-diphosphonic acid, and 1-hydroxypropylidene-1,1-diphosphonic acid.
The organic phosphonic acids of the formula (2) are preferably selected from amino,-tri(methylenephosphonic acid) which corresponds to a compound of the formula (2) in which n=0, ethylenediamine-tetra(methylenephosphonic acid) which corresponds to a compound of the formula (2) in which n=1, diethylenetriamine-penta(methylenephosphonic acid) which corresponds to a compound of the formula (2) in which n=2, and triethylenetetraminehexa(methylenephosphonic acid) which corresponds to a compound of the formula (2) in which n=3. Preferably, the organic phosphonic acids of the formula (2) in which n is 0.1 or 2 are used. The organic phosphonic acid component (B) is preferably contained in an amount of from 0,2 to 5 g/1, more preferably from 0.3 to 2 g/l, in the hydrogen peroxide bleaching liquid.
The stabilizer of the present invention is preferably added in an amount of 0.25 to 15 g/l to a hydrogen peroxide aqueous solution, to provide a bleaching solution.
A fiber material to be bleached is brought into contact with the bleaching solution and is heated at a desired temperature of from room temperature to a boiling point temperature of the bleaching liquid. The bleaching solution may contain a usual additive for example, a surfactant, in a usual manner. The fiber material to be bleached are usually selected from cotton, hemp, flax, and regenerated cellulose fiber materials. However, the fiber material may be another fiber material, for example, blend materials of cellulosic fibers, for example, cotton fibers, with synthetic fibers, for example, polyester fibers.
The bleaching solution containing the stabilizer of the present invention can be used in any type of bleaching machines, for example, non-continuous (batch type) bleaching machines including winch type, Kier type, Obermaier type, and jigger type bleaching machines, and continuous bleaching machines including J-box type, L-box type, Perble Range type, and Benteler type bleaching machines. Especially, the stabilizer of the present invention is suitable for the continuous bleaching machines in which the bleaching solution is used in a small liquor ratio.
SPECIFIC EXAMPLES
The present invention will be further explained by way of specific examples, which, however, are representative and do not restrict the scope of the present invention in any way.
In the examples, the brightness and stiffness of bleached fabric were determined as follows. Stiffness represents a touch of the fabric.
(1) Whiteness
The whiteness of a fabric was determined by measuring a light reflection on the fabric surface at a wave length of 440 m μm by a Macbeth Colorimeter MS-2020 (Trademark).
(2) Stiffness
The stiffness of a fabric was represented by a resistance in 8 unit of a fabric swatch having a length of 10 cm and a width of 10 cm when the swatch was forced to pass through a stainless steel ring having an inside diameter of 3 cm and a thickness of 0.5 mm by a tensile testing machine (Trademark: Tensilon UTM-III-100, made by Toyo Baldwin Co.).
EXAMPLES 1 to 4 and COMPARATIVE EXAMPLES 1 to 5
In each of the above-numbered examples and comparative examples, a bleaching solution was prepared from 40 ml of a 35% hydrogen proxide aqueous solution, a stabilizer having the composition and amount as shown in Table 1, 1 g/l of a surfactant (which was a mixture of an anionic surfactant and a non-ionic surfactant and was available under a trademark of Sunmol S-50, made by Nikka Chemical Industry Co., Ltd.) and 3 g/l of sodium hydroxide flakes.
A knitted fabric made of cotton yarn having a yarn count number of 40 was immersed in the bleaching solution, was squeezed at a pick up of 100% based on the weight of the cotton fabric, and was heated with steam at a temperature of 100° C for 40 minutes in a high pressure steaming type bleaching machine.
The bleached fabric exhibited the whiteness and touch as shown in Table 1.
As Table 1 clearly shows, the bleached fabrics in Examples 1 to 4 had a satisfactory whiteness and touch.
TABLE 1__________________________________________________________________________ Example No. Comparative Example ExampleItem 1 2 3 4 5 1 2 3 4__________________________________________________________________________StabilizerSodium silicate (Grade No. 3) 10 -- -- -- -- -- -- -- --(g/l)PHAS (*).sub.1 (g/l) -- 1 2 -- 1 0.5 0.5 0.5PLAC (*).sub.2 (g/l) -- -- -- -- -- -- -- -- 0.5Sodium pyrophosphate (g/l) -- -- -- -- 3 -- -- -- --1-Hydroxyethylidene-1,1- -- -- -- 3 -- 0.5 -- -- 0.5diphosphonic acid (g/l)Pentasocium aminotri- -- -- -- -- -- -- 0.5 -- --(methylenephosphonate) (g/l)Ethylenediamine tetra- -- -- -- -- -- -- -- 0.5 --(methylenephosphonic acid) (g/l)PropertyWhiteness (%) 88.4 88.5 89.4 86.1 89.0 90.5 90.4 90.8 90.1Touch (Stiffness) (g) 58 42 45 38 51 41 40 42 40__________________________________________________________________________ Note: (*).sub.1 PHAS was sodium polyhydroxyacrylate which was produced by reacting PLAC with NaOH. (*).sub.2 PLAC was a polylactone of polyhydroxyacrylate having an averag molecular weight of 100,000, and available under a trademark of ClareneL, made by Solvay Co.
EXAMPLES 5 to 8 and COMPARATIVE EXAMPLES 6 to 9
In each of the above-numbered examples and comparative examples, a bleaching solution was prepared from 20 g/l of a 35% hydrogen peroxide aqueous solution, a stabilizer having the composition and amount as indicated in Table 2, 1 g/l of Sunmol S-50, and 2 g/l of sodium hydroxide flakes.
A cotton plain weave fabric (Broad cloth) consisting of cotton yarn having a yarn count number of 40 was impregnated with 90%, based on the weight of the fabric, of the bleaching solution, and was heated with steam at a temperature of 95° C. for 30 minutes in a bleaching machine.
The resultant breached fabric was subjected to the whiteness test.
Also, the cotton seed-removing effect of the bleaching solution on the cotton fabric was evaluated by naked eye observation into the following classes.
Good: No seeds found in the bleached fabric
Slightly bad: A few seeds found in the bleached fabric
Bad: A large number of seeds found in the bleached fabric.
The results of the test and observation are shown in Table 2.
Table 2 clearly shows that the bleaching liquids of Examples 5 to 8 exhibited a satisfactory bleaching and cotton seed-removing effect.
TABLE 2__________________________________________________________________________ Example No. Comparative Example ExampleItem 6 7 8 9 5 6 7 8__________________________________________________________________________StabilizerSodium silicate (Grade No. 2) 7 -- -- -- -- -- -- --(g/l)Neolate PH-150 (*).sub.2 (g/l) -- 7 -- -- -- -- -- --PHAS (g/l) -- -- 0.7 1.5 0.7 0.7 0.7 1.01-Hydroxyethylidene-1,1- -- -- -- -- 0.7 -- -- --diphosphonic acid (g/l)Aminotri (methylenephosphonic -- -- -- -- -- 0.7 -- --acid) (g/l)Ethylenediamine tetra- -- -- -- -- -- -- 0.7 0.5(methylenephosphonic acid) (g/l)PropertyWhiteness (%) 84.0 84.2 84.5 85.8 86.0 86.1 85.9 86.3Cotton seed-removing effect Good Good Bad Slightly Good Good Good Good bad__________________________________________________________________________ Note: (*).sub.3 Neolate PH150: Trademark of a low silicate type stabilizer mad by Nikka Chemical Industry Co.
EXAMPLES 9 to 13
In each of the above-numbered examples, the same procedures as those described in Example 1 were carried out except that the stabilizer had the composition and amount as shown in Table 3.
The organic phosphonic acid compounds and poly-α-hydroxyacrylic acid compounds were in the form of potassium or ammonium salts.
The bleaching results for the cotton knitted fabric are shown in Table 3.
Table 3 clearly shows that the bleaching solution of Examples 9 to 13 exhibited on excellent bleaching and brightening effect without degrading the touch of the bleached fabrics.
TABLE 3__________________________________________________________________________ Example No.Item 9 10 11 12 13__________________________________________________________________________PHAP (g/l) (*).sub.4 0.5 0.5 0.5 -- --PHAA (g/l) (*).sub.5 -- -- -- 0.5 0.51-Hydroxyethylidene-1,1-diphosphonic 0.5 -- -- 0.5 --acid (g/l) (*).sub.6Hexamethylenediamine-tetra (methylene- -- 0.5 -- -- 0.5phosphonic acid) (g/l) (*).sub.7Diethylenetriamine-penta (methylene- -- -- 0.5 -- --phosphonic acid) (g/l) (*).sub.8PropertyWhiteness (%) 90.3 90.4 90.3 90.1 90.4Touch (Stiffness) (g) 41 41 40 40 41__________________________________________________________________________ Note: (*).sub.4 PHAP: Poetaaium polyαhydroxyacrylate (*).sub.5 PHAA: Ammonium polyhydroxyacrylate (*).sub.6 sodium salt (*).sub.7 sodium salt (*).sub.8 sodium salt
EXAMPLES 14 to 16 and COMPARATIVE EXAMPLES 10 to 12
In each of the above-numbered examples and comparative examples, two pieces of a cotton poplin cloth were scoured in an ordinary manner, were impregnated separately with a 1% FeSO 4 .7H 2 O aqueous solution and with a 1% CuSO 4 .5H 2 O aqueous solution in an amount of 250 g/m 2 , and then dried.
The ion salt-containing and copper salt-containing pieces of the fabric were bleached, separately from each other, in the same manner as described in Example 9, except that the stabilizer used had the composition and amount as indicated in Table 4.
The bleached pieces of the fabric were subjected to a tensile test by using an autograph tensile test machine (a constant speed tension test), in which a specimen gripped with a pair of grips spaced 5 cm from each other was stretched at a stretching speed of 200 mm/min. The tensile strength of the specimen was indicated by an average value of fine measurements in each of the warp and weft directions.
The result of the tensile test of the bleached fabric is shown in Table 4.
Table 4 clearly shows that the bleached fabrics in Examples 14 to 16 exhibited satisfactory tensile strength in the warp and weft directions thereof, even though the bleaching procedures were carried out in the presence of heavy metal ions, that is, iron ions (Fe ++ ) or copper ions (Cu ++ ).
TABLE 4__________________________________________________________________________ Example No. Comparative Example ExampleItem 10 11 12 14 15 16__________________________________________________________________________Stabilizer Sodium silicate (Grade No. 3) 10 -- -- -- -- -- (g/l) PHAS (g/l) -- 1 2 0.7 0.7 0.7 1-Hydroxyethylidene-1,1- -- -- -- 0.5 -- -- diphosphonic acid (g/l) Pentasodium aminotri- -- -- -- -- 0.5 -- (methylenephosphonate) (g/l) Ethylenediamine tetra (methylene -- -- -- 0.5 phosphonic acid (g/l)Tensile Fe.sup.++ Warp 17.0 20.0 21.0 21.5 22.0 21.8strength Weft 8.4 10.4 10.5 11.2 10.9 11.8(kg/10 mm) Cu.sup.++ Warp 13.5 15.0 16.5 17.1 16.9 17.3 Weft 4.5 5.5 5.8 7.0 7.1 6.9__________________________________________________________________________
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A method of bleaching a cellulosic fiber material with hydrogen peroxide, comprising:
(a) impregnating a cellulosic fiber material with an aqueous bleaching solution containing hydrogen peroxide and a stabilizer comprising:
(i) 1 to 100 parts by weight of at least one hydroxyacrylic acid polymer selected from the group consisting of poly-α-hydroxyacrylic acids, and salts thereof and polylactone corresponding thereto; and
(ii) 1 to 50 parts by weight of at least one organic phosphate acid compound selected from the group consisting of methylene,1,1-diphosphonic acid, ethylidene-1,1-diphosphonic acid, butylidene-1,1-disphosphonic acid, 1-hydroxyethylidene-1,1-diphosphonic acid, 1-hydroxypropyl-idene-1,1-diphosphonic acid, amino-tri(methylenephosphonic acid), hexamethylene diamine tetra(methylenephosphonic acid), triethylenetetramine hexa(methylenephosphonic acid), and salts of the above-mentioned organic phosphonic acids, and
(b) heating the impregnated cellulosic fiber material with steam.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/727,516, filed Oct. 18, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to portable sheltering structures similar to canopies, umbrellas, tents, etc., and particularly to a portable collapsible awning that includes a canopy and a walkway awning extending from the canopy, and further having an end adapted for resting on a vehicle roof to provide door-to-door protection when entering and exiting the vehicle.
[0004] 2. Description of the Related Art
[0005] Covered walkways for protecting users from rain, snow and other inclement weather have been available in a wide variety of configurations for many years. Such walkways are typically in the form of a large umbrella or an awning that is fixed to a building or to the ground in a stationary manner. Although fixed awnings and umbrellas may be collapsed, they are not readily transportable.
[0006] Portable and collapsible covering systems have been utilized for a variety of purposes, and such systems typically include a plurality of support frame members joined together by cross bars, allowing the frame members to be collapsed and expanded in the longitudinal direction, similar in manner to an accordion. Such systems, however, are only collapsible in one direction and, thus, must be transported in a conveyance or vehicle that is at least as wide as the individual frame members. In order to make such a system easily transportable, the width of each frame member must be reduced, which does not allow the covering to serve a large group of people.
[0007] Further, such portable coverings are not adapted for use with a vehicle. If it is desired to provide protection from the vehicle's door to the user's destination, the frame must be positioned close to the door of the vehicle. The frame, however, would prevent the vehicle door from being fully opened. It would be desirable to provide a system allowing for the free opening of the vehicle door and providing a covered walkway from the door to the user's destination. Thus, a portable collapsible awning solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0008] The portable collapsible awning includes a main collapsible frame structure for supporting a canopy. The main collapsible frame is collapsible and portable, adapted for storage and transport in the trunk of a vehicle, and provides transportable protection from the elements. The main collapsible frame structure includes a plurality of vertical supports, which may be in the form of collapsible, telescoping rods. Each of the vertical supports is pivotally joined to one another by collapsible, scissors-like cross bars. The vertical supports define a canopy frame, and are expandable and collapsible simultaneously in both the lateral and longitudinal directions. A retractable wheel is provided on the lower end of each vertical support, allowing the main frame to be easily positioned with respect to the vehicle.
[0009] An auxiliary frame is further releasably attached at a proximal end to the main collapsible frame structure for supporting a walkway awning. The distal end of the auxiliary frame is adapted for releasable mounting on a roof of a vehicle, creating a covered walkway from the vehicle door to the canopy supported only at the ends of the walkway awning, which may be positioned adjacent a building entrance or other destination.
[0010] These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an environmental, side view of a portable collapsible awning according to the present invention.
[0012] FIG. 2 is a side view of the internal frame structure of the portable collapsible awning of the present invention.
[0013] FIG. 3A is a front view of the internal frame structure of the portable collapsible awning of the present invention.
[0014] FIG. 3B is a front view of the internal frame structure of the portable collapsible awning of the present invention in a partially collapsed state.
[0015] FIG. 4 is a partially exploded side view of the internal frame structure of the portable collapsible awning of the present invention in a partially collapsed state.
[0016] FIG. 5 is an exploded perspective view of an auxiliary frame structure of the portable collapsible awning according to the present invention.
[0017] FIG. 6 is an exploded perspective view of the auxiliary frame structure an auxiliary canopy of the portable collapsible awning according to the present invention.
[0018] FIG. 7 is a top view of the internal frame structure of the portable collapsible awning according to the present invention.
[0019] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Now referring to FIG. 1 , there is shown a portable, collapsible awning, referred to generally as 10 in the drawings, providing easily transportable protection from the elements. Particularly, the portable collapsible awning 10 includes a main support frame 14 for supporting a main canopy, formed from first and second canopy sheets 16 and 18 , and a walkway awning 20 extending from the main canopy, and which is supported on a removable frame, which will be described in further detail below.
[0021] As best shown in FIG. 1 , a proximal end of walkway awning 20 is supported by the main support frame 14 , and the distal end rests on the roof of vehicle 12 , thus providing a covered walkway from the vehicle door to the user's destination while providing clearance for the opening of the vehicle door. Since the walkway awning 20 is only supported at its ends without any intermediate vertical columns or posts, the walkway awning 20 allows the main support frame 14 to be distanced apart from the vehicle, leaving ample space for the opening of the vehicle door, while providing a continuous covered walkway for the user. A magnet 21 or any other suitable means for releasable attachment may be mounted to awning 20 , if desired, for securing the awning 20 to the roof of the vehicle. Preferably, magnet 21 is covered with cloth or other covering material for preventing scratches or other damage to the roof of the vehicle. The magnet 21 may be secured to the awning 20 by any suitable process, dependent upon the needs and desires of the user.
[0022] As will be described in further detail below, the main support frame 14 is collapsible in the vertical, lateral and longitudinal directions. Further, walkway awning 20 is removable from the main support frame 14 . The nature of the collapsible awning 10 allows the awning 10 to be easily transported and set up both quickly and efficiently. When not in use, portable, collapsible awning 10 may be stored in the trunk of the vehicle 12 , either on its own or in a separate container or bag. The portable, collapsible awning 10 may be manufactured in any size, depending upon the needs and desires of the user. In the preferred embodiment, the frame 14 , in its expanded state, is approximately nine feet long in the lateral direction and approximately sixteen to eighteen feet long in the longitudinal direction, thus providing enough space for several people to fit underneath the awning 10 .
[0023] Canopy sheets 16 and 18 and the walkway awning 20 are formed from lightweight, waterproof materials, such as canvas, nylon, vinyl, plastic or the like. Canopy sheets 16 , 18 and walkway awning 20 may have indicia printed thereon, or may include decorative elements, such as the frill border shown in FIG. 1 .
[0024] FIG. 2 shows the internal frame structure of the portable, collapsible canopy 10 , without the canopy sheets 16 , 18 or the walkway awning 20 . The main frame structure is formed from a plurality of vertical supports 22 , which may be telescoping rods, allowing for the collapse of awning 10 in the vertical direction, as will be described in further detail below. A wheel 28 is mounted on the lower end of each vertical support 22 , allowing the support frame 14 to be selectively positioned and transported by the user. As best shown in FIG. 4 , each wheel 28 is retractable within a respective wheel housing 26 . The retraction of wheels 28 within wheel housings 26 allows the frame 14 to be stably positioned and, further, aids in the transport of awning 10 when awning 10 is in its collapsed state. Further, if desired, the assembled awning 10 can be moved by the users during use; i.e., the users could stand underneath the awning 10 and move the awning 10 as they walked, thus providing a mobile covering.
[0025] The structural elements of support frame 14 , including vertical supports 22 , are formed from lightweight, strong and non-corrosive materials, such as aluminum, plastic or the like. As best shown in FIG. 3A , the positioning of vertical supports 22 when main support frame 14 is in its expanded state defines a passage or walkway for the user.
[0026] Each vertical support 22 has a handle 24 pivotally joined thereto, providing hand grips for the user to position the awning 10 . Each handle 24 may be pivoted back into a vertical storage position when not in use, as shown in FIG. 4 .
[0027] As shown in the side view of FIG. 2 and the top view of FIG. 7 , adjacent vertical supports 22 are joined to one another, in the longitudinal direction, by a pair of cross bars 34 , 36 . The upper ends of each cross bar 34 , 36 are pivotally secured to the upper ends of vertical supports 22 by pivot pins 74 . The lower ends of each cross bar 34 , 36 are pivotally secured to sliding rings 32 , which are slidably mounted on vertical supports 22 .
[0028] Each cross bar 34 is pivotally joined at its center to a respective cross bar 36 by pivot pin 38 , to form a pivoting, scissors-like connection. As best shown in the partially collapsed view of FIG. 4 , the pivoting scissors-like interconnection of cross bars 34 , 36 and the slidable mounting of sliding rings 32 allows the frame 14 to be easily collapsed and expanded in the longitudinal direction. Further, an upper horizontal support is mounted to the upper ends of vertical supports 22 , extending in the longitudinal direction. As best shown in FIG. 2 and FIG. 7 , each longitudinal support of frame 14 includes a pair of pivotally joined support bars 40 , 42 . The longitudinally opposed ends of support bars 40 , 42 are pivotally secured to opposed vertical supports 22 by pivot pins 74 , and support bars 40 , 42 are pivotally joined to one another by pivot pin 44 . As shown in FIG. 4 , when the frame 14 is in a collapsed state, support bars 40 , 42 pivot downwardly in order to conserve space, thus maintaining the transportable profile of frame 14 .
[0029] As shown in the front view of FIG. 3A , the vertical supports 22 are joined to one another in the lateral direction in a similar manner to that described above with respect to the longitudinal direction. The upper ends of cross bars 56 , 58 are pivotally joined to the upper ends of vertical supports 22 by pivot pins 75 , similar to the pivotal connection of pivot pins 74 , described above. Cross bars 56 , 58 are joined to one another at their centers by pivot pin 60 , pivotally joining cross bars 56 , 58 in a scissors-like configuration.
[0030] The lower ends of cross bars 56 , 58 are pivotally secured to sliding rings 30 , which are mounted on vertical supports 22 . As shown, sliding rings 30 are positioned below sliding rings 32 and, as illustrated in FIG. 3B and FIG. 4 , sliding rings 30 and 32 move up and down on vertical supports 22 simultaneously, thus providing for the simultaneous expansion and collapse of frame 14 in both the longitudinal and lateral directions. This simultaneous collapse and expansion in both directions allows for the optimally efficient set up and collapse of the awning 10 .
[0031] Similar to the longitudinal horizontal supports 40 , 42 described above, a lateral horizontal support, formed from support bars 62 , 64 , is mounted on the upper ends of vertical supports 22 in the lateral direction. Support bars 62 , 64 are pivotally mounted to vertical supports 22 at their opposed ends by pivot pins 75 , and are pivotally joined to one another by pivot pin 66 . As shown in FIG. 3B , in the collapsed state, support bars 62 , 64 pivot downwardly, similar to the pivoting of support bars 40 , 42 , in order to minimize the size of frame 14 in its collapsed and portable state.
[0032] As best shown in FIG. 2 , canopy supports 46 , 48 are provided for supporting, respectively, canopy sheets 16 , 18 . Each canopy support is pivotally mounted to a vertical support 22 at its lower end by pivot pin 74 . Canopy supports 46 , 48 are not joined to one another. Each support 46 , 48 has an upper edge contoured in such a manner that the upper edges abut one another, but are not fastened to one another, the supports 46 , 48 forming a gabled or arched roof frame. This allows canopy supports 46 , 48 to be pivoted downwardly, as shown in FIG. 4 , when it is desired to place awning 10 in its collapsed state.
[0033] As best shown in FIGS. 5 and 6 , walkway awning 20 is mounted on a pair of lateral supports 50 , 54 and a pair of longitudinal supports 52 . Lateral support 50 is mounted to the upper ends of vertical supports 22 opposite support bars 62 , 64 . The lateral support 50 is releasably mounted to support frame 14 through the use of hooks, latches or other suitable releasable fasteners. During collapse of awning 10 , lateral support 50 is removed from frame 14 , allowing for the collapse of the awning 10 and the separation and separate storage of walkway awning 20 and supports 52 , 54 .
[0034] As shown in FIG. 5 , lateral support 50 includes a pair of recesses 68 for removably receiving the proximal ends of longitudinal supports 52 . Similarly, lateral support 54 includes a matching pair of recesses 70 for receiving the distal ends of longitudinal supports 52 . Each longitudinal support 52 may be a spring-loaded telescoping rod or tension rod, allowing for the efficient collapse and assembly of awning 10 .
[0035] Lateral support 54 is permanently fixed to the distal end of walkway awning 20 . Thus, during disassembly lateral support 50 , longitudinal supports 52 and the walkway awning 20 with the lateral support 54 are stored separately. In use, lateral support 54 rests on the roof of vehicle 12 , as shown in FIG. 1 . As shown in FIG. 6 , a hook member 72 is formed on the proximal end of walkway awning 20 , allowing for releasable engagement of walkway awning 20 with lateral support 50 .
[0036] Walkway awning 20 with the lateral support 54 , lateral support 50 and the longitudinal supports 52 are all separable and may be stored and transported separately, allowing for the quick and efficient assembly and knock-down of the awning 10 . Frame 14 is, further, collapsible in the vertical, lateral and longitudinal directions, allowing for the efficient assembly and collapse of the entire awning 10 , which may be easily transported and stored in, for example, the trunk of vehicle 12 . The separate parts of the collapsed and disassembled awning 10 may, alternately, be stored in a bag or other storage container. The awning 10 provides a covered walkway from the vehicle door to the user's destination and is appropriate for use at weddings, proms, formal occasions, vehicle valet stations, funerals or any other event, locale or occasion where a covered walkway would be necessary or desired.
[0037] It is to be understood that the present invention is not limited to the embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
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The portable collapsible awning provides a main collapsible frame structure for supporting a canopy, which is easily collapsible and portable, providing transportable protection from the elements. The main collapsible frame structure includes a plurality of vertical supports, which are each pivotally joined to one another by collapsible scissors-like crossbars. The vertical supports define a passageway for pedestrians, and are expandable and collapsible simultaneously in both the lateral and longitudinal directions. An auxiliary frame is further releasably attached at a proximal end to the main collapsible frame structure for supporting a walkway awning. The distal end of the auxiliary frame is adapted for overlying a portion of a roof of a vehicle, creating a covered walkway from the vehicle door to the user's destination without vertical supports or frame members intermediate the main canopy and the vehicle.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present invention is a continuation application of U.S. patent application Ser. No. 13/599,567 of Robert H. KOERNER, entitled “DRAINAGE MANAGEMENT SYSTEM AND METHOD,” filed on Aug. 30, 2012, now allowed, which claims benefit of priority to U.S. Provisional Patent Application Ser. No. 61/530,953 of Robert H. KOERNER, entitled “DRAINAGE MANAGEMENT SYSTEM AND METHOD,” filed on Sep. 3, 2011, the entire disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to systems and methods for drainage management, and can include a drain management system employing a weighted object devised for the purpose of positioning and holding down trough structures used for the conveyance of liquids, such as storm water drainage, irrigation distribution, a diversionary device when positioned in rotated positions, and the like
2. Discussion of the Background
In recent years, solutions to combat erosion and drainage typically employ closed piping, prefabricated continual or cast in place concrete lining systems of various shapes and configurations, construction of liners made from materials, such as stones or graded aggregates. However, such drainage management systems and methods typically are not cost effective, are not reusable, and lack ease of maintenance. Therefore, there is a need for a method and system for drainage management that addresses the above and other problems with current methods and systems.
SUMMARY OF THE INVENTION
The above and other problems are addressed by exemplary embodiments of the present invention, which advantageously provide drainage management systems and methods that relate to the inexpensive lining of an open liquid conveyance system and/or diversion of fluids. The drainage management systems and methods of the present invention can be used to hold down an open conveyance system, and not necessarily a closed system.
Accordingly, aspects of the present invention relate to a system and method for drainage management, including a pipe that is cut along a longitudinal section thereof; and a pipe block having a curved section corresponding to a diameter of the cut pipe and including supporting legs. The curved section of the pipe block is configured to support the cut pipe.
The system and method can include an under pipe barrier section located along the drainage management system and configured for stopping flowing water on an outside of the drainage management system for erosion control.
The system and method can include an end pipe barrier section located at an end the drainage management system and configured for disallowing water passage to an outside of the drainage management system to avoid erosion.
The system and method can include an end barrier closing block section located within the end pipe barrier section and configured for closing off an end of the drainage management system.
Still other aspects, features, and advantages of the present invention are readily apparent from the following detailed description, simply by illustrating a number of illustrative embodiments and implementations, including the best mode contemplated for carrying out the present invention. The present invention is also capable of other and different embodiments, and its several details can be modified in various respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the present 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:
FIGS. 1-8 are used to describe drainage management systems and methods, according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention generally relates to systems and methods for drainage management, and can include a drain management system employing a weighted object devised for the purpose of positioning and holding down trough structures used for the conveyance of liquids, such as storm water drainage, irrigation distribution, a diversionary device when positioned in rotated positions, and the like. Advantageously, the drain management system can be used for the construction of an open drainage way by use of inexpensive and readily available and various sized circular plastic or other suitable material pipes of length cut into determined partial circles longitudinally and positioned and held down by weighted objects specifically formed and shaped for the mechanical purposes necessary to perform the intended use. Of equal value is the effect to environmental issues of erosion, sedimentation, enhancing water quality as well as a means of controlling pollution issues, and the like.
The earth is subject to natural and manmade flow of water that obeys the laws of gravity and in the process has developed water courses through all forms of materials. Civilization in developed locations improve on collecting and directing water flows of different sources (e.g., mostly rain) to allow a controlled system to aid in society living a never ending improvement on living conditions for health and welfare. Most collection and conveyance systems end into open area referred to commonly as ditches or waterways, natural and manmade. These areas left unattended in the majority of situations create erosion in quantities and rates depending on the soils the water comes into contact.
Solutions to erosion are closed piping, prefabricated continual or cast in place concrete lining systems of various shapes and configurations, construction of liners made from materials, such as stones or graded aggregates. By contrast, the drainage management systems and methods of the present invention provide for cost effectiveness, reusability, and ease of maintenance, and can be used to stop or prevent erosion, while at the same time controlling water flow energy, removing sedimentation from flowing water, and the like.
To counteract erosion that is considered destructive to the health and welfare of the people in many forms, laws as well as common sense approaches are applied to the drainage systems to prevent erosion. An example of a devised system is the Smart Ditch System (see, e.g., the World Wide Web at smartditchsystem.com). Such a system is a specifically manufactured plastic conveyance system that is positioned and held down with mechanical anchor devices made specifically for the system. However, what is not accomplished by such a system is use of materials already commonly available worldwide, nor does the system allow for simple and fast installation, nor the ability to allow replacement or relocating of the system without any problem or loss of the original value.
Therefore, there is a need for a method and system for drainage management that addresses the above and other problems with current methods and systems. The above and other needs are addressed by embodiments of the present invention, which provide drainage management systems and methods of the present invention that need not replicate mat type systems of any suitable type for bank type erosion from running water or wave/tidal action of moving water. In addition, the drainage management systems and methods of the present invention need not be employed for holding down items in water, such as pipelines or cables of any suitable type. Rather, the drainage management systems and methods of the present invention relate to the inexpensive lining of an open liquid conveyance system and/or diversion of fluids. The drainage management systems and methods of the present invention can be used to hold down an open conveyance system, and not necessarily a closed system.
Accordingly, in illustrative aspects, there are provided systems, and methods for drainage management including at least one of a cut pipe as shown or described in FIG. 3 ; and a pipe block as shown or described in FIG. 1, 2 or 4 . The systems and methods further comprising an under pipe barrier section as shown or described in FIG. 5 , an end pipe barrier section as shown or described in FIG. 6 , and an end barrier closing block section as shown or described in FIG. 7 .
Advantageously, the drainage management systems and methods of the present invention can employ use of common materials in a manner to lower required expertise, lower investments for production, lower material costs, lower material shipping costs, lower installation costs, lower level of preciseness needed for installation, lower maintenance costs, lower replacement costs, create a 100% recyclable green product, stop or prevent soil erosion, stop or prevent bank sloughing, create sedimentation pooling, oxygenate water by turbulence, reduce water flow energy by turbulence, and the like.
In FIGS. 1-8 , a pipe ditch liner 200 (e.g., made of plastic or any other suitable material, etc.) shown in FIG. 3 , can be a commonly manufactured solid, ribbed, or rib lined plastic or other material drainage pipe in any suitable diameter of various lengths and that are cut in half, in third, or any suitable lesser radian of a circle of the pipe, etc., as needed, longitudinally as shown with cut lines 201 to provide a liquid flow area of approximately one half, one third, or any suitable lesser radian of the circle of the pipe, etc., being used. Such cut pipe can be performed at and obtained from the pipe factory, which then allows lower shipping costs due to the bulk dimension of a pipe being reduced due to use of space not determined by the full circumference of the pipe. Existing manufactured pipes 200 can also, with minimal time and tools, be cut at the installation site, if necessary.
Jointing of continuous pieces can be performed as the pipe is manufactured with an “over under” lapping as an industry standard shown at 202 and commonly known as “bell and spigot” or “male and female connector” (e.g., manufactured or easily cut in the field for custom lengths of pipe). Existing systems of “sealing the joint” as shown at 202 can be performed at the user's discretion for the effectiveness of the seal at the joint 202 .
Placement of such a piping segment 200 allows for liberal line/grade or bedding conditions. The half pipe 200 stops the bottom erosion of soils keeping the water from saturating earth on the bottom or sides of a natural or constructed soil system. The pipe 200 can be held in place by pipe blocks of FIGS. 1-2 and stops the bottom side slopes from sloughing into the flow area due to the solid side wall structure of the pipe 200 to counteract tangential forces. The pipe 200 holds back the side walls and is kept in shape and from moving by the forces induced by the pipe blocks of FIGS. 1-2 .
In FIGS. 1-2 , concrete blocks or pipe blocks 100 can be suitably shaped and for example, made of reinforced concrete, and the like. The material can be concrete 101 for the its strength, longevity, and weight along with reinforcement 102 to unify the block 100 during manufacturing, transportation, and installation, creating an engineered product adhering to design structural codes and standards for use and safety. The profile shape of the block 100 can include a radius 103 that within a suitable tolerance is the same as the inside diameter of the pipe 200 associated therewith, so as to conform to the general inside diameter of the pipe 200 size being used. Such tolerance provides a frictional fit due to the mass of the block 100 as the block 100 rests upon the pipe 200 at predetermined suitable intervals, providing a great reduction of seepage of water between the block 100 and the pipe 200 , and provides the forces necessary to mechanically lock joints by using gravity due to the mass of the block 100 gravity force and the opposite or opposing force of the material under the pipe 200 .
The thickness of the radius concrete 104 induces turbulence as fluids flow over them and between the installed blocks 100 and the interior of the pipe 200 surface intentionally to reduce water flow energy with the added result of the settlement of sediment within the system to be cleaned out periodically, and which stops sedimentation from flowing down stream to natural waters and provides the advantage of the turbulence oxygenating the water to aid in the bio degradation of organics in the water.
A top portion 105 connects the internal radius structural element to the external two legs 106 , which sit outside of the piping 200 being used. The design is such to allow for lifting of the block 100 with various rigging methods and to allow variability for thickness of the wall of the pipe 200 manufactured by various styles or designs. The two legs 106 are vertical and include a height 107 of approximate determination related to the radius 103 and thickness 104 of the pipe 200 used, plus an increased minor addition 108 of approximately 2 inches to allow the legs 106 to settle into the earth a minimal amount before the exterior of the pipe 200 being held down contacts graded base material and undergoes the process of natural settlement of the legs 106 alone as time goes by. This allows the piping system to balance the distribution of static and dynamic, natural and induced forces, between the bottom of the exterior pipe 200 and the legs 106 after legs 106 are initially settled. The lengthening of the legs 106 to the length 107 provide an initial settlement of the block 100 into the soils to prevent the tangential forces shifting of the block 100 after placement and during the exterior backfilling of the piping system against exterior walls and blocks.
As shown in FIG. 1 , the height by H 1 relates to the pipe diameter and concrete thickness. The width W 1 is the pipe thickness (e.g., 2 inches or more). The inside pipe diameter is shown by D 1 . The height H 2 relates to the concrete thickness. The width W 2 can be around a minimum of 5 inches. The legs 106 are tapered as shown by T 1 so as to be wider at the bottom for assisting form release, and the like. The pipe thickness T 2 can be variable, as needed. The width W 3 can relate to the pipe thickness, for providing additional space, and based on the concrete thickness.
In further illustrative embodiments, the profile of the section 105 need not be square shaped at the internal and external edges or corners, and the like. For example, the transition direction changes at the section 105 can have a curved shape (e.g., as in FIG. 4D ) or any other suitable geometrical shape, and the like, for manufacturing, structural, or esthetic, and the like, purposes, as will be appreciated by those of ordinary skill in the relevant art(s).
The depth dimension 109 (e.g., or side width of the block 100 sitting longitudinal on the half pipe 200 ) of the block 100 can be a calculated dimension for the calculated weight of the novel block 100 for the following reasons. The block 100 induces the natural force of gravity to counteract the natural lifting force of buoyancy. The buoyancy of a piping system used in areas with a fluid nature can be subject to the lowering of frictional soil values and the natural laws of engineered displacement of fluids. The block 100 induces the natural forces of gravity to counteract the natural lifting force of frost. Since some installation of the system can include areas subject to frost of various depths and may not be of a diameter radius depth to be below the established frost line, the block 100 can use the element of mass to reduce this frost force. The block 100 mass is also a factor to determine spacing of the blocks 100 set on the continually installed pipe 200 . A cost analysis of production, handling, transporting, and installation can determine a suitable spacing, center to center, for example, of 10 lineal feet, and the like. However, alternate sizing with a relationship to mass and material type and joint spacing can be altered to fit specific conditions including the complete lining of the plastic pipe 200 . This alternate use lends itself to the upward extension of the legs to produce a “wall” effect above the original system technology cast as part of the block unit. Advantageously, the dimensional depth in conjunction with concrete block 100 thickness aides in the spanning of the joints held in place by the mass creating frictional values between base material to plastic, plastic to plastic, plastic to concrete, while compressing the joint between the base material and the block 100 .
As shown in FIG. 2 , the block 200 can employ the reinforcements 102 that are cage bar centered as shown by CBC, and which can be based on industry standards, codes, and the like, as needed. The reinforcements 102 can include variable cross pieces for reinforcement, cage stabilization, lift hook extensions, and the like.
As shown in FIG. 3 , the length L can vary, as needed, and the cut pipe 300 can be made from a common ribbed plastic pipe, and the like. The cut pipe 300 can include bell and spigot lap joint ends 202 .
In FIG. 4 , alternate variations of the blocks 100 and potential uses of the system are shown. The pipe blocks 100 can be manufactured in profiles to range from vertical 110 to horizontal 111 installations. The pipe blocks 100 also can be manufactured to radian 112 sections for wide but shallow uses. The blocks 100 can be manufactured to allow an angled (e.g., any suitable angle between 110 to 111 ) installation of the pipe 200 for desired installation. The blocks 100 can be manufactured to allow an angled installation of the pipe to aid in wave or tide water from fully extending into a shore line. This use has the potential of a fast and temporary installation to hinder the travel of pollutants floating on water from intrusion into inland areas. Short installations in midstream are possibilities for material control for the potential of redirecting flow to stop downstream bank erosion (e.g., one piece installed and then covered with big rock unifies the rocks so water acts against the unit of rocks instead of each individual rock).
As shown in FIG. 4A , a plastic pipe can slide into the pipe block 110 for vertical position of pipe section, as shown by S. In FIG. 4B , the pipe block 112 can be configured for a radian section, wide but shallow installation. In FIG. 4C , the pipe block 111 can be configured for normal applications. In FIG. 4D , the pipe block 130 can be configured with curved shapes.
In FIG. 5 , an under pipe barrier section 113 is shown. The precast concrete section 113 can be of a considerable size larger than the pipe 200 section for the purpose of stopping flowing water on the outside of the pipe block system to aid in erosion control, line, and grade of pipe 200 being installed in conjunction with normal installation of pipe blocks 100 . The pipe barrier section 113 can be employed at the beginning and end sections of the system and/or wherever deemed necessary. The elements of the barrier 113 include a reinforced slab of concrete with lifting holes 116 . A partial circumference relating to the exterior diameter of the ribbed exterior wall of the pipe being used is molded at 114 . A novel portion of the barrier 113 is the integral formed lip 115 that is sized to fit between the plastic pipe 200 ribs. The weight of the pipe block above completes the mechanical connection that virtually prevents water flow passing along the outside of the pipe block system to stop erosion and resulting displacement or settlement of the surround backfill. This is also a benefit to tangential above grade connections for surface drainage with our without a main tributary system. Formed in place, the lifting holes 116 add convenience to the barrier 113 .
In FIG. 6 , an end pipe barrier section 117 is shown. The barrier 117 is best used at the upstream end of a pipe system, but can also be used at the downstream end piece, if caution of seepage is addressed with sealant materials. The purpose of the barrier 117 is to disallow water passage to the outside of the pipe system to avoid erosion or the costly installation of onsite cast in place methods. The elements are novel in that a simple placement of the pipe 200 used is fitted into the cast in place groove 118 for preventing the pipe 200 from horizontal and vertical motion up or down or sideways. In conjunction with the placement of a pipe block 100 adjacent to the end barrier 117 , the weight of the designed block 117 prevents lifting from buoyancy or frost lift while using the extent of bottom surface area of the pipe block 100 and barrier 113 counteracting settlement. The overhang lip 119 replicates the profile of the interior shape in a normal pipe block 104 allowing for continuity of the system. Lifting holes 120 are of value for lifting of the barrier 117 for manufacturing, transportation, and installation as well as removal for maintenance or re-use.
In FIG. 7 , an end barrier closing block section 121 is shown. The closing block 121 is manufactured to sit within the end pipe barrier 117 to close off the entire end at the beginning or end of a pipe block system. Placement at of the closing block 121 on the inside or outside of the end pipe barrier 117 is determined by the purpose needed and soil conditions and the feeding method into the pipe block system. The block 121 benefits from dimensional stability and weight to remain in place. The extended lip 122 aligns against the parallel surface of the end pipe barrier 117 and prevents tangential movement in horizontal directions due to soils positioned against the backside on upstream installation, or the additional connection of drilled in place drop pins for downstream applications or as additional locking of the block to the end barrier. As with other components, a lifting hole 123 provides for safe and easy movement of the component.
In FIG. 8 , the drainage management systems is shown, for example, including the pipe block 100 , the cut pipe 200 , the end pipe barrier 113 or 117 and the closing block 121 that fits on the end pipe barrier 117 (not shown). Thus, the drainage management systems and methods of the present invention can include the reinforced concrete blocks of FIGS. 1-2 and 4-8 and the pipes 200 of FIG. 3 shaped to line ditches for controlling movement of channeled water, tides, or waves from bodies of water. The application of the drainage management systems and methods counteract the natural forces of buoyancy and frost lift, stop erosion of bottom soils and stop bank sloughing due to soil saturations at the base flow line and vertical erosion undermining side banks. In the common installation of lining an open ditch, the pipe 200 of FIG. 3 lines a minimal lower portion of an open natural conveyance system for water or fluid drainage and is kept on line and grade by the mass of the concrete blocks of FIGS. 1-2 and 4-8 counteracting buoyancy and frost lift. The variations for vertical, angled, or normal installations are variable in all parameters of dimensions or site conditions and for the purpose intended. The profile of pipe 200 of FIG. 3 can be of any suitable radian degree so as to meld with the shape of the pipe blocks of FIGS. 1-2 and 4-8 .
Advantageously, the drainage management systems and methods of the present invention employ common manufactured materials in a different form, require minimal cost of manufacturing and handling, provide a system not in existence of such simplicity and cost through all phases of production, transportation, installation, provide a product reducing long term maintenance and repair, provide a product completely recyclable or reusable or relocated, stop ditch bottom erosion, stop side bank sloughing, clean sediment out of water, oxygenate water, reduce water flow energy with minimal capacity rate change, provide a low tech production and installation product easily learned in the field, are usable as a method for shoreline disaster pollution, are usable as a stream or river side bank erosion possibilities, are usable as an in stream diversion to avoid downstream bank erosion, and are usable as an irrigation distribution system, and the like.
Although the systems and methods of FIGS. 1-8 are described in terms of being employed for drainage management, and the like, the systems and methods of FIGS. 1-8 can be employed for other types of suitable applications where water flow and erosion management are desired, as will be appreciated by those of ordinary skill in the relevant art(s).
While the present inventions have been described in connection with a number of illustrative embodiments, and implementations, the present inventions are not so limited, but rather cover various modifications, and equivalent arrangements, which fall within the purview of the appended claims.
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Systems and methods for drainage management, including a pipe that is cut along a longitudinal section thereof; and a pipe block having a curved section corresponding to a diameter of the cut pipe and including supporting legs. The curved section of the pipe block is configured to support the cut pipe.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of U.S. patent application Ser. No. 07/052,723,filed May 20, 1987 now abandoned which is a continuation of U.S. application Ser. No.818,993 filed Jan. 13, 1986, now U.S. Pat. No. 4,639,262 which is a continuation-in-part of U.S. application Ser. No. 622,217, filed Jan. 19, 1984 abandoned, which is a continuation-in-part of U.S. application Ser. No. 568,717, filed Jan. 6, 1984 now U.S. Pat. No. 4,572,728, which is a continuation-in-part of U.S. application Ser. No. 511,270, filed July 6, 1983, now U.S. Pat. No. 4,498,303 which are incorporated herein by reference.
TECHNICAL FIELD
This invention relates generally to the recovery and liquefaction of carbon dioxide and relates more particularly to a process and application for liquefying a flow of relatively low purity carbon dioxide gas in conjunction with providing an economical commercially resalable food grade carbon dioxide product.
BACKGROUND OF THE INVENTION
The United States of America has a policy of utilizing the present national coal reserves of approximately 3.5 trillion tons of coal in the 820 power plants that will burn coal over the next 100 years. This will produce about 10.29 trillion tons of carbon dioxide to be vented to the atmosphere. The world is now being made aware of the "greenhouse effect" which predicts that the accumulation of carbon dioxide and other gases in the atmosphere will raise the global temperature by about 2° C. by 2050 and by about 5° C. by 2100. This is expected to be disastrous and accordingly, all nations are preparing immediately to reduce carbon dioxide emissions drastically. The United States Government has issued a report of a study of this problem "Can We Delay a Greenhouse Warning?" This study notes that control of CO 2 emissions from plants is an important step to take, and that the only technically feasible process is that of absorbing CO 2 in nonethanolamine (MEA process), but that process is too costly in that it seriously reduces the capacities of the plants so much that it would not be economically feasible. Applicant's process is intended to meet that problem head-on and provide an economically feasible process for removing CO 2 from stack gases or other gas streams low in CO 2 content, i.e., less than about 85% CO 2 .
Another advantage of the present process is to provide carbon dioxide and nitrogen for use in programs of enhanced oil recovery (EOR). These programs are designed to go beyond the present art of primary and secondary methods of recovering petroleum from underground reservoirs. Only about 25-30% of the petroleum is recovered by the conventional primary and secondary methods. EOR programs increase that recovery to about 45-50% using carbon dioxide and nitrogen. Approximately 900-5400 cubic meters of CO 2 are required per cubic meter of petroleum recovered. The applicant's process will provide an economical source of CO 2 for such a process.
The process of this invention was developed specifically, over a period of about 6 years to recover carbon dioxide economically from gas streams which all other processes, e.g., MEA process, fail to do at all or fail to do in an economically feasible fashion. Preferred procedures in the process of this invention are accomplished by using any of three types of patented separators for the separation and liquefaction of carbon dioxide from the treated gas stream contaminated with carbon dioxide. The patented separators are described in U.S. Pat. Nos. 4,498,303; 4,572,728; or 4,639,262; and they describe gas-to-gas separation and gas-to-liquid separation. The step of separation is the key to an economically feasible process that does not rely on any expensive solution step such as in the MEA process. Other features of the present process are to utilize for heating or cooling any of the various gas and liquid streams in the process for heat exchange with other streams in the process. Furthermore, heat energy is converted to kinetic energy by expanding pressurized gas in turbines that may drive electric generators to produce electric power for use in the plant. The treated gas streams contain substantial amounts of nitrogen and oxygen and these gases are separated, purified and liquefied to produce valuable products that may be sold commercially and thereby reduce overall costs of removing carbon dioxide from flue gases and other gas streams vented to the atmosphere. There is no teaching in the prior art to expect that a process of this type would be successful in an economic sense. As a matter of fact, the consensus of the industry was that it would be impossible to accomplish. Hence, the MEA process was considered by the U.S. Government to be the only way to separate carbon dioxide from low purity streams, i.e., less than about 85% CO 2 .
The present process also purifies the flue gas of oxides of sulfur and the oxides of nitrogen so that the purified gas stream that is vented to the atmosphere will meet more stringent specifications than the Government's Environmental Protection Agency standards. The contaminating flue gas stream will be purified of sulfur dioxide to less than 0.3 PPM, carbon monoxide less than 10 PPM, and oxides of nitrogen to less than 10 PPM by volume. These food grade carbon dioxide specifications are current industry standards. The purification of the contaminating gas of vaporous odors and particulates are not part of this invention and therefore, are not discussed for both simplicity and proprietary reasons.
Various present methods of liquefying high purity 90% or better carbon dixoide gas are well known. Typically, the liquefaction process of a relatively pure carbon dioxide comprises of compressing the gaseous carbon dioxide to a pressure of approximately 233.85 psig to 312.1 psig and then removing the latent heat of condensation with a secondary refrigerant at an evaporating temperature below the saturation temperature of the carbon dioxide pressure or -12° F. or -4° F. respectively. The theoretical range of pressures over which vaporous carbon dioxide can be condensed to a liquid is approximately 60.43 psig to 1057.4 psig.
Low purity carbon dioxide also contains contaminating gases with a lower temperature of condensation than carbon dioxide and these contaminating gases require a lower temperature refrigerant to condense than the carbon dioxide vapors. Therefore, the carbon dioxide may be separated from a contaminating gas source by fractional condensation. This invention specifically removes the carbon dioxide vapors from a gas stream between any compressor created saturation point down to the triple point of carbon dioxide. Any carbon dioxide below the triple point is unrecoverable.
This invention relates to a process for recovering carbon dioxide vapors from a gas stream such as flue gas, industrial waste gas streams or any other low purity carbon dioxide gas stream, particularly to a process for recovering carbon dioxide at purities of less than about 85% that are too low to recover economically by a conventional carbon dioxide liquefaction system. It specifically replaces the MEA chemical absorption process. This invention produces carbon dioxide liquid or vapor at a substantial utility cost reduction below all existing MEA technology.
It has proved to be most difficult and costly to recover, purify and liquefy the carbon dioxide vapors when they are present in low concentrations in a gas stream. Thus, all known processes which recover carbon dioxide vapors present in a gas at low concentrations involve high investment and/or production utility costs. In particular, in all MEA type absorption processes, the excessive amounts of steam required to regenerate the absorbent prohibits economic recovery of carbon dioxide from low purity gas sources, such as a steam boiler flue stack gases which are in the magnitude of 8 to 15% volume carbon dioxide purity.
There are basically three types of carbon dioxide vapor and gas stream recovery combinations: (1) 85-100% pure carbon dioxide vapor-laden streams, (2) less than 85% and greater than 50% carbon dioxide vapor-laden gas streams, (3) 50% and less carbon dioxide vapor-laden gas streams. In Item (2) above, we are removing the non-condensable gases from the condensable carbon dioxide vapors. In Item (3) above, we are removing the condensable carbon dioxide vapor from the non-condensable gases. The above is determined mathematically by the ratio of the carbon dioxide vapor pressure to the partial pressure of the non-condensable gas stream. When this ratio is greater than one, we are removing the non-condensable gas from the carbon dioxide vapor. When this ratio is equal to one or less, we are removing the carbon dioxide vapor from the non-condensable gas. When we are removing a non-condensable gas from a carbon dioxide vapor we reach the point in fractional condensation where this ratio becomes one and then the carbon dioxide vapor must be removed from the non-condensable gas.
The removal of carbon dioxide from the non-condensable gas can occur only when the carbon dioxide vapor pressure is above the carbon dioxide triple point of -69.9° F. The removal of carbon dioxide vapor pressure below the triple point will cause freezing of the carbon dioxide. Therefore, the carbon dioxide vapors contained in the non-condensable gas who's dewpoint is below the triple point is non-recoverable vapors and are vented.
The invention has two types of non-condensable vent procedures; a continuous vent process and a batch vent process. The batch vent process is applicable for approximately 50% or greater carbon dioxide purity gas stream. It's primary advantage is that it minimizes the amount of non-recoverable carbon dioxide vapor vented. It operates on the basic principle that the higher the non-condensable gas pressure, the less carbon dioxide vapor at saturation conditions it will hold. The carbon dioxide vapor pressure maintained equilibrium conditions and any increase in carbon dioxide vapor pressure will condense to a liquid. The continuous vent process will vent all the carbon dioxide vapors in the non-condensable gas stream. Example: a 95% carbon dioxide vapor stream at -12° F. will vent 5.3% of the carbon dioxide vapor on a continuous vent process. The same 95% carbon dioxide vapor stream will vent 1.0% of the carbon dioxide vapor on a batch vent process.
BRIEF SUMMARY OF THE INVENTION
This invention relates to a process for the recovery of carbon dioxide from a gaseous mixture containing water and less than about 85% carbon dioxide, the process which comprises:
a. cooling the gaseous mixture to remove substantially all water;
b. compressing the cooled gaseous mixture to an elevated temperature and pressure and drying the compressed gaseous mixture to a dewpoint of not higher than about -85° F.;
c. cooling the compressed dried gas to liquefy said carbon dioxide therein and to separate the liquid carbon dioxide from the remaining noncondensed gas mixture; and
d. heating the noncondensed gas mixture and expanding said gas to produce kinetic energy and a cooled gas mixture.
In one specifically preferred embodiment the invention includes the use of any available hot gas or liquid stream to heat the noncondensed gas mixture in step d. and the conversion of the heat energy in that hot noncondensed gas mixture into kinetic energy by expansion in a turbine. In another embodiment the gaseous mixture treated in step a. is a flue gas containing less than 50% carbon dioxide. In still another embodiment the compressed dried gas of step c is introduced into a mass of liquid carbon dioxide to cause condensation of the carbon dioxide in that compressed dried gas.
In one preferred embodiment the original gas mixture is cooled to condense and remove nearly all of the contaminating water vapor and at the same time to reduce the specific volume and density of the gas stream, thereby, reducing the horsepower requirements of compression. The gas stream is then compressed to an elevated pressure, so that the partial pressure of the carbon dioxide is equal to a saturation temperature of approximately -12° F. or some other preferred saturation temperature.
All water vapor is removed from the contaminating gas stream at either an intermediate pressure or the discharge pressure of the gas compressor by desiccant drying to produce a water vapor dewpoint at pressure (DPP) of -85° F. This low dewpoint eliminates the freezing of water vapor during the separation and liquefaction of the vaporous carbon dioxide. The frost and ice formation in the carbon dioxide liquefier/separator would cause reduced capacity and eventual blockage of the liquefier/ separator with the results of no liquid carbon dioxide output to the storage tank.
The compressed and dried low purity carbon dioxide gas then passes through a gas to gas regenerative type heat exchanger. It's primary function is to recover the mechanical refrigeration energy expended to cool the separated high pressure contaminating gases. The gas to gas cooler accomplishes this energy savings by cooling the compressed and dried low purity carbon dioxide gas stream while in count-current flow it warms the refrigerated or cooled contaminating gases.
The compressed and dried low purity carbon dioxide gas then enters the gas to liquid separator (U.S. Pat. No. 4,498,303), or the gas to gas separator (U.S. Pat. No. 4,572,728 or U.S. Pat. No. 4,639,262) for liquefaction and separation of the carbon dioxide vapors from the contaminating gases. The gas to liquid or gas to gas separator is basically a vertical carbon dioxide absorber tower. The compressed carbon dixoide vapors are absorbed in the absorbent liquid carbon dioxide and the non-condensable gases pass through the absorbent and are vented.
The cooled separated non-condensable gas, further, is used as the coolant to cool the low purity carbon dioxide gas stream prior to compression. This step of the process has a dual advantage in that it recovers the mechanical refrigeration energy required to cool the separated high pressure contaminating gasses and at the same time recovers waste heat energy from the low purity carbon dioxide gas stream for recovery in an expansion turbine as mechanical work.
The recovery of the compression horsepower energy and waste heat is accomplished by an expansion turbine and converted by a generator to electrical power for the various compressor motors. In an especially advantageous mode the expansion turbine consists of multiple stages of expansion. Each stage is pre-heated by alternate sources of heat recovery. It is another object of the expansion turbine to use the expanded low pressure contaminating gas stream as a refrigerant for use in the liquefier/separator inplace of a conventional mechanical refrigeration system or for other process coolant requirements, such as gas coolers, compressors intercoolers and aftercoolers or precoolers. In the especially advantageous mode, by balancing the work generated into electrical power by the expansion turbine versus the refrigeration gas produced by the expansion process, will allow the lowest overall kilowatt reduction in the production of the food grade carbon dioxide. This has the results of minimum utility costs per pound of carbon dioxide produced.
These and other objects, features and advantages of the present invention will become apparent after a review of the following detailed description of the disclosed embodiment and the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing FIG. 1 is a single line flow schematic view of a disclosed embodiment of the low purity carbon dioxide recovery system of the present invention. It depicts the preferred mode of the embodiment of the expansion work process.
The drawing FIG. 2 is a single line flow schematic view of a disclosed embodiment of the low purity carbon dioxide recovery system of the present invention. It depicts an advantageous mode of the embodiment of the combination expansion work and refrigeration process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawing there is shown a preferred embodiment 100 of the invention wherein a flow of relatively low purity carbon dioxide gas is purified, compressed, dried, separated and liquefied in conjunction with providing pure food grade liquid or gaseous carbon dioxide or an industrial grade liquid or gaseous carbon dioxide. The typical source of low purity carbon dioxide gas is from an industrial high sulfur 3 to 4% coal fired electrical power generation plant and commonly called flue gas. This flue gas contains relatively large amounts of contaminating gases such as nitrogen, water vapor, sulfur dioxide and oxygen. The major contaminate nitrogen has a substantially lower condensation temperature than that of carbon dioxide. The embodiment 100 will typically be used to advantage in a flue gas separation (FGS) plant for the commercial production of foodgrade liquid carbon dioxide and or nitrogen.
The impure and lean carbon dioxide gas stream will be flue gas from the combustion of a fossil fuel. The flue gas is removed downstream of the electrostatic precipitator relatively free of solid particulates (fly ash, coal dust and mineral matter) and at a temperature of at least 350° F. and perhaps as high as 1200° F. or more. The sulfur content of the fuel has been reduced from 3.7% to less than 0.3PPM by volume of sulfur dioxide. The constituents of the cooled flue gas at 60° F. and 14.7 psia or at the inlet to the flue gas compressor is approximately nitrogen, 77%, carbon dioxide 14%, oxygen 4%, sulfur about 0.3PPM, and the remainder water vapor.
The flue gas is conducted via conduit 1 to the inlet of the flue gas cooler, heat exchanger, 2 the heat exchanger is either a conventional shell and tube or the finned coil type. The coolant in the shell is refrigerated nitrogen gas from the carbon dioxide separation process. The cooled flue gas and any condensed water is carried by conduit, 3 to water separator (knock-out drum) Item 4. All condensed water vapor is separated from the flue gas stream and the condensed water is sent to drain by a water trap or water-leg seal. The flue gas with a reduced water dewpoint is conducted by conduit 5 to the second stage flue gas cooler, heat exchanger Item 6. The flue gas cooler is either a conventional shell and tube or finned coil type. The coolant in the shell is evaporated ammonia from the mechanical refrigeration system. The cooled flue gas and any condensed water is carried by conduit 7 to water separator (knock-out drum) 8. All condensed water vapor is separated from the flue gas stream and the water is sent to drain by a water trap or water-leg seal.
The flue gas with reduced water dewpoint is conducted by conduit 9 to the inlet of the gas turbine flue gas compressor set, 10. The gas turbine flue gas compressor set consists of the following items:
10A - Flue Gas Compressor-Centrifugal Type,
10B - Power Turbine,
10C - Air Turbine,
10D - Fuel Combustor, and
10E - Air Compressor
The centrifugal flue gas compressor using a gas turbine driver serves as the first stage or first two stages of gas compression. The flue gas is discharged at an elevated pressure and cooled by a conventional aftercooler (not shown) to 95° F.
This compressed and cooled gas is conducted via conduit 11 to the inlet of a direct contact flue gas cooler or water wash 12. This is a packed bed counter current flow vertical scrubber. The once-thru water coolant flow rate 46 is adjusted for 1 to 2° F. temperature rise of the effluent discharge water to drain 47.
The cooled and washed gas is conducted from the top outlet of the water wash 12 via conduit 13 to the inlet of the mulitple stage positive displacement flue gas compressor with electric motor driver, 14. All intercoolers and aftercoolers for simplicity are not shown. At an intermediate stage of gas compression of approximately 300 psig and 95° F. the flue gas is conducted via conduit 15 to a dessiccant type dryer 16 where all the water vapor is removed to a -85° F. dewpoint at pressure (DPP). The dryed flue gas is then conducted via conduit 17 to the next stage of compression. The compressed flue gas is at an elevated pressure of 1200 to 2,000 psia and is discharged from the flue gas compressor at approximately 95° F. downstream of the aftercooler. A trap dryer of a molecular sieve or a dessicant may be installed at the condensing pressure to guarantee a low dewpoint of the gas stream.
This cooled and compressed gas is conducted via conduit 18 to and thru the gas to gas regenerative type precooler, 19. All sensible heat is removed from the flue gas stream and a small amount of latent heat of condensation of the vaporous carbon dioxide may occur. The coolant for the gas to gas precooler, 19, is refrigerated nitrogen gas from the carbon dioxide separation process in 21.
The cooled flue gas is conducted by conduit 20 into the inlet of liquid carbon dioxide separator 21 (as explained in U.S. Pat. No. 4,498,303, dated Feb. 12, 1985). This is a fractional condensation liquefier/separator which liquefies the vaporous carbon dioxide and separates the non-condensable flue gases (N2, 02, etc.). The liquefier is basically a vertical carbon dioxide absorber tower. The compressed carbon dioxide vapors are absorbed in the liquid carbon dioxide (the absorbent) and the non-condensable gases pass through the absorbent and are vented via conduit 23. The liquid carbon dioxide is conducted by conduit 22 to a carbon dioxide liquid storage tank for use. The secondary refrigerant enters the liquefier/separator, 21, by conduit 50 and exits the liquefier/separator, 21, by conduit 49. This refrigerant may be supplied by either a conventional mechanical refrigeration system (two stage), cascade system, Joule-Thomson Valve or expander. Flow control valve 48 maintains a back pressure on the carbon dioxide liquefier/ separator 21, so that the carbon dioxide condensing pressure is 75.1 psia at all times.
The vented nitrogen gas is then conducted from valve 48 via conduit 51 to the gas-to-gas regenerative heat exchanger 19, and is heated from -69° F. to +94° F. The heat source is compressed dry flue gas which is being cooled down in temperature and then heated. Nitrogen vent gas is conducted by conduit 24 to the inlet of the flue gas cooler 2, where the gas is heated to within 6° F. of the flue gas temperature.
The heated nitrogen vent gas is then conducted via conduit 25, to the heat recovery heat exchanger 26, where the nitrogen vent gas is further heated. Heat is applied to the heat recovery heat exchanger via conduit 43 which conducts the exhaust gas at a temperature of at least 850° F., e.g., 850°-1200° F. from the gas turbine engine. The heated nitrogen vent gas is then conducted by conduit 27 to the inlet of the first stage of expansion in the turbo-expander 28. The gas is then expanded down to the first stage discharge pressure. The work produced by the expansion process drives the electrical generator 33 and produces electricity to drive all electric motors on the multi-stage flue gas compressor and mechanical refrigeration compressor. The cooled and reduced pressure nitrogen vent gas is then conducted by conduit 29 to the heat recovery heat exchanger 26, where the nitrogen vent gas is once more heated. Additional stages of expansion and heat recovery are dependent on the waste heat available and the gas pressure available. The work produced by the expansion process drives the electrical generator 33, and produces electricity.
The cooled and low pressure nitrogen vent gas is then conducted by conduit 37 to the conduit 39 and returned to the chimney and a slip stream is separated by valves from the main gas stream. This slip stream is conducted by conduit 40 to the preheaters 41, which heat the dryer purge gas. The heated dryer purge gas is conducted by conduit 42 to the desiccant dryer where it is used to reactivate the dryers desiccant beds. The heat source conducted by conduit 44 for the dryer purge gas preheater is the gas turbine engines exhaust gas from the discharge of the heated recovery heat exchanger 26.
The amount of heat recovery is dependent upon the total heat available from the flue gas stream which is recovered in the 1st stage flue gas cooler, and from heat available from other sources such as high temperature combustion gas, flue stack gas, and other waste heat streams. This will determine the number of turbo expander 28 stages.
Further heat recovery is accomplished in a steam turbine 34. Any onsite waste steam available is conducted via conduit 35 to the inlet of steam turbine 34, which converts the steam heat energy into mechanical energy which drives the generator 33 and produces electricity and reduces the electrical KW costs for carbon dioxide production. The back pressure steam and condensate is conducted via conduit 36 for inplant process application or returned to the boiler as condensate.
It is further part of this invention that both liquid carbon dioxide and liquid nitrogen may be produced simultaneously from the flue gas stream for commercial resale or use. The flow schematic would remain the same as the preferred mode of the embodiment as depicted in FIG. 1 with following process modifications.
The vented non-condensables nitrogen gas in conduit 23 in the outlet of separator 21, a gas-to-liquid carbon dioxide separator, passes through flow control valve 48, which functions as a back pressure regulator. The vented nitrogen is conducted in conduit 51 where through separating valves a slip stream of nitrogen for recovery and liquefaction from a range of 1% to 100% is conducted into conduit 52. Conduit 52 conducts the nitrogen slip stream into a typical nitrogen purification system to reclaim and remove the by-product waste CO 2 . This CO 2 must be removed prior to liquefaction of the nitrogen or it will cause freezing of heat exchangers and orifices. A conventional MEA or other chemical solvent process will be used. Conduit 52 conducts the nitrogen slip stream into a conventional nitrogen refrigeration system, a conventional liquid nitrogen generator or a typical Joule-Thomson Refrigerator. These three conventional nitrogen systems are depicted and explained in detail in the 1968 ASHRAE, Guide And Data Book, entitled "Application in Chapter 49, Page 576, FIG. 3, Typical Joule-Thomson Refrigerator, Page 585, FIG. 19, Nitrogen Refrigeration System and Page 585, FIG. 20, Simplified Flow Diagram of Liquid Oxygen Generator.
It is a further part of the invention that in place of 21 of the preferred embodiment of FIG. 1, there may be used a gas-to-liquid carbon dioxide separator/liquefier (U.S. Pat. No. 4,498,303 dated Feb. 12, 1985), a conventional horizontal or vertical carbon dioxide liquefier, having a shell-and-tube type heat exchanger, or a conventional liquid-to-gas separator.
Further, it is part of this invention that the preferred mode of the embodiment of the combination expansion work and refrigeration process as depicted in FIG. 2 may be used to produce economical food grade carbon dioxide for commercial resale. The fundamental difference of the design is that the centrifugal flue gas compressor is not needed with a gas turbine driver 10 (FIG. 1), and the reheat cycle for the multiple stage turbine expander 28, in conjunction is not needed with the heat recovery heat exchanger 26.
In the preferred mode of operation as depicted in FIG. 2, the discharge temperature of the nitrogen noncondensable vent gas at the outlet of the turbine expander will be approximately -130° F. This cooled nitrogen gas can be used as a refrigerant precooler 23 and in after cooler 19 (FIG. 2). The effluent-warmed nitrogen gas stream will be returned to the chimney at approximately +224.6° F. via conduit 44.
It is also part of this invention that any combination of the preferred mode of the embodiment of the expansion work process as depicted in FIG. 1 and the advantageous mode of the embodiment of the combination expansion work and refrigeration process as depicted in FIG. 2 may be used in conjunction for the most efficient energy system for the specific Carbon Dioxide Recovery Plant installation. Typically, this would permit heat recovery from the flue gas chimney, boiler or other waste heat sources to be used, so that, all intermediate stages of the multiple stage turbo expander may be heated to 600° to 650° F. or other temperature in lieu of using the gas turbine engine exhaust gas. Further, a conventional electric motor driver may be used on the flue gas centrifugal compressor 10A of FIG. 1, in pace of the depicted gas turbine driver.
It is also part of this invention that a conventional gas membrane separator may be used for the first and/or second stages of bulk gas separation. The membrane separator would be used to enrich the carbon dioxide volume percentage in the flue gas stream initially at about 8 to 20% to approximately 60 to 80% carbon dioxide by volume or greater using multiple stages of membrane separators. The membrane separator would be installed after compression of the flue gases to an intermediate pressure of 250 to 600 psig.
Although the present invention has been described in conjunction with the preferred embodiments, it is to be understood that modifications and variations may be utilized without departing from the principles and scope of the invention as defined by the following claims.
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A process for the economical recovery of carbon dioxide from a gas stream containing less than 85% carbon dioxide, by cooling the contaminating gas to remove water vapor, compressing the cooled gas to an elevated temperature and pressure, and drying the gas to a dewpoint of not more than about -85° F.; condensing and removing the carbon dioxide from the dried compressed gas; and heating the remaining noncondensed gas mixture and expanding it to produce and recover kinetic energy and a cooled gas mixture.
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This is a continuation of application Ser. No. 08/055,095, filed on May 3, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to combinations of dimercaptothiadiazole-mercaptan coupled dithio compounds with amines which have proven to be highly effective multifunctional antiwear/extreme pressure additives for lubricants and fuels.
2. Description of Related Art
Dimercaptothiadiazole derivatives, such as 2,5-dimercapto-1,3,4-thiadiazole, disodium 2,5-dimercaptothiadiazole, and 2,5-bis(t-nonyl-dithio) thiadiazole, are well known for their antioxidancy, anticorrosion, and metal passivation properties in a variety of lubricant applications, as disclosed in U.S. Pat. Nos. 4,661,273, 4,678,592 and 4,584,114.
Furthermore, U.S. Pat. No. 5,186,850 discloses that the incorporation of the heterocyclic dimercaptothiadiazole functionality into succinimide structures provides ashless dispersants with multifunctional antiwear, antioxidant and corrosion inhibitor properties in lubricant compositions. Additionally, various reaction products of mercapto- and dimercaptothiadiazoles have been known to possess extreme pressure/antiwear properties, in a variety of lubricant formulations, as exemplified in U.S. Pat. Nos. 4,661,273; 4,382,869; and 4,678,592.
The use of amines in lubricants and the detergent industry has been well known for their alkalinity, surface activity, and neutralization capability. Amine phosphate is one class of additives used extensively in industrial oils, and polyamine-derived succinimides are key components in ashless dispersants of engine oils.
Reaction products of dimercaptothiadiazole derived alcohols and alkenyl succininc anhydrides and their subsequent amine reaction products have been found to be effective antiwear/antioxidant additives for lubricants; see U.S. Pat. No. 4,908,144. U.S. Pat. No. 5,188,746 discloses antiwear/antioxidant additives for lubricants based on dimercaptothiadiazole derivatives of acrylate and methacrylate polymers and amine reaction products thereof.
It has now been found that the use of these combinations of thiadiazole-derived dithio additives with amine derivatives, in accordance with the present invention, provide exceptional antiwear/EP activity with significantly enhanced metal passivating/corrosion inhibiting properties for lubricants and fuels.
BRIEF SUMMARY OF THE INVENTION
Lubricant and fuel compositions in accordance with the invention containing small additive concentration of a combination of a dimercaptothiadiazole-mercaptan coupled compound with an amine product possess excellent antiwear properties coupled with good extreme pressure activities. Additional antioxidation, cleanliness, antifatigue, high temperature stabilizing, and friction modifying properties are likely. Both the thiadiazole-dithio moiety and the amine/ammonium salt moiety are believed to provide the basis for the synergistic antiwear and EP property of these novel additives.
All of these beneficial properties are believed to be enhanced as a result of this novel internal synergism. This unique internal synergism concept is believed to be applicable to similar structures containing (a) thiadiazole groups, (b) dithio linking groups, (c) amine groups within the same component. The products of this invention show good stability and compatibility when used in the presence of other commonly used additives in fuel or lubricant compositions.
These remarkable benefits are also expected for a variety of synthetic and mineral oil based lubricants and fuels particularly light distillate fuels containing these additives. The compositions of matter and the lubricant and fuel compositions are believed to be novel. To the best of our knowledge, these compositions have not been previously used as antiwear/extreme pressure additives in lubricating oils, greases, or fuel applications.
More specifically this invention is directed to improved lubricant or fuel compositions comprising a major proportion of an oil of lubricating viscosity or a grease prepared therefrom, or a major proportion of a liquid hydrocarbyl or hydrocarboxy fuel and a minor proportion of a multifunctional antiwear/extreme pressure additive product of reaction consisting of combinations of dimercaptothiadiazole-mercaptan coupled dithio compounds with hydrocarbyl amines.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preparation
2,5-dimercapto-1,3,4-thiadiazole (DMTD), made by the reaction of hydrazine with carbon disulfide) oxidatively coupled with alkyl mercaptans, such as nonyl, to form thiadiazole-derived dithio compounds (Structure A). These dithio adducts were then blended with various amines to form a new group of additive blends. ##STR1## However, applicants do not wish to be bound by a particular structure(s) or formula for the additive reaction products in accordance with the invention [Structure (s) B] i.e., the combination of the dithio adducts blended with the various amines.
The mercaptothiadiazoles may be prepared as above or made in any convenient manner or obtained as an article of commerce. Any suitable mercaptothiadiazole such as 2,5-dimercapto-1,3,4-thiadiazole; 3,5-dimercapto-1,2,4-thiadiazole; 4,5-dimercapto-1,2,5- thiadiazole; etc. Accordingly, the hydrocarbyl groups need not be alkyl or limited to C 9 H 19 but may be R as in the below generalized structure: ##STR2## where R and R 1 can be the same or different and are hydrogen or C 1 to about C 30 hydrocarbyl selected from alkyl, aryl, aralkyl, alkaryl and may optionally contain additional O, S, or N or mixtures thereof. Preferably R is CnH 2n+1 , where n is 1 to about 30.
Mercaptobenzothiazoles such as 6,7-dimercaptobenzo-2,1,3-thiadiazole are also believed to be suitable.
Generally, the amines used in this invention are aliphatic and can be primary, secondary, or tertiary and preferably alkylamines or arylamines.
Non-limiting examples of primary amines are methylamine; ethylamine; n-propylamine; isopropylamine; n-butylamine; dodecylamine; triacontylamine; allylamine; 2-propynlamine; cyclohexylamine; propargylamine; isobutylamine; sec-butylamine; 2-ethylhexylamine; cyclopropylmethylamine; t-butylamine; 1,1-dimethyl-2-propynlamine; 1,1-diethyl-2-propynylamine; 1-ethynylcyclohexylamine and benzylamine.
Non-limiting examples of secondary amines are dimethylamine, diethylamine, dibutylamine, diotylamine, ditetradecylamine, diallylamine, di-2-hexenylamine, dicyclohexylamine, methylethylamine, methyl cyclohexylamine, diisopropylamine, diisopentylamine, ethyl cyclohexylamine, (3-amine-propyl)alkenylamine wherein the alkenyl group has 16 to 18 carbon atoms; (3-aminopropyl) alkenylamine wherein the alkenyl group has 18, 20 and 22 carbon atoms; and dihydrogenated tallow amine (e.g. Armeen 2HT).
Non-limiting examples of tertiary amines are trimethyamine, dimethyl ethylamine, triethylamine, tributylamine, trioctylamine, triallylamine, triisopentylamine, tricyclohexylamine, dimenthyl octylamine, n-hexadecyldimethylamine, (e.g. Armeen DM16D) n-octadecyl-dimethylamine (e.g. Armeen DM18D), methyl di-hydrogenated tallowamine (e.g. Armeen M2HT), and methyl dicocoamine (e.g. Armeen M2C).
Non-limiting examples of arylamines are aniline 2-chloroaniline; 3-chloroaniline; 4-chloroaniline; 2-methyl-4-chloroaniline; 2,4-dichloroaniline; 3,4-dichloroaniline; 2,5-dichloro-4-nitroaniline; m-tri-fluoromethylaniline; isopropulaniline; p-methoxyaniline; N-methoxymethyl-2,6-diethylaniline; a-naphthylamine; N-sec-butl-4-t-butyl-2,6-dinitroaniline; 3-amino-2,5-dichlorobenzoic acid; N,N-dipropyl, a,a,a-trifluoro-2,6-dinitro-p-toluidine; 4-bromo-3-chloroaniline; 4(4'-chlorophenoxy) aniline; N 3 , N 3 -diethyl-2,4-dinitro-6-trifluoromethyl-m-phenylenediamine; p-dimethylaminoaniline; diphenylamine; p-bromoaniline; m-aminophenyl-t-butylcarbamate; o-phenylenediamine; m-phenylenediamine; 4-dimethylamino-3,5-dimethylphenol; 4-(methylsulfonyl)-2,6-dinitro-N,N-dipropylaniline; 3,5-dinitro-N,N-dipropylsulfanilamide; N-sec-butyl-4-t-butyl-2,6-dinitroaniline; m-toluisine; p-toluidine; m-t-butylaniline; o-anisidine; p-anisidine; dimethylaniline; o-nitroaniline; p-nitroaniline; and 4,4'-oxydianiline.
Non-limiting examples of heterocyclic amines are 3-amino-1,2,4-triazole; 2-chloro-4-ehtylamino-6-isopropylamino-s-triazine; pyridine; piperidine; piperazine; morphiline; 4,4'-dipyridyl; 8-hydroxyquinoline; 4-amino-6-t-butyl-3-(methykthio)-1,2,4-triazine-5(4H)-one; 6-ethoxy-1,2-dihydro-2,2,,4-trimethylquinoline; indole; hexahydro-1H-azepine; 4-amino-5-chloro-2-pheyl-3(2H)-pyridazinone; pyrrole; imidazolidine; isoquinoline; 2,4-lutidine; 2-methyl-5-ethylpyridine; 2-dimethyl aminopyridine; a-picoline; B-picoline; y-picoline; quinoline; and 4,4'-dipyridine.
Non-limiting examples of other salt forming amino compounds contemplated are 2-chloroethyl dimethylamine; diethanilaminel guanidine; dodecylguanidine; 3-(4-chlorophenyl)-1,1-dimethylurea, 3-(3,4,-dichlorophenyl)-1,1-dimethylurea, Fenuron; Tandex; B-alanine; methyl glycine; glycinamide; aminoacetonitrile; aminoethanthiol; aminoacetic acid; diethyl ethanolamine; diethylenetriamine; isopropanolamine; diisopropanolaminel triisopropanolamine; ethylenediamine; hexamethylenetetramine; hydrazine; phenothiazine; sulfanilic acid; tetraethylenepentamine; thiourea; urea; triethanolamine; triethylenetetramine; diethanol soyaamine (e.g. Ethomeen S-12) and didecaoxyethylene soyaamine (e.g. Ethomeen S-20).
Examples of highly suitable amines are:
a) cyclic amines: dicyclohexylamine, 1,4-diaminocyclohexane, piperidine, hexamethyleneimine, etc.;
b) heterocyclic amines: morpholine, aminopropyl morpholine (APM), aminoethyl piperazine (AEP);
c) etheramines: C 6 to C 13 alkyloxypropylamines (Exxon and Sherex), polyoxyalkylene amines (Texaco Jeffamine);
d) diamines: Exxon etherdiamines (DA-14, DA-17), Texaco polyoxyalkylene diamine, Akzo Duomeens (Duomeen C&O);
e) straight chain amines: ethylamine, propylamine, butylamine, pentylamine, hexylamine, dioctylamine, dicocoamine, etc.;
f) branched chain amines: 2-ethylhexylamine, isopropylamine, isobutylamine, diisobutylamine, bis(2-ethylhexyl)amine, tert-alkyl amine(C18-C22), dicocoalkyl-methylamine.
An excess of one reagent or another can be used. Molar quantities, less than molar quantities, or more than molar quantities of either amines or dithio-adducts can be used.
Conditions for the above reactions may vary widely depending upon specific reactants, the presence or absence of a solvent and the like. Any suitable set of reaction conditions known to the art may be used. Hydrocarbon solvents such as toluene or xylenes are frequently used. Generally stoichiometric or equimolar ratios of reactants are used. However, more than molar or less than molar amounts may be used. In any event, reaction conditions are not viewed as critical. Generally speaking, the reaction temperature may vary from ambient to about 250° C. or reflux, the pressure may be autogenous or vary from ambient to about 100 psi with reaction times varying from about one hour to about 48 hours or more.
Clearly the use of additive concentrations of these dithio adducts coupled with various amines provide exceptional antiwear, load-carrying activity and corrosion inhibiting properties, etc. when incorporated into fuel and lubricant compositions.
The additives embodied herein are utilized in lubricating oil or grease compositions in an amount which imparts significant antioxidant, load-carrying and corrosions inhibiting characteristics to oil or grease as well as reducing the friction of engines operating with the oil in its crankcase. Concentrations of about 0.001 to about 10 wt. % based on the total weight of the composition can be used. Preferably, the concentration is from 0.1 to about 3 wt. %. It is expected that these materials would also be suitable for use in liquid hydrocarbyl or alcoholic or mixed hydrocarbyl/alcoholic fuel compositions. They are generally utilized in amounts varying from about 50 to about 500 pounds per 1000 barrels of fuel.
The additives have the ability to improve the antiwear characteristics and friction reducing characteristics of various oleagenous materials such as hydrocarbyl lubricating media which may comprise liquid oils in the form of either a mineral oil or a synthetic oil, or in the form of a grease in which the aforementioned oils are employed as a vehicle.
In general, mineral oils, both paraffinic, naphthenic and mixtures thereof, employed as the lubricant, or grease vehicle, may be of any suitable lubricating viscosity range, as for example, from about 45 SSU at 100° F. to about 6000 SSU at 100° F. and preferably, from about 50 to about 250 SSU at 210° F. These oils may have viscosity indexes ranging to about 95 are preferred. The average molecular weights of these oils may range from about 250 to about 800. Where the lubricant is to be employed in the form of a grease, the lubricating oil is generally employed in an amount sufficient to balance the total grease composition, after accounting for the desired quantity of the thickening agent, and other additive components to be included in the grease formulation.
A wide variety of materials may be employed as thickening or gelling agents. These may include any of the conventional metal salts or soaps, which are dispersed in the lubricating vehicle in grease-forming quantities in an amount to impart to the resulting grease composition the desired consistency. Other thickening agents that may be employed in the grease formulation may comprise the non-soap thickeners, such as surface-modified clays and silicas, aryl ureas, calcium complexes and similar materials. In general, grease thickeners may be employed which do not melt and dissolve when used at the required temperature within a particular environment; however, in all other respects, any materials which is normally employed for thickening or gelling hydrocarbon fluids for foaming grease can be used in preparing grease in accordance with the present invention.
In instances where synthetic oils, or synthetic oils employed as the lubricant or vehicle for the grease, are desired in preference to mineral oils, or in combination therewith, various compounds of this type may be successfully utilized. Typical synthetic oils include, but are not limited to, polyisobutylene, polybutenes, hydrogenated polydecenes, polypropylene glycol, polyethylene glycol, trimethylolpropane esters, neopentyl and pentaerythritol esters, di(2-ethylhexyl) sebacate, di(2-ethylhexyl) adipate, dibutyl phthalate, fluorocarbons, silicate esters, silanes, esters of phosphorus-containing acids, liquid ureas, ferrocene derivatives, hydrogenated synthetic oils, chain-type polyphenyls, siloxanes and silicones (polysiloxanes), alkyl-substituted diphenyl ethers typified by a butyl-substituted bis(p-phenoxy phenyl) ether, phenoxy phenylethers.
It is to be understood, however, that the compositions contemplated herein can also contain other materials. For example, corrosion inhibitors, extreme pressure agents and the like can be used as exemplified respectively by metallic phenates sulfonates, polymeric succinimides, non-metallic or metallic phosphorodithioates and the like. These materials do not detract from the value of the compositions of this invention, rather the materials serve to impart their customary properties to the particular compositions in which they are incorporated.
The following examples are merely illustrative and are not meant to be limitations on the scope of this invention.
EXAMPLE 1
Approximately 95 gm of 2,5-bis(t-nonyl-dithio)thiadiazole (commercially obtained from Amoco Chemical Company under the tradename Amoco 158 or from Mobil Chemical Company under the tradename Mobilad C-610) and 5 gm of isodecyloxypropylamine (commercially obtained from Sherex Chemical Company under the tradename Adogen 180) were blended together in a mixer at 80° C. for two hours. After a quick filtration, approximately 99.5 gm of yellow-brown liquid was recovered as desired blending product.
EXAMPLE 2
Approximately 90 gm of 2,5-bis(t-nonyl-dithio)thiadiazole and 10 gm of isodecyloxypropylamine were blended together in a mixer at 80° C. for two hours. After a quick filtration, approximately 99.2 gm of yellow-brown liquid was recovered as desired blending product.
EXAMPLE 3
The reaction procedure of Example 2 was followed with one exception: C 18-22 tert-alkyl primary amine (commercially obtained from Rohm Haas Chemical Company under the tradename Primene JM-T) was used instead of isodecyloxypropylamine.
EXAMPLE 4
The reaction procedure of Example 1 was followed with one exception: oleyl 1,3-diaminopropane (commercially obtained from AKZO Chemical Company under the tradename Duomeen O) was used instead of isodecyloxypropylamine.
Evaluation
The products of Examples 2, 3 and 4 were blended into industrial oils and evaluated for antiwear performance using the Four-Ball test (Table 1).
TABLE 1______________________________________Four-Ball Wear Test Wear Scar Diameter in Mm, 30 Minute Test - 200° F. 60 Kg 40 KgItem 1500 rpm 1800 rpm______________________________________Base oil (80% solvent 2.12 0.733paraffinic bright, 20% solventparaffinic neutral mineral oils)1% Mobilad C-610 0.784 0.6001% Example 2 0.739 0.5891% Example 3 0.772 0.6361% Example 4 0.794 0.609______________________________________
As can be seen from the above wear test results, the product exhibits considerable antiwear activity.
The products of the examples were also blended into fully formulated engine oils: Example 1 was evaluated for load carrying capacity using the Four Ball EP Test (Table 2); Examples 1 and 2 were evaluated in the FZG Gear tester (Table 3).
TABLE 2______________________________________Four-Ball EP Test and ASTM Copper Strip corrosion(EP: 1760 rpm/10 sec./25° C.; D130-6:250F/3 h.,D130-8:210F/3 h/1% H.sub.2 O Plus 1% Plus 1%Item Base oil* Mobilad C-610 Example 1______________________________________Last Non-seizure 100 100 126Load (kg)Weld Load (Kg) 200 250 250Load Wear Index 41.4 46.4 53.8(LWI)Copper Strip (D130-6) 2B 2D 1ACopper Strip (D130-8) 2A 2A 1A______________________________________ *Base oil is a fully formulated synthetic engine oil containing a performance additive package including detergent, dispersant, antioxidant corrosion inhibitor, and a small amount of zinc dithiophosphate.
TABLE 3______________________________________Item FZG (pass stage)______________________________________Base oil (fully formulated synthetic 7oil with additive package containingantioxidant, rust inhibitor, detergent,and dispersant)Base oil plus 1% Example 1 10Base oil plus 1% Example 2 12______________________________________
In the Four Ball Wear Test three stationary balls are placed in a lubricant cup and a lubricant containing the compound to be tested is added thereto, and a fourth ball is placed in a chuck mounted on a device which can be used to spin the ball at known speeds and loads. The examples were tested using half inch stainless steel balls of 52100 steel for thirty minutes under 60/40 kg load at 1500 and 1800 rpm and 200° F. If additional information concerning this test is desired consult test method ASTM D2266 and/or U.S. Pat. No. 4,761,482.
The Copper Strip Corrosivity Test (ASTM D-130) measures a product's propensity to corrode copper due to, for example, contained sulfur groups. Further details may be found in ASTM Standards on Petroleum Products and Lubricants, published annually by the American Society for testing Materials.
The Four-Ball EP Test (ASTM) D-2783) measures the extreme pressure characteristics or load-carrying properties of a lubricant by determining Load Wear Index (LWI) and weld point. A test ball is rotated under load at a tetrahedral position on top of three stationary balls immersed in lubricant. Measurements of scars on the three stationary balls are used to calculate LWI's, and the weld is the load at which the four balls weld together in 10 seconds. The last non-seizure load is the last load at which the measured scar diameter is not more than 5% above the compensation line at the load. The compensation line is a logarithmic plot where the coordinates are scar diameter in millimeters and applied load in kilograms obtained under dynamic conditions. The higher the LWI value the better. See U.S. Pat. No. 4,965,002, which is incorporated herein by reference, and ASTM D-2783.
The FZG Gear Test (DIN-51.354). In this test, dip-lubricated gears are weighed and operated at a fixed speed and fixed initial oil temperature (90° C.) in the gear oil under test. The load on the teeth is increased in increments. After each load stage, the weight changes are determined and recorded. The results are reported in Table 3. The higher the Fail Stage value the better the material. The lower the wear value the better the weight change and/or visual condition. Further details can be found in CEC method L-07-A-71.
As shown above, the products of this invention show very good antiwear, extreme pressure activities as evidenced by improving wear characteristics and scoring load capacity from stage 7 to stage 10-12 in FZG tester, and LWI in Four Ball EP test. In addition, the product of this invention also shows excellent corrosivity control.
The use of additive blends of bis(alkyl-dithio)thiadiazoles and amines in premium quality industrial and engine lubricants will significantly enhance the stability, improve load-carrying, reduce the wear, and extend the service life. These additive blends may also have the potential to benefit gasoline and diesel fuels by improving the antioxidation, antiwear, and anticorrosion characteristics of these fuels. These novel compositions described in this patent information are useful at low concentrations and do not contain any potentially undesirable metals or phosphorus. These dual functional antiwear/EP-antioxidants can be readily commercially made.
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Combinations of dimercaptothiadiazole-mercaptan coupled derivatives with amines have been found to be effective load-carrying additives for lubricants and fuels.
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This application claims the benefit of U.S. Provisional Application No. 61/969,321, filed Mar. 24, 2014
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to fabric marking and cutting devices that are used in sewing, such as quilting to mark and cut specific angular orientation on the fabric.
2. Description of Prior Art
Prior art devices of this type have provided a variety of different cutting guides; see for example U.S. Pat. Nos. 4,349,966, 5,579,670, 6,925,724 and Design Pat. D374,404.
U.S. Pat. No. 4,349,966 is directed to an aligning guide and measuring device having a flat with a raised flange along one edge.
U.S. Pat. No. 5,579,670 discloses a method and system for making quilting pieces having a template and a cutting guide with a rail along one edge thereof.
U.S. Pat. No. 6,925,724 illustrates a square or rectangular quilting ruler with sets of equally spaced rulings running parallel thereto and at right angles so as to be visible when in associated use.
U.S. Pat. No. 7,568,295 claims a quilting tool having a transparent parallelogram plate and guidelines associated thereon.
Finally, in Design Pat. D374,404, a quilting ruler is shown having a rectangular surface with a flange inwardly of one edge.
SUMMARY OF THE INVENTION
A fabric alignment, marking and cutting guide having a self-healing fabric placement surface on which the alignment guide with a top and side raised material engagement edge surfaces are positioned. A hinged transparent triangle guide plate extends from one raised surface for select placement over fabric positioned and aligned on the cutting surface for accurate repetitive diagonal marking and cuts there along.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the fabric alignment marking and cutting guide of the invention.
FIG. 2 is a top plan view thereof shown in use by marking for cutting.
FIG. 3 is a top plan view illustrating alternate material placement on the cutting surface with guide edge engagement for cutting.
FIG. 4 is a top plan view of an alternate use configuration with an independent straight edge.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 of the drawings, a fabric alignment marking and cutting guide 10 of the invention can be seen having a support base 11 with spaced oppositely disposed parallel top and bottom edges 12 and 13 and corresponding spaced parallel perimeter side edges 14 and 15 defining a square base configuration. Preferably the base material is of a self-healing configuration so that it can be effectively cut upon without permanent markings affecting future cutting as will be well known and understood by those skilled in the art.
A pair of upstanding perimeter flat guide angles 16 and 17 are positioned at right angles to one another along and extend inwardly from the respective top edge 12 and the side edge 14 of the base 11 . The guide angles 16 and 17 have effacing ends 16 A and 17 A which are in spaced angular orientation to one another forming a cutting gap at 18 therebetween that aligns with the primary diagonal line D illustrated by a line indicia positioned on the base 11 and a secondary parallel line D′ for aligning to mark ¼ inch from the edge of fabrics as will be described in greater detail hereinafter.
A right angle triangular transparent guide panel 19 is hinged along one side to the perimeter guide angle 16 by a selective hinge configuration 20 . A lifting tab 21 is formed integrally with and extends from a free side edge surface 22 adjacent the panel's defined angular edge cutting surface 23 . The hinged configuration 20 may be of any continuous (piano type) or multiple spaced hinged elements so as to assure edge orientation when selectively operated from a first flat base engagement position to an upstanding position as seen in solid and broken lines in FIG. 1 of the drawings.
It will be seen that the cutting guide edge surface 23 of the hinged triangular guide transparent guide panel 19 defines a “true” diagonal across a surface S of the support base 11 and is correspondingly in alignment between the hereinbefore described end gap 18 between the respective guide angles 16 and 17 which will allow for a continuous cutting action therealong as will be described in detail hereinafter.
In use, the fabric alignment, marking and cutting guide 10 , as seen in FIGS. 2 and 3 of the drawings (in this example) a fabric square 24 to be cut is positioned on the support base 11 's surface S which is divided into equal portions by a cross gridline pattern 25 . The transparent guide panel 19 is raised and the fabric square 24 is placed on the grid line supporting base 11 surface S in abutting relationship to the respective perimeter guide angles 16 and 17 . The guide panel 19 is then lowered onto the fabric square 24 holding it firmly in place. It will be seen that this provides a true and accurate diagonal guide there across for marking M or cutting along the guide edge surface 23 of the guide panel 19 which in this example for cutting an illustrative rotary cutter representation 26 is shown graphically in FIG. 3 of the drawings and is well known in the art can pass along against the guide edge surface 23 cutting the fabric panel 24 diagonally and proceed through the angle gap 18 in a single continuous action or conversely begin at the angle gap 18 and pass along the guide edge surface 23 cutting the fabric as noted.
Alternate fabric square placement is possible and can be seen as illustrated in FIG. 3 of the drawings wherein a fabric square 26 is aligned on the base 11 surface S by use of the gridline pattern 25 and a diagonal marking and a cut can be made, again by using the triangular guide panel 19 positioned thereover, as described.
It will be evident from the above description that the divided grid line pattern 25 on the base 11 can also be used independently of the guide panel 19 as seen in FIG. 4 of the drawings as follows. A fabric square 27 can therefore be positioned on the base surface S by the alignment with the gridline pattern 25 and independent straight edge 28 may be used to overlie and act as a marking guide via a marker M, in broken lines, and then a cutting edge guide for a rotary cutter representation 29 as illustrated.
The support base 11 in this example, as noted, is preferably made of a self-healing cutting mat surface of a ⅛ inch thickness and divided by the right angular cross gridline pattern 25 in equal incremental increments, such as one-inch in this illustration or other dimensional aspects chosen for alternate applications as would be evident to those skilled in the art. Additionally, a secondary guide line D′ can be seen in spaced relation to the primary diagonal line D which would allow for aligning to mark ¼ inch from the edge of fabrics.
It will be seen that incremental indicia measurements are marked along each of the guide angles 16 and 17 , in this example at one-inch and ⅛ inch intervals and may be of different colors for easy identification. The transparent movable guide edge panel 19 is preferably made of synthetic resin material with a non-slip bottom surface BS for engagement against the fabric to assure stability thereto while marking or cutting.
It will thus be seen that a new and novel fabric alignment marking and cutting guide of the invention has been illustrated and described and will provide ability to selectively mark diagonal lines on square fabrics fast, easy and accurately. It is evident that the guide is a time saving device when marking the squares and that the straight edge corner liners will assure that the diagonal mark is accurate and the right triangle remains stationary when marking to assure the diagonal mark is also accurate. The cutting base 11 can be used as a cutting surface for rotary cutters, as described, and wherein the right angle panel 19 can be used to guide the rotary blade when cutting diagonal lines as hereinbefore described.
It will thus be evident that various changes and modifications may be made thereto without departing from the spirit of the invention. Therefore I claim:
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A fabric alignment, marking and/or cutting guide that allows for accurate marking, and/or cutting of fabric along the diagonal using a multiple axis fixed edge alignment and a movable triangular angle. The alignment guide has a square cutting board with right angularly positioned upstanding angular edge surfaces for material engagement. A transparent hinged triangular cutting guide plate extends from one alignment edge surface defining a true diagonal line guide edge across a material square to be marked and cut positioned on the cutting board under the triangle guide plate.
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CROSS-REFERENCES TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to personal computers, specifically a device to protect a personal computer from children.
2. Description of the Related Art
To date, it is believed that there has not been a child proof mechanism for a personal computer made or conceived that is within the parameters of the instant invention. Heretofore, when a personal computer was within a child's reach, there was no device to protect the personal computer from the child's unintended mischief. No personal computer guard exists to prevent inadvertent computer shutdown or unintended destruction to some other device, including but not limited to the floppy disk drives, the CD-ROM drive, the tape drive, the floppy disk, the compact disc, or the tape.
There have been several different types of protective devices for personal computers. Derman (U.S. Pat. No.: 5,052,199) discloses an adjustable U-shaped locking bracket for a personal computer with an additional bracket to block disk drive access. Lakoski et al. (U.S. Pat. No.: 4,989,009) discloses a PC protective cover that has slots for ventilation and is pivotally mounted on one side and locked via a key on the other side to provide both security and ease of access. Broadwater (U.S. Pat. No.: 5,305,621) discloses a computer diskette drive lockout device that relies on the "locking disk" and keyed lock to provide ease of access and security. Lan et al. (U.S. Pat. No.: 5,116,261) discloses a locking panel that restricts access to the entire front of the computer. The panel has a separate locking window to allow access to the disk drives and slots for ventilation. Further, Frater et al. (U.S. Pat. No.: 5,085,395) discloses the use of a three piece restraining system consisting of two parallel side bars and a cross member pivotally mounted therebetween.
While the protective devices aforementioned may be satisfactory for some applications, none teaches the use of a slot and tab configuration, to provide for ease of installation, ease of removal, and width adjustment as with the present invention.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, a device for making a personal computer child resistant comprises two adhesive-backed mounting plates, each being comprised of a flat body with one slot and one tab, and a single guard, comprised of a flat body with slots at each end for attachment to both mounting plates and with an optional adhesive-backed brace near its center.
Accordingly, the prominent objects and advantages of this invention are: the personal computer is made child proof, the elegant, adjustable design of the invention will accommodate various sized, shaped, and configured personal computers, and the invention is not expensive to make.
Additional objects and advantages are the device is easy-to-install and easy-to-use by the adult and cannot be mastered by a young child.
Still further objects and advantages will become apparent from a consideration of the ensuing description and accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a pictorial front view of the component child proof guard for a personal computer according to the invention.
FIG. 2 is a diagram detailing each component part of the child proof guard for a personal computer according to the invention.
FIG. 3 is an overall perspective view of the child proof guard for a personal computer according to the invention where the personal computer has a tower configuration and the invention is deployed.
FIG. 4 is an overall perspective view of the child proof guard for a personal computer according to the invention where the personal computer has a tower configuration and the invention is not in use.
FIG. 5 is an overall perspective view of the child proof guard for a personal computer according to the invention where the personal computer has a desktop configuration and the invention is deployed.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the child proof guard for a personal computer according to the invention is illustrated in FIG. 1. Two mirror image mounting plates 10 and 12 are shown. FIG. 1 shows a guard 14 attached to the two mounting plates. In the preferred embodiment, the guard and the mounting plates are constructed out of flexible plastic. However, the guard and the mounting plates can consist of any other material that can be repeatedly bent without fracturing such as, but not limited to, vinyl, nylon, rubber, various impregnated or laminated fibrous materials, various plasticized materials, etc. The guard and the mounting plates can be fabricated by a punch press or from a mold.
FIG. 2 is a diagram detailing each component part of the child proof guard for a personal computer according to the invention. It depicts the details of the invention's main embodiment. As shown in FIG. 2, each mounting plate 10 or 12 is rectangular in shape. FIG. 2 shows mounting adhesive 16 on the interior of the mounting plate. FIG. 2 shows a slot with a tab 18 at the front of the mounting plate, visible from both the interior and exterior perspectives. FIG. 2 also depicts the guard 14. The guard is rectangular in shape. At one end of the guard, there is a single slot 20. At the other end of the guard, there is a set of slots 22. The exact number of these slots is variable and should be large enough to cover the widest anticipated personal computer width. On the interior of the guard, there is an optional adhesive-backed brace 24.
FIG. 3 is an overall perspective view of the child proof guard for a personal computer according to the invention where the personal computer has a tower (vertical) orientation and the invention is deployed. With this configuration, the guard is snapped into place and is fully functional.
FIG. 4 is an overall perspective view of the child proof guard for a personal computer according to the invention where the personal computer has a tower configuration and the invention is not in use. With this configuration, the guard has been removed and the mounting plates remain. Thus, this configuration allows for power on/off of the computer and/or normal operation of other computer devices (i.e., insertion/ejection of disks from the disk drives, insertion/ejection of compact discs from the CD ROM drives, etc.) depending on the chosen deployed location of the invention.
FIG. 5 is another perspective view of the child proof guard for a personal computer according to the invention where the personal computer has a desktop (horizontal) orientation and the invention is deployed. The guard slots are snapped onto the mounting plate tabs and thus, enabled.
In operation and for purposes of illustration, mounting adhesive is referenced, not by way of limitation as other methods of attachment are readily obvious for attaching the mounting plates to the personal computer such as, but not limited to, VELCRO (hook and loop fasteners), and the like.
Operation and use of the child proof guard for a personal computer is simple and straightforward.
1. Assuming the personal computer has a tower orientation (FIG. 3), one of tile mounting plates is adhered on one side of the tower case, near the top of the case and in line with the computer device to be protected (i.e., the power switch or the floppy disk drive). The mounting plate is mounted so that slot is freestanding, protruding beyond the edge of the personal computer.
2. The other mounting plate is adhered to the other side of the tower in the same fashion as described above and in line with the first mounting plate.
3. If there is a protruding device(s) (i.e., power switch, reset button, etc.) on the face of the personal computer, the optional adhesive-backed brace is adhered to the interior of the guard.
4. Holding the guard with the single slot end to the right and the adjustable slot end to the left, the guard's single slot end is fed first through the leftmost mounting plate slot and then through the rightmost mounting plate slot. The guard's single slot is then snapped onto the tab of the slot of the rightmost mounting plate. With the single slot end of the guard secured, the appropriate slot at the adjustable end of the guard, given the width of the tower, becomes evident. The appropriate adjustable guard slot is then snapped onto the tab of leftmost mounting plate. The excess guard length may be clipped with scissors. This deployed configuration is depicted in FIG. 1, FIG. 3, and FIG. 5. With this configuration, the child proof guard is activated and the computer device is protected.
5. To disable the invention, the adult must only unlock the guard by unhooking the guard from both mounting plate tabs and then sliding the guard clear from both mounting plates. This disabled configuration is depicted in FIG. 4.
Accordingly, it can be seen that, according to the invention, a child proof guard for a personal computer is provided which makes the personal computer child resistant, accommodates various sized, shaped, and configured personal computers, is not expensive to fabricate, is reliable, easy to install, and easy to use.
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Various other embodiments and ramifications are possible within it's scope. For example, the slots in the guard can be other shapes, such as circular, oval, triangular, etc., the tabs in the mounting plates can be other shapes, such as circular, triangular, etc.
Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, and not by the examples given.
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A device for making a personal computer child proof is disclosed. The device includes two mirror image adhesive-backed mounting plates and one guard. One mounting plate is adhered to one side of the personal computer case. The second mounting plate is adhered to the opposite side of the personal computer case. The guard is fed through both mounting plates and snapped into the deployed position. To disable the guard, the adult need only unhook the guard and feed it clear from both mounting plates.
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This invention relates to the construction of cylindrical tanks having vertical sections and has particular reference to a construction of an elongated board or a plank or a tank segment that is normally flat, but automatically assumes the curvature radius of the tank during construction before the tank is filled with liquid.
BACKGROUND OF THE INVENTION
Tanks for holding liquids such as water and oil have traditionally been formed of vertical wooden boards pulled into a cylindrical shape by horizontal outside tension bands. The bands have been tightened to the point of crushing the adjoining edges to prevent leakage.
The usual wooden vertical tank board has a horizontal width that is two or at most three times the thickness of the board to avoid vertical cracks. When water or other liquid is placed in the tank, the hydraulic pressure forces the wooden boards outwardly and the steel circumferential bands must be tightened again until the bands cut deep enough into the edges of the wood boards to counteract the outward force of the water or other liquid. While it is possible to shape the outer surface of the boards with the arc of the finished cylindrical tank, this is expensive and seldom done. Instead, commercially available flat boards are used.
There has been a great need for a waterproof tank that can be quickly assembled and which is free from leakage.
SUMMARY OF THE INVENTION
We have devised a tongue-and-groove board, preferably formed of plastic or other crush-resistant material, that can be quickly assembled with other such boards to form a waterproof tank. Furthermore, as the outside horizontal bands are tightened to pull our boards together, crushing is avoided and the boards are bent to define an arc in a horizontal plane, this arc of the tank being constructed regardless of the diameter of the tank within wide limits.
We achieve this result by having a section in my load that has a thin web joining a thick tongue section on one edge and a correspondingly thick groove section on the other edge. Further, we displace this web to one side so that the web section and the tongue-and-groove section define a continuous smooth outside surface which is normally flat, but which is a smooth arc when the segments are assembled into a tank.
DETAILED DESCRIPTION
Various objects, advantages, and features of the invention will be apparent in the following description and claims considered together with the accompanying drawings forming an integral part of this specification and in which:
FIG. 1 is a cross sectional view through a presently preferred form of tank segment.
FIG. 2 is a plan view of several tank segments of FIG. 1 surrounded by a horizontal tension band prior to tightening.
FIG. 3 is a plan view of the segment of FIG. 1 after it has been deflected to rest against the outer tensioning band.
FIG. 4 is an enlarged plan view showing the joint between the groove of one tank segment and the tongue of the other tank segment.
FIG. 5 is a dimensioned diagram of one example of my tank segments.
FIG. 6 is a sectional view of a modified form of segments without a tongue and groove.
FIG. 7 is a sectional view through still another modified form of tank segment showing grooved edges on both edges.
Referring to FIG. 1, a tank segment 10 has a thin web 11 having a thickness W joined at one edge to a thick groove section 12 having a longitudinally extending groove 13 and a thickness dimension G that is much greater than the web thickness W. The groove section 12 has an inner corner 9 that is preferably quite square. The other edge of the web 11 is joined to a tongue section 14 having an outwardly projecting tongue 16 and having a thickness dimension T. The tongue section thickness T is preferably the same as the groove section thickness dimension G of the groove section 12. The tongue section 14 has an inner corner 15 that is also preferably square.
Referring to FIG. 2, there is shown in exaggerated scale several tank segments in their normal flat condition butted together and loosely surrounded by a tension band 17. Normally, the tank segments are vertical and the band 17 is in a horizontal plane. As the band 17 is tightened, the tank segments 10 are bowed as shown in FIG. 3. This bowing is caused by a force F being applied at the inner corner 9 of the groove section 12 and the inner corner 15 of the tongue section 14 by the adjoining corner 15 and 9, respectively, of the adjoining groove and tongue sections.
Referring to FIG. 3, the band 17 has been tightened and the bowing just described causes the web 11 to rest against the curved band 17. When the tank is filled with a liquid placing a hydrostatic load on the vertical tank segments 10, there will be no deflection of the web 11, because it is already at its maximum deflection. There will be no tendency for the tongue and groove joints to separate under hydrostatic load, because the bands 17 are tightened sufficiently to accommodate this load without elastic stretching. Such tensioning does exert a compressive load in the general direction of the arrows F, and ordinarily such a compressive load would crumple the thin web 11. However, in its bowed condition of FIG. 3, the web 11 and the entire cross section are extremely stable due to the support of the band 17. In such a condition, even very thin webs 11 can sustain tremendous compressive loads.
Referring now to FIG. 4, a presently preferred seal is illustrated between a groove section 12 and a tongue section 14. The tongue 16 has less length than the depth of the groove 13, allowing room for a tubular seal 18 of rubber-like material which has a friction engagement with the inner end of the tongue 16 and the bottom of the groove 13. As liquid enters the crack between the corners 9 and 15, it forces the seal upwardly as viewed in FIG. 4 (outwardly of a tank formed of the segments 10) until it deforms in the upper part of the space to form a tight seal in the same fashion as the well-known "O-rings" in hydraulic components. The seal 18 may be solid, depending upon its composition, to achieve sealing.
EXAMPLE
While various materials of construction may be employed, the following example utilizing a plastic explains the action of any material. A polyester plastic reinforced with lengthwise strands of fiberglass has a transverse bending strength of 79,600 psi, a transverse compressive strength of 78,870 psi, and a transverse bending modulus of 1.71×10 6 psi. This material is preferably a pultrusion wherein fibers are pulled out the extrusion orifice along with the plastic, insuring linearity of the fibers.
Referring to FIG. 5, it is assumed that tank segments have a width of ten inches; thus, sixty-four such vertical segments form a tank having a radius of 101.859 inches. If such a tank is 71/2 feet high, it will hold about ten thousand gallons. The dimensions of the web 11 and the groove section 12 and the tongue section 14 are all stated in FIG. 5. A radius centerline 20 is used as a calculation reference; the amount that the flat web 11 must deflect to engage the band 17 is a dimension y which is calculated to be 0.12274 inch. This radius line 20 forms an angle A with the half width of segment 10. Another important angle is the one formed from the groove corner 9 to the center of the web 11 at the line 20, and this angle is designated as θ.
The section modulus Z is 0.002604, and the moment of inertia I is 0.00016275 per vertical inch of segment 10. Taking the case of a beam supported at both ends and having a load at the center and knowing y, the amount the beam has to deflect to reach the band 17, this force is calculated at 2.55544 pounds per vertical inch of segment 10. The circumferential force F required to provide this deflection load is
F=2.55544×1/Tan θ=34.0726 pounds
per vertical inch of segments 10. This force F is easily achieved by tensioning the horizontal bands 17.
For a 10,000-gallon tank, the bottom band 17 will receive the greatest stress and is tensioned to a load of 1800 pounds (of which 720 is required to counteract the hydrostatic load). The question arises whether the material of the segment 10 is strong enough to resist this overload stress prior to filling the tank. Referring still to FIG. 5, the cross sectional area of the two abutting tongue-and-groove sections is 0.255 square inches per vertical or linear inch of segment 10, and the load of 1800 pounds results in a pressure of 7,060 pounds per square inch, which is grossly less than the compressive strength of the material of 78,870 psi. Considering now the compression forces in the web which is 0.125 inch thick, the compressive force there is 14,400 psi, also considerably under the compressive strength of 78,870 psi. Usually, the web has a smaller compression area and is the limiting factor in compression.
The bending of the segments between horizontal bands due to hydrostatic loads produces a tendency of the tank segments 10 to bulge outwardly, the amount of bulging depending upon the resistance to bending in a vertical plane. This factor is well-known in tank design, and the high tensile strength of pultrusion fiberglass plastics causes them to compare favorably with steel. The size, number, spacing, and tension of the horizontal bands is well-known.
It will be appreciated by those skilled in the art that my normally flat tank segments 10 will automatically arc to the outer curvature of the tank by the mere tightening of the horizontal bands 17. This occurs regardless of the diameter of the tank so long as the elastic limit of the segment material is not exceeded. A universal segment is therefore created, resulting in great versatility and requiring only a small inventory of segments for a large number of tank sizes.
Further, this automatic arcing of the segments brings the entire exterior of the segments into contact with the horizontal bands, avoiding any cutting into the segment of the bands as is commonly the case when flat boards are used for the construction of tanks.
From the foregoing example, it is apparent that the tongue-and-groove thicknesses T and G need to be greater than the web thickness W only by an amount sufficient so that a bending moment arm is created to cause the bending of the segment 10 into contact with the band 17 as shown in FIG. 3.
This relative thickness is directly proportional to the width of the web 10 as shown by the angle θ of FIG. 5. It is directly proportional also to the stiffness of the web or its resistance to bending, which therefore is directly proportional to the Young's modulus for the particular material.
Further, it is apparent that the outer surface of the web 11 ought to be coincident with the outer surface of the groove section 12 and the tongue section 14 in order to obtain the greatest uniformity in bearing upon the bands 17. Also, the abutting surfaces of the tongues and grooves should be at right angles to this outer surface. Tongue-and-groove structures are not necessary, but are highly convenient in arranging the segments 10 as in FIG. 2 prior to tightening the bands 17. Also, the tongue-and-groove structure is easier to seal than many others.
Illustrated in FIG. 6 is a tank segment 30 having a web 31 and thicker edge sections 32 held by fasteners 33; the joint between the edges is sealed by a blob of caulking 34. Illustrated in FIG. 7 is a tank segment 40 having a web 41 and thicker edge sections 42, each of which has a groove 43, and sealing and alignment are obtained by inserting a rubber rod 44 between adjoining segments.
In addition to tanks my self-arcing segments may be used as horizontal flumes either semicylindrical for liquids like water or closed horizontal pipes for gases or liquids. The bands of semicylindrical flumes may be tightened against opposite ends of diameter beams. In either case, it is only necessary to stagger the joints in lengths of segments and seal the abutting ends in any suitable manner. Similarly, the segments may be used for smoke stacks, the material of construction being selected for the particular temperature and corrosion characteristics of the gases being conducted. Various other uses will occur to those skilled in the art. With regard to the pultrusion plastic, I presently prefer to use, in addition to the lengthwise fibers, short lengths of fiber that are randomly oriented, generally referred to as "matt" in the industry.
This invention has been described with reference to presently preferred embodiments as required by the statutes, but is not limited thereto, as this disclosure is illustrative only. The invention is not limited to this disclosure, and the following claims encompass all variations and modifications that fall within the true spirit and scope of the invention.
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Vertical boards or tank segments are compressed by outer horizontal bands that cause the vertical edges of these tank segments to press together. Each tank segment has a web and edge structures that are thicker than the web measured in a radial direction in the finished tank. The compression of the horizontal bands causes these edge sections to exert a bending movement on the web, bending the web outwardly until it contacts the outer horizontal bands. One size of tank segment, therefore, serves for a large number of different diameters of cylindrical tank. The webs are formed flat, and the thickened edges are preferably tongue-and-groove configuration.
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PRIORITY TO RELATED APPLICATION(S)
[0001] This application claims the benefit of European Patent Application No. 10196161.3, filed Dec. 21, 2010, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to sustained release liquid pharmaceutical compositions comprising a peptide analogue of glucagon-like peptide-1 (GLP-1) or salts thereof having an improved release profile and to methods for preparing such compositions.
[0003] More specifically, the invention relates to improved sustained release liquid pharmaceutical compositions comprising [Aib 8,35 ]hGLP-1(7-36)NH 2 , a GLP-1 analogue with the amino acid sequence according to SEQ ID No. 1:
[0004] His-Aib-Glu-Gly-Thr-Phe-Thr-Ser-Asp-Val-Ser-Ser-Tyr-Leu-Glu-Gly-Gln-Ala-Ala-Lys-Glu-Phe-Ile-Ala-Trp-Leu-Val-Lys-Aib-Arg-NH 2 ,
[0000] wherein 26 of these amino acids are in the natural L configuration while four are not chiral. The naturally occurring amino acid residues in position 8 (Ala) and 35 (Gly) have been substituted by α-aminoisobutyric acid (Aib). [Aib 8,35 ]hGLP-1(7-36)NH 2 is also known as taspoglutide.
[0005] The improved sustained release liquid pharmaceutical compositions further comprise a divalent metal salt, preferably zinc chloride, wherein the molar ratio range of the peptide analogue to the divalent metal is 1.5 to 1, a liquid such as water, and optionally acetic acid and/or an acetate salt, wherein the molar ratio range of the acetic acid and/or acetate salt to the peptide is less than 3.2 to 1, and are characterized in that the final pH of the composition in the range of 4.4 to 4.6 is adjusted by addition of hydrochloric acid.
BACKGROUND OF THE INVENTION
[0006] GLP-1 is secreted in the body from intestinal L cells as a gut hormone. The biologically active forms of GLP-1 are GLP-1 (7-37) and GLP-1 (7-36)NH 2 . Those peptides result from selective cleavage of proglucagon. Once in the circulation, GLP-1 has a half life of less than 2 minutes, due to rapid degradation by the enzyme dipeptidylase-4 (DPP-4). It is a potent antihyperglycemic hormone, inducing glucose-dependent stimulation of insulin secretion while suppressing glucagon secretion. GLP-1 and analogues thereof are thus useful in subjects having non-insulin dependent diabetes as well as for the treatment of gestational diabetes mellitus
[0007] In addition, there are a number of therapeutic uses, for which GLP-1 and analogues thereof have been suggested, including enhancing neuroprotection, and/or alleviating a symptom of a disease or disorder of the central nervous system, e.g., through modulation of neurogenesis, and e.g., Parkinson's Disease, Alzheimer's Disease, Huntington's Disease, ALS, stroke, ADD, and neuropsychiatric syndromes), preventing beta-cell deterioration, stimulation of beta-cell proliferation, treating obesity by suppressing appetite and inducing satiety, reducing the morbidity and/or mortality associated with myocardial infarction and stroke, treating acute coronary syndrome characterized by an absence of Q-wave, myocardial infarction, attenuating postsurgical catabolic changes, treating hibernating myocardium or diabetic cardiomyopathy, suppressing plasma blood levels of norepinepherine, increasing urinary sodium excretion, decreasing urinary potassium concentration, treating conditions or disorders associated with toxic hypervolemia, e.g., renal failure, congestive heart failure, nephrotic syndrome, cirrhosis, pulmonary edema, and hypertension, inducing an inotropic response and increasing cardiac contractility, treating polycystic ovary syndrome, treating respiratory distress, improving nutrition via a non-alimentary route, i.e., via intravenous, subcutaneous, intramuscular, peritoneal, or other injection or infusion, treating nephropathy, treating left ventricular systolic dysfunction, e.g., with abnormal left ventricular ejection fraction, inhibiting antro-duodenal motility, e.g., for the treatment or prevention of gastrointestinal disorders such as diarrhea, post-operative dumping syndrome and irritable bowel syndrome, and as premedication endoscopic procedures, treating critical illness polyneuropathy (CIPN) and systemic inflammatory response syndrome (SIRS), modulating triglyceride levels and treating dyslipidemia, treating organ tissue injury caused by reperfusion of blood flow following ischemia and treating coronary heart disease risk factor (CHDRF) syndrome.
[0008] The therapeutic potential of GLP-1 is, however, limited in view of its metabolic instability, having a plasma half-life (t 1/2 ) of only 1 to 2 min. in vivo. A number of attempts have been taken to improve the therapeutic potential of GLP-1 and its analogues through improvements in formulation.
[0009] European patent publication No. EP 0 619 322 A2 describes the preparation of micro-crystalline forms of GLP-1(7-37)OH by mixing solutions of the protein in pH 7 to 8.5 buffer with certain combinations of salts and low molecular weight polyethylene glycols (PEG). Similarly, biodegradable polymers, such as poly(lactic-co-glycolic acid) (PLGA) and a triblock copolymer of poly [(dl-lactide-co-glycolide)-β-ethylene glycol-/3-(-lactide-co-glycolide)], have also been suggested for use in sustained delivery formulations of GLP-1 peptides. However the use of such biodegradable polymers has been disfavored in the art since these polymers generally have poor solubility in water and require water-immiscible organic solvents, e.g., methylene chloride, and/or harsh preparation conditions during manufacture. Such organic solvents and/or harsh preparation conditions are considered to increase the risk of inducing conformational change of the peptide or protein of interest, resulting in decreased structural integrity and compromised biological activity.
[0010] There is a need for GLP-1 formulations which are more easily and reliably manufactured, and which are more easily and reproducibly administered to a patient Sustained release liquid pharmaceutical compositions comprising [Aib 8,35 ]hGLP-1(7-36)NH 2 , a liquid, zinc and/or zinc chloride and an acetate and/or acetic acid, wherein the molar ratio range of the peptide to zinc is approximately 6:1 to 1:1 and the molar ratio range of the acetate and/or acetic acid to the peptide is approximately 1:1 to 6:1, and wherein the pH of said pharmaceutical composition is within the range of 4 to 5, are disclosed in WO 2010/089672. Subcutaneous administration of sustained release formulations of [Aib 8,35 ]hGLP-1(7-36)NH 2 with a divalent metal salt such as zinc salts aims for the formation of a solidified depot under the skin and a sustained release of [Aib 8,35 ]hGLP-1(7-36)NH 2 . These compositions have the advantage of forming a solidified depot under the skin when injected subcutaneously and are thus able to release the peptide over a time range of at least one week to two weeks. However, the plasma profiles obtained after a single (s.c.) administration to dogs (see FIGS. 1 to 3, 5 and 6 of WO 2010/089672) clearly show, that the compositions are characterized by an initial burst, i.e. by high initial plasma concentration shortly after administration, which is assumed to be responsible for the occurrence of dose-related, side effects such as vomiting.
[0011] The object of the present invention therefore is to modify the original pharmaceutical composition of [Aib 8,35 ]hGLP-1(7-36)NH 2 in order to obtain a pharmaceutical composition with an improved sustained release profile in which the initial burst effect (i.e. the initial plasma concentration) is reduced in order to eliminate unwanted side effects.
[0012] It was found that this object could be reached with the sustained release liquid pharmaceutical composition as outlined below.
SUMMARY OF THE INVENTION
[0013] The present invention relates to a sustained release liquid pharmaceutical composition having a pH in the range of 4.4 to 4.6 comprising:
[0014] a liquid solvent,
[0015] a peptide analogue having the formula
[0000] [Aib 8,35 ]hGLP-1(7-36)NH 2 (I), and
[0016] a divalent metal salt, wherein the molar ratio range of the peptide analogue to the divalent metal is 1.5 to 1,
[0000] characterized in that the final pH in the range of 4.4 to 4.6 is adjusted by addition of hydrochloric acid.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention relates to a sustained release liquid pharmaceutical composition having a pH in the range of 4.4 to 4.6 comprising:
[0018] a liquid solvent,
[0019] a peptide analogue having the formula
[0000] [Aib 8,35 ](7-36)NH 2 (I),
[0020] a divalent metal salt, wherein the molar ratio range of the peptide analogue to the divalent metal is 1.5 to 1, and
[0021] optionally acetic acid and/or an acetate salt, wherein the molar ratio range of the acetic acid and/or acetate salt to the peptide is less than 3.2 to 1,
[0000] characterized in that the final pH in the range of 4.4 to 4.6 is adjusted by addition of hydrochloric acid.
[0022] In particular, the invention relates to a sustained release liquid pharmaceutical composition having a pH in the range of 4.4 to 4.6 comprising:
[0023] water,
[0024] a peptide analogue having the formula
[0000] [Aib 8,35 ]hGLP-1(7-36)NH 2 (I),
[0025] a divalent metal salt, wherein the molar ratio range of the peptide analogue to the divalent metal is 1.5 to 1, and
[0026] optionally acetic acid and/or an acetate salt, wherein the molar ratio range of the acetic acid and/or acetate salt to the peptide is less than 3.2 to 1,
[0000] characterized in that the final pH in the range of 4.4 to 4.6 is adjusted by addition of hydrochloric acid.
[0027] In particular, the acetate salt is sodium acetate trihydrate.
[0028] The divalent metal salt is selected from the group consisting of zinc cloride (ZnCl 2 ), zinc acetate dihydrate, copper chloride (CuCl2) and copper acetate. More particularly, the divalent metal salt is zinc chloride.
[0029] Thus, the present invention relates to a sustained release liquid pharmaceutical composition having a pH in the range of 4.4 to 4.6 comprising:
[0030] water,
[0031] a peptide analogue having the formula
[0000] [Aib 8,35 ]hGLP-1(7-36)NH 2 (I),
[0032] zinc chloride, wherein the molar ratio range of the peptide analogue to zinc chloride is 1.5 to 1, and
[0033] optionally acetic acid and or sodium acetate trihydrate, wherein the molar ratio range of the acetic acid and/or acetate salt to the peptide is less than 3.2 to 1,
[0000] characterized in that the final pH in the range of 4.4 to 4.6 is adjusted by addition of hydrochloric acid.
[0034] In particular, the concentration of zinc chloride is 2.72 mg/ml (20 mM).
[0035] In particular, the concentration of the peptide analogue [Aib 8,35 ]hGLP-1(7-36)NH 2 is 100 mg/ml (30 mM).
[0036] The invention further relates to a liquid pharmaceutical composition as defined above, wherein the maximum concentration of acetic acid and/or sodium acetate trihydrate is 95 mM.
[0037] In particular, the present invention relates to a sustained release liquid pharmaceutical composition having a pH in the range of 4.4 to 4.6 comprising:
[0038] water,
[0039] [Aib 8,35 ]hGLP-1(7-36)NH 2 in a concentration of 100 mg/ml (30 mM)
[0040] zinc chloride in a concentration of 2.72 mg/ml (20 mM), and
[0041] acetic acid and/or an acetate salt, wherein acetic acid is added in a concentration range of 0 mM to 75 mM,
[0000] characterized in that the final pH in the range of 4.4 to 4.6 is adjusted by addition of hydrochloric acid.
[0042] In particular, acetic acid is added in a concentration range of 0 mM to 47.5 mM. More particularly, acetic acid is added in a concentration of 20 mM.
[0043] The invention further relates to a liquid pharmaceutical composition as defined above, wherein the composition further comprises sodium chloride in a concentration range of 0 mM to 50 mM.
[0044] The pharmaceutical compositions according to the invention are further characterized in that they are stable at a temperature of 5° C. for a period of at least one year.
[0045] The term “sustained release” as used herein means a release which results in a measurable serum level of the biologically active peptide analogue of formula I, for a period of at least 1 week and more preferably for a period of at least 2 weeks.
[0046] Thus, the invention relates to pharmaceutical compositions, wherein the composition is formulated such that [Aib 8,35 ]hGLP-1(7-36)NH 2 is released within the human subject for at least approximately 1 week, preferably 2 weeks.
[0047] The sustained release profile and ability of the pharmaceutical compositions of the present invention to show a reduced initial burst effect has been investigated by using in vitro precipitation and dissolution assays.
[0048] In the precipitation assay a certain amount of the pharmaceutical composition is added to a phosphate buffer solution of pH 7.4 (see Example 3.1). The mixture is then centrifuged and the remaining dissolved peptide analogue of formula I (([Aib 8,35 ]hGLP-1(7-36)NH 2 ) in the supernatent is measured by analytical HPLC, A high amount of peptide in solution corresponds to a strong initial burst effect.
[0049] In particular, the pharmaceutical compositions according to the invention are those, wherein less than 2.5% of the dose of the peptide analogue of formula I ([Aib 8,35 ]hGLP-1(7-36)NH 2 ) can be detected in the supernatant after precipitation in phosphate buffer pH 7.4 and subsequent centrifugation.
[0050] In the dissolution assay, the release of the peptide from a precipitated depot to a continuous flow of release medium can be studied (Example 3.2). 0.2 ml of the pharmaceutical composition are added into a cell filled with glass beadlets. The release medium is a Hanks balanced salt solution (HBSS) modified with 25 mM HEPES (4-(2-Hydroxyethyl)piperazine-1-ethanesulfonic acid) buffering agent at pH 7.4 which flows through the cell. Samples are collected after 5, 10, 15, 30 and 60 min and their content of dissolved/released peptide is analyzed.
[0051] Particularly interesting pharmaceutical compositions according to the invention are those, wherein less than 0.015 mg/min of the peptide analogue of formula I are released after 5 min during dissolution in modified HBSS buffer pH 7.4.
[0052] The present invention further relates to a method for preparing the pharmaceutical compositions as defined above, comprising the steps of
[0000] a) combining the liquid solvent and acetic acid and/or acetate salt to obtain an acidified solution,
b) dissolving the peptide analogue in the acidified solution,
c) adding zinc chloride and optionally sodium chloride; and
d) adjusting the pH of the final solution with hydrochloric acid to be in the range of 4.4 to 4.6. Zinc chloride and sodium chloride can be added as solutions or they can be added in the solid state and dissolved in the acidified solution.
[0053] More particularly, the invention is concerned with the method as described above further comprising the steps of
[0000] e) sterile filtrating the composition resulting from step d), and
f) filling a container with the composition.
[0054] As described above, the pharmaceutical compositions as described above are specifically suitable for subcutaneous administration, i.e. for injection into the skin. The invention thus also relates to a pharmaceutical composition according to the invention, wherein it is kept in a container, for example a pre-filled syringe.
[0055] Thus, the invention also relates to a pre-filled syringe containing a pharmaceutical composition according to the invention. In particular, the pre-filled syringe contains 0.2 ml of the pharmaceutical composition according to the invention.
[0056] The pharmaceutical compositions according to the invention are especially suitable for use in the treatment of Type 2 diabetes or gestational diabetes. They are also useful for the treatment of other metabolic diseases such as obesity, central nervous system diseases such as Alzheimer's disease, renal failure and cardiovascular diseases such as congestive heart failure, myocardial infarction, stroke and acute coronary syndrome, polycystic ovary syndrome nephrotic syndrome.
EXAMPLES
Example 1
Preparation of [Aib 8,35 ]hGLP-1(7-36)NH 2 (Drug Substance)
Preparation of the Peptide:
[0057] The crude peptide [Aib 8,35 ]hGLP-1(7-36)NH 2 can be prepared according to the methods described in WO 2007/147816 and WO 2009/074483 by producing three fragments and coupling these fragments in solution.
RP-HPLC Purification:
[0058] Purification of the crude peptide was performed on a RP (reversed phase) stationary phase. Thus, the sorbent is RP material such as silica gel (e.g. Kromasil 100-16-C18) or acrylic ester macroreticular adsorbent (e.g. Amberchrom CG71M). The purification involved a 1 st pass chromatographic purification at a pH of approximately 2, followed by a 2 nd pass at a pH of approximately 9.
1 st Chromatography:
[0059] Crude [Aib 8,35 ]hGLP-1(7-36)NH 2 was dissolved in water/acetonitrile/acetic acid (e.g. 90/9/1 v/v/v) and loaded onto a HPLC column (loading up to 20 g/L, bed depth approx. 25 cm) and the purification program (a gradient from aqueous ammonium phosphate (approx. pH 2)/acetonitrile (80/20 v/v) to aqueous ammonium phosphate (approx. pH 2)/acetonitrile (60/40 v/v)) was initiated. Fractions were collected and diluted with water or diluted ammonium hydroxide solution.
2 nd Chromatography:
[0060] The pooled, diluted fractions from Chromatography 1 of [Aib 8,35 ]hGLP-1(7-36)NH 2 were loaded onto the HPLC column and the purification program (a gradient from aqueous ammonium acetate (approx. pH 9-10)/acetonitrile (85/15 v/v) to aqueous ammonium acetate (approx. pH 9-10)/acetonitrile (35/65 v/v)) was initiated. The fractions were collected and optionally diluted with water, diluted acetic acid or ammonium acetate. They were then loaded directly onto the HPLC column for the following concentration step.
Concentration Step:
[0061] The pooled, diluted fractions from Chromatography 2 were loaded onto the same HPLC column and eluted quickly using a different mobile phase to concentrate peptide for isolation. As the mobile phase a gradient from aqueous ammonium acetate (approx. pH 9)/methanol (85/15 v/v) to aqueous ammonium acetate (approx. pH 9)/methanol (20/80 v/v) was used. The peptide containing fractions were pooled for isolation.
Isolation:
[0062] In order to obtain a dry drug substance which is suitable for the drug formulation, the solution can either be subjected to precipitation, lyophilization or spray-drying techniques. Precipitation of the peptide:
[0063] The peptide solutions were slowly fed with isopropanol (IPA) at a temperature between 20° C. and 25° C. The mixture became cloudy. After stirring overnight at 20 to 25° C. the precipitating product [Aib 8,35 ]hGLP-1(7-36)NH 2 was filtered and washed with IPA and then dried at 25° C. under vacuum until a constant weight was obtained.
[0064] Alternatively, the peptide can be isolated by spray-drying as described in WO 2010/072621:
[0000] The peptide containing fraction were directly fed to a Niro SD-4-R-CC (Spraying chamber 0 1.2×0.75 m, capacity 8 kg H 2 OZh). After a few hours, a fine powder of [Aib 8,35 ]hGLP-1(7-36)NH 2 was collected from the cyclone.
Example 2
Formulation Procedures
A) Materials:
[0065] Zinc chloride, sodium chloride and 1M hydrochloric acid were purchased from Merck. Acetic acid (99.5%) was purchased from Fluka. Sodium acetate trihydrate was purchased from Hänseler AG. Water for injection was internally produced by double-destillation.
B) Preparation of Stock Solutions:
[0066] Zinc Chloride: 5.236 g zinc chloride was dissolved in 100 mL water for injection.
[0000] Sodium Chloride: 5.844 g sodium chloride was dissolved in 100 mL water for injection.
Sodium acetate trihydrate: 10.478 g sodium acetate trihydrate was dissolved in 100 mL water for injection.
C) Preparation of Liquid Formulations:
[0067] Approximately 70% of target volume water for injection was filled into a compounding container and then acidified with acidic acid, 1N hydrochloric acid or combination of both. In case of acidic acid/sodium acetate mixtures sodium acetate trihydrate stock solution was added to the solution. Subsequently, [Aib 8,35 ]hGLP-1(7-36)NH 2 was added under stirring to the acidified solution. After dissolution of all solid [Aib 8,35 ]hGLP-1(7-36)NH 2 zinc chloride and/or sodium chloride stock solutions were added to the formulations. After further stirring the pH was measured and adjusted, respectively, by addition of 1N hydrochloric acid. Finally, water for injection was added to the formulation until the target volume has been reached. The final bulk formulation was sterile-filtered using a 0.22 μm PVDF filter into a clean and sterile container. The sterile bulk formulation was filled into heat-sterilized 6 mL glass vials with a fill volume of 5 mL. The vials were stoppered with teflonized serum stoppers and crimped with aluminium caps. Sterile filtration and vial filling were performed under aseptic conditions using a laminar air-flow bench.
Overview of Tested Compositions
[0068]
[0000]
[Aib 8, 35 ]hGLP-1(7-36)NH 2
fixed
100 mg/mL (30 mM)
(GLP-1 analogue)
Zinc chloride
fixed
2.72 mg/mL (20 mM)
Acetate 1
varied
0 to 95 mM
pH
varied
4.4 to 4.6
Sodium chloride
varied
0 to 50 mM
Water for Injection
fixed
Quantum satis ad volume
1 provided as a mixtures of acetic acid and sodium acetate trihydrate or acetic acid and hydrochloric acid
[0000]
TABLE 1
Tested compositions
Fixed
Comp.
Parameters
Acetate
pH
NaCl
A
100 mg/mL
95
mM acetic acid
4.46
0 mM
B
GLP-1 analogue
0
mM acetic acid
4.49
50 mM
2.72 mg/mL
Ad pH 1N HCl
C
Zinc chloride
47.5
mM acetic acid
4.51-4.55
25 mM
Qs ad volume
Ad pH 1N HCl
D
Water for
75
mM acetic acid
4.49
50 mM
injection
20
mM sodium
acetate trihydrate
E
0
mM acetic acid
4.41
50 mM
Ad pH 1N HCl
F
75
mM acetic acid
4.60
0 mM
20
mM sodium
acetate trihydrate
G
0
mM acetic acid
4.42
0 mM
Ad pH 1N HCl
H
95
mM acetic acid
4.54
50 mM
I
0
mM acetic acid
4.54
0 mM
Ad pH 1N HCl
J
20
mM acetic acid
4.51
0 mM
Ad pH 1N HCl
Composition A (Original Formulation, Comparative Example)
[0069] 100 mg/mL (30 mM) [Aib 8,35 ]hGLP-1(7-36)NH 2
[0070] 95 mM Acetic Acid
[0071] 2.72 mg/mL (20 mM) Zinc Chloride
[0072] pH 4.5
[0073] Water for Injection (quantum satis ad volume)
Composition B
[0074] 100 mg/mL (30 mM) [Aib 8,35 ]hGLP-1(7-36)NH 2
[0075] 0 mM Acetic Acid
[0076] 2.72 mg/mL (20 mM) Zinc Chloride
[0077] 50 mM Sodium Chloride
[0078] Hydrochloric acid quantum satis ad pH 4.5
[0079] Water for Injection (quantum satis ad volume)
Composition C
[0080] 100 mg/mL (30 mM) [Aib 8,35 ]hGLP-1(7-36)NH 2
[0081] 47.5 mM Acetic Acid
[0082] 2.72 mg/mL (20 mM) Zinc Chloride
[0083] 25 mM Sodium Chloride
[0084] Hydrochloric acid quantum satis ad pH 4.5
[0085] Water for Injection (quantum satis ad volume)
Composition D
[0086] 100 mg/mL (30 mM) [Aib 8,35 ]hGLP-1(7-36)NH 2
[0087] 75 mM Acetic Acid
[0088] 20 mM Sodium Acetate Trihydrate
[0089] 2.72 mg/mL (20 mM) Zinc Chloride
[0090] 50 mM Sodium Chloride
[0091] pH 4.5
[0092] Water for Injection (quantum satis ad volume)
Composition E
[0093] 100 mg/mL (30 mM) [Aib 8,35 ]hGLP-1(7-36)NH 2
[0094] 0 mM Acetic Acid
[0095] 2.72 mg/mL (20 mM) Zinc Chloride
[0096] 50 mM Sodium Chloride
[0097] Hydrochloric acid quantum satis ad pH 4.4
[0098] Water for Injection (quantum satis ad volume)
Composition F
[0099] 100 mg/mL (30 mM) [Aib 8,35 ]hGLP-1(7-36)NH 2
[0100] 75 mM Acetic Acid
[0101] 20 mM Sodium Acetate Trihydrate
[0102] 2.72 mg/mL (20 mM) Zinc Chloride
[0103] pH 4.60
[0104] Water for Injection (quantum satis ad volume)
Composition G
[0105] 100 mg/mL (30 mM) [Aib 8,35 ]hGLP-1(7-36)NH 2
[0106] 0 mM Acetic Acid
[0107] 2.72 mg/mL (20 mM) Zinc Chloride
[0108] Hydrochloric acid quantum satis ad pH 4.4
[0109] Water for Injection (quantum satis ad volume)
Composition H
[0110] 100 mg/mL (30 mM) [Aib 8,35 ]hGLP-1(7-36)NH 2
[0111] 95 mM Acetic Acid
[0112] 2.72 mg/mL (20 mM) Zinc Chloride
[0113] 50 mM Sodium Chloride
[0114] pH 4.5
[0115] Water for Injection (quantum satis ad volume)
Composition I
[0116] 100 mg/mL (30 mM) [Aib 8,35 ]hGLP-1(7-36)NH 2
[0117] 0 mM Acetic Acid
[0118] 2.72 mg/mL (20 mM) Zinc Chloride
[0119] Hydrochloric acid quantum satis ad pH 4.5
[0120] Water for Injection (quantum satis ad volume)
Composition J
[0121] 100 mg/mL (30 mM) [Aib 8,35 ]hGLP-1(7-36)NH 2
[0122] 20 mM Acetic Acid
[0123] 2.72 mg/mL (20 mM) Zinc Chloride
[0124] Hydrochloric acid quantum satis ad pH 4.5
[0125] Water for Injection (quantum satis ad volume)
Example 3
Analytical Procedures
[0126] The impact of formulation modifications on the sustained release profile of [Aib 8,35 ]hGLP-1(7-36)NH 2 was investigated by using in vitro precipitation and dissolution assays. Furthermore, formulations of [Aib 8,35 ]hGLP-1(7-36)NH 2 were analyzed for buffer capacity, viscosity and turbidity.
Example 3.1
Precipitation Assay
[0127] The precipitation assay measures the remaining soluble active ingredient after precipitation of [Aib 8,35 ]hGLP-1(7-36)NH 2 formulation in a (USP) 50 mM phosphate buffer pH 7.4. 200 μl of the [Aib 8,35 ]hGLP-1(7-36)NH 2 formulation were mixed with 250 μl of phosphate buffer. The mixture was centrifuged and the clear supernatant was analyzed for the concentration of [Aib 8,35 ]hGLP-1(7-36)NH 2 .
[0000]
TABLE 2
Relative content of [Aib 8,35 ]hGLP-1(7-36)NH 2 in the
supernatant after precipitation in phosphate buffer pH 7.4 and
subsequent centrifugation.
Comp.
A
B
C
D
E
F
G
H
I
J
% dose in
15.8
0.2
0.5
2.3
0.3
2.3
0.6
2.4
0.2
0.3
supernatant
[0128] Modified formulations showed a significant reduction of [Aib 8,35 ]hGLP-1(7-36)NH 2 solubility in phosphate buffer pH 7.4 in comparison of the original formulation (A).
Example 3.2
Dissolution Assay in HBSS Medium
[0129] The dissolution assay measures the release of [Aib 8,35 ]hGLP-1(7-36)NH 2 from a precipitated depot to a continuous flow of release medium as a function of time. 200 μl of the [Aib 8,35 ]hGLP-1(7-36)NH 2 formulation were added to a USP IV powder cell filled with glass beadles. The dissolution assay was run with 2 mL/min for 60 min in the open configuration. Samples were collected after 5, 10, 15, 30 and 60 min. The release medium was a modified Hanks balanced salt solution (HBSS) with 25 mM HEPES at pH 7.4 as buffering agent according to Iyer et al., J. Pharmaceut. Biomed. Anal . (2006), pages 119-125, Characterization of a potential medium for “biorelevant” in vitro release testing of a naltrexone implant, employing a validated stability-indicating HPLC method).
[0000]
TABLE 3
Released amount of [Aib 8,35 ]hGLP-1(7-36)NH 2 per time in mg/min during
dissolution in modified HBSS buffer pH 7.4.
Comp.
A
B
C
D
E
F
G
H
I
J
mg/min
0.054
0.001
0.006
0.005
0.004
0.009
0.006
0.004
0.011
0.000
dissolved
after 5 min
mg/min
0.058
0.006
0.007
0.016
0.008
0.006
0.012
0.009
0.017
0.006
dissolved
after 10 min
mg/min
0.059
0.009
0.010
0.020
0.008
0.010
0.014
0.014
0.014
0.010
dissolved
after 15 min
mg/min
0.059
0.011
0.015
0.021
0.008
0.021
0.014
0.023
0.010
0.011
dissolved
after 30 min
mg/min
0.047
0.016
0.017
0.026
0.006
0.020
0.012
0.028
0.011
0.013
dissolved
after 60 min
[0130] Modified formulations showed a significant reduction of dissolution of [Aib 8,35 ]hGLP-1(7-36)NH 2 in modified HBSS pH 7.4 in comparison to the original formulation (A).
Example 3.3
Determination of Buffer Capacity
[0131] The buffer capacity assay determines the amount of NaOH needed to titrate a defined amount of [Aib 8,35 ]hGLP-1(7-36)NH 2 formulation to a pH of 7.4.
[0132] 5 mL of the [Aib 8,35 ]hGLP-1(7-36)NH 2 formulation was filled into 20 mL glass beaker. 0.1M sodium hydroxide was added under continuous stirring to the solution. The pH was recorded potentiometrically using a glass electrode until a pH of 7.4 is reached. The buffer capacity is reported as mmol sodium hydroxide per L test solution.
[0000]
TABLE 4
Buffer capacity of [Aib 8,35 ]hGLP-1(7-36)NH 2 formulations:
Comp.
A
B
C
D
E
F
G
H
I
J
mmol/L
107
64
82
114
70
99
69
99
59
62
NaOH to
reach pH
7.4
[0133] Modified formulations B, C, E, G, I and J showed a clear reduction of buffer capacity in comparison to the original formulation (A) and formulations D and H.
Example 3.4
Determination of Viscosity
[0134] The viscosity was determined on a plate and cone rheometer at a shear rate of 2000 s −1 and at a temperature of 20° C. The viscosity is a relevant parameter to assess the syringe ability of a formulation through a needle for subcutaneous delivery and a viscosity below 10 mPas is desirable for a very easy manual injection (W. Rungseevijitprapa and R. Bodmeier; Eur. J. Pharm. Sci. 36 (2009), 524-531. Injectability of biodegradable in situ forming microparticle systems (ISM)).
[0000]
TABLE 5
Viscosity of [Aib 8,35 ]hGLP-1(7-36)NH 2 formulations
determined on a plate and cone rheometer at a shear rate of
2000 s −1 and a temperature of 20° C.
Comp.
A
B
C
D
E
F
G
H
I
J
Viscosity
3.5
10.3
4.7
11.4
6.8
4.3
3.5
9.8
3.7
3.3
in mPas
[0135] The viscosity of formulations A, C, F, G, I and J was clearly lower than determined for formulations B, D, E and H. The presence of 50 mM sodium chloride in the formulations B, D, E and H led to a clear increase of viscosity.
Example 3.5
Determination of Turbidity
[0136] The turbidity of the [Aib 8,35 ]hGLP-1(7-36)NH 2 formulations was measured on a Hach 2199 AN turbid meter. The turbidity indicates the physical stability of a liquid solution and an elevated turbidity points to a decreased solubility of [Aib 8,35 ]hGLP-1(7-36)NH 2 and the risk of potential precipitation.
[0000]
TABLE 6
Turbidity of [Aib 8,35 ]hGLP-1(7-36)NH 2 formulations
Comp.
A
B
C
D
E
F
G
H
I
J
Turbidity
4.6
23.5
10.3
29.5
15.5
7.8
4.0
24.9
5.2
4.1
in FTU
[0137] The turbidity of formulations A, C, F, G, I and J is clearly lower than determined for the formulations B, D, E and H. The presence of 50 mM sodium chloride in the formulations B, D, E and H led to a clear increase of turbidity.
|
This invention relates to sustained release liquid pharmaceutical compositions containing a peptide analogue of glucagon-like peptide-1 or salts thereof having an improved release profile. The invention also relates to methods for preparing such compositions.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application Ser. No. 62/040,592, filed Aug. 22, 2014, by David Dwelley and Andrew J. Gardner.
FIELD OF THE INVENTION
[0002] This invention relates to Power over Data Line (PoDL) systems, where DC power is transmitted over differential data lines. The invention more particularly relates to a detection and classification scheme for such a PoDL system so that full DC power is only transmitted by the Power Sourcing Equipment (PSE) once it is determined that the Powered Device (PD) is PoDL-compatible.
BACKGROUND
[0003] FIG. 1 illustrates a conventional PoDL system with a PSE 10 and a PD 12 . The PSE 10 is shown as excluding the various AC and DC filters and the master PHY 16 (physical layer); however, the PSE 10 may alternatively be designated as including all of the circuitry on the left side of the twisted wire pair 14 . The master PHY 16 is a transceiver containing conventional circuitry (e.g., transformers, amplifiers, conditioning circuits, etc.) that receives and transmits the relatively high speed Ethernet differential data and ensures that the data signals have the proper characteristics in accordance with the IEEE802.3 physical layer standards for T1 Ethernet.
[0004] The PSE 10 controls the coupling of the DC voltage V IN , generated by a voltage source, to the PD 12 .
[0005] The Ethernet differential data may be generated and received by a host processing system that may be considered part of the PSE 10 .
[0006] The PD 12 is shown as excluding the various AC and DC filters and the slave PHY 18 ; however, the PD 12 may alternatively be designated as including all of the circuitry on the right side of the twisted wire pair 14 . The slave PHY 18 may be identical to the master PHY 16 and is powered by the DC voltage V IN transmitted by the PSE 10 . The Ethernet differential data on the PD side may be generated and received by a slave processing system that may be considered part of the PD 12 . The PD 12 may contain a DC/DC converter for converting the incoming voltage to a target voltage V OUT . The V OUT may be used only to power the PD 12 and slave PHY 18 or may be used to power additional equipment. The DC voltage range supplied by the PSE 10 is dictated by the IEEE802.3bu standard.
[0007] The capacitors C PSE and C PD smooth the voltages V IN and V OUT .
[0008] The inductors L 1 , L 2 , L 3 , and L 4 pass DC but block the Ethernet AC differential data, and the capacitors C 1 , C 2 , C 3 , and C 4 pass the AC differential data but block DC. The various inductors and capacitors are referred to as a coupling/decoupling network since they couple the DC and AC to the wire pair 14 and decouple the DC and AC from the wire pair 14 .
[0009] The PoDL system includes circuitry in the PSE 10 and PD 12 that performs a detection and classification routine before the PSE 10 can couple the DC voltage V IN to the wire pair 14 . The detection and classification signals must be transmitted/received via the coupling/decoupling network. The requirements for detection and classification schemes for PoDL preclude re-using the schemes used for the much older Power over Ethernet (PoE). In PoE, at least two wire pairs in the standard CAT-5 cable are used to transmit the DC voltage and conduct the differential data signals. In a conventional PoE system, a PSE controls the magnitudes of current-limited signals on the wire pairs that are directly used by a PD to power the PD and generate a characteristic response that conveys PoE-related characteristics of the PD. Very limited information can be communicated using this conventional PoE technique. Only after the PD has conveyed that it is PoE-compatible, can the PSE couple the DC voltage source to the wire pairs to fully power the PD.
[0010] What is needed is an improved low-current detection and classification scheme for a PoDL system that can be used to rapidly convey any desired information prior the full DC voltage being coupled across the wire pair. This new detection and classification scheme specifically for use with PoDL should make use of the differences between PoDL (one wire pair) and PoE (two wire pairs).
SUMMARY
[0011] An Ethernet PoDL detection and classification scheme using the wire pair as a half-duplex, serial 1-wire data bus is disclosed. This offers significant advantages over Ethernet PoE schemes currently in use, since any amount of information may be communicated during the low-current handshaking phase. For example, the PSE/PD serial link may also be used as an auxiliary communication channel, separate from the two PHYs, prior to normal Ethernet operation in order to determine the slave PHY's maximum data rate capability as well as other parameters.
[0012] In a PoDL system, the PD requires a source of power in order to transmit its detection and classification information (or any other information) before the PSE is allowed to supply the full DC voltage via the wire pair.
[0013] In one embodiment of the invention, the PSE includes a low-magnitude, pull-up current source and a pull down MOSFET coupled to a first wire in the wire pair. The other wire in the wire pair acts as a common reference. Logic controlling the pull-down MOSFET is used to transmit data via the first wire to the PD.
[0014] In order to initially isolate the PSE's DC voltage source from the PD, a first switch in the PSE between the voltage source and the wire pair is opened. The pull-up current bypasses the first switch so is always coupled to the first wire via a first inductor (a low pass filter).
[0015] The pull-up current charges a capacitor through a rectifier in the PD, and the voltage across the capacitor is limited by a shunt regulator to, for example, 4.5 volts. This voltage is used to power PD logic circuitry that carries out the detection and classification routine. The PD logic and the PSE logic communicate via the controlling of the respective pull-down MOSFETs to complete the detection and classification routine without the need for the PSE master PHY or the PD slave PHY (the PHYs are eventually used for normal Ethernet communications via the wire pair). The communication during the handshaking phase is via the control of the pull-down MOSFETs and is of a low enough frequency to pass through the low-pass inductors of the coupling/decoupling network. In contrast, the normal Ethernet communications via the PHYs are a high frequency and pass through the high-pass capacitors of the coupling/decoupling network. Therefore, the present system creates an additional communication channel between the PSE and the PD using frequency division multiplexing.
[0016] As seen, the wire pair is used as a half-duplex 1-wire serial link during the detection and classification phase (and any additional portion of the handshaking phase), where all power for the PD logic is derived from the same pull-up current source in the PSE that is used for the transmission of data.
[0017] After a successful detection and classification routine, the first switch coupling the PSE voltage source to the wire pair is closed to fully power the PD side for normal operation of the system.
[0018] During the low power handshaking phase, the PSE may control the low power pull-up current and measure the corresponding change in voltage to determine the round trip resistance of the wire pair. This resistance may be used to adjust the PoDL voltage applied to the wire pair during normal operation to compensate for the wire pair resistance.
[0019] Other embodiments are disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 illustrates a conventional PoDL system using a conventional detection and classification scheme during a handshaking phase.
[0021] FIGS. 2A and 2B together illustrate a PoDL system in accordance with a first embodiment of the invention.
[0022] FIG. 3 is a flowchart showing steps conducted when performing a detection and classification routine using the system of FIG. 2 .
[0023] FIG. 4 illustrates a PoDL system where multiple PDs are connected in parallel, and the handshaking phase also includes the transmission of information to the PSE regarding the multiple PDs.
[0024] Elements that are the same or equivalent in the various figures are labeled with the same numeral.
DETAILED DESCRIPTION
[0025] An Ethernet PoDL detection and classification scheme is disclosed where a PSE and a PD communicate binary serial data over a half-duplex, 1-wire link. Data is communicated on the wire using a constant pull-up current source in the PSE and controllable pull-down MOSFETs in the PSE and PD. The PD circuitry receives power during the handshaking phase from the PSE's pull-up current charging a capacitor in the PD to an operating voltage. The 1-wire serial link uses one of the wires in the wire pair that communicates differential Ethernet data during normal operations. After a successful handshaking phase, the PSE couples a DC voltage source across the wire pair to fully power the PD during normal operation. Therefore, the system includes a novel low frequency communications channel for the handshaking phase and a conventional high frequency channel for the Ethernet data during normal operation.
[0026] FIGS. 2A and 2B together illustrate an example of a PoDL system that makes use of one embodiment of the invention. The operation of the system of FIGS. 2 A/ 2 B will be described with respect to the flowchart of FIG. 3 .
[0027] The inductors L 1 -L 4 perform the conventional passing of DC (or low frequency signals), and the capacitors C 1 -C 4 perform the conventional passing of relatively high frequency AC differential Ethernet signals during normal operation, as discussed with respect to FIG. 1 .
[0028] The PSE 20 includes a voltage source 22 that provides a PoDL voltage V PSE . During normal operation of the PoDL system, V PSE is supplied to the PD 24 via the closed switch SW 1 , the inductors L 1 and L 2 , the wire pair 14 , the inductors L 3 and L 4 , and the closed switch SW 2 . The switches SW 1 and SW 2 may be MOSFETs. However, the switches SW 1 and SW 2 cannot be closed until the system has performed a detection and classification routine that conveys the pertinent PD and PSE characteristics. If, during the detection and classification routine, the PSE 20 discovers that the PD 24 is not PoDL-compatible, the voltage V PSE will not be applied to the wire pair 14 , and the PD must be powered locally for all functions.
[0029] The invention primarily relates to how the PD can be powered during the detection and classification phase and communicate with the PSE during this phase without the PD being powered by the V PSE voltage source 22 .
[0030] In step 26 of FIG. 3 , the PSE 10 is powered up. If the PoDL system is in an automobile, the powering up may occur upon turning the ignition switch.
[0031] The voltage source 22 may be used to supply power to all the circuitry in the PSE 20 , or the PSE 20 may be powered by a different voltage source. In one embodiment, the voltage source 22 provides 5-12 volts. Upon powering up of the PSE 10 , the pull-up current source 27 generates a low current I PUP , such as a few milliamps. The pull-down MOSFET M 1 is initially off. The MOSFET M 1 is later controlled by the PSE logic 30 to transmit digital codes to the PD logic 32 to transmit detection and classification information as well as any other information during the handshaking phase.
[0032] In step 34 , during the detection and classification phase, the switch SW 1 is off (open). The switch SW 1 is only conductive (closed) when the PSE logic 30 supplies a high signal at its SWX_EN terminal. The switch SW 2 on the PD side is also open upon start-up and is only closed when the PD logic 32 supplies a high signal at its SWX_EN terminal. Therefore, at this point, the voltage source 22 is not coupled to the PD side via the wire pair 14 .
[0033] In step 40 , the pull-up current source 27 is coupled to the “top” wire terminal 42 via the inductor L 1 , and the top wire of the wire pair 14 is pulled up in voltage. The pull-up current I PUP charges the PD capacitor C HOLDUP , via the inductor L 3 and diode D 1 , and the voltage across the capacitor C HOLDUP ramps up. This voltage is coupled to the voltage input terminal IN of the PD logic 32 .
[0034] In step 44 , the shunt regulator 46 effectively detects the voltage across the capacitor C HOLDUP by detecting the voltage at node 47 . The voltage at node 47 corresponds to a current through the shunt regulator 46 . The shunt regulator 46 limits this current to a threshold current I LIM and, by doing so, limits the voltage across the capacitor C HOLDUP to a target operating voltage for powering the PD logic 32 . In the example, this operating voltage is 4.5 volts.
[0035] A reference voltage REF is generated by the shunt regulator 46 , and this reference voltage is compared to a divided node 47 voltage, set by resistors R DIV1 and R DIV2 . When the voltages match, the hysteresis comparator 48 issues a signal REG — 0V to the PD logic 32 signifying that the desired operating voltage has been achieved. The PD logic 32 then initiates the detection and classification routine.
[0036] During normal operation, when the full V PSE voltage is being applied to the PD side, the PD logic 32 disables the shunt regulator 46 , via the enable terminal EN, with the signal REG_EN so the shunt regulator 46 becomes an open circuit.
[0037] Other techniques for limiting the voltage across the capacitor C HOLDUP can be used, such as using zener diodes.
[0038] In step 49 , the shunted voltage is used to power the PD logic 32 . The PD logic 32 includes circuitry for carrying out the detection and classification routine and any other handshaking routine. Such circuitry may include a processor and a memory, or a state machine, or other logic circuits that respond to any PSE inquiries and transmit the pertinent PoDL characteristics to the PSE 20 .
[0039] While the PSE logic 30 and PD logic 32 are communicating while selectively pulling the wire low, via MOSFETs M 1 and M 2 , the capacitor C HOLDUP provides a charge reservoir for powering the PD logic 32 . Consequently, C HOLDUP should be large enough to minimize any droop in the target operating voltage resulting from the PD current I CC during the maximum required low assertion time (t bus — low(max) ) of the bus, i.e.,
[0000]
t
bus_low
(
max
)
×
I
CC
C
HOLDUP
≤
V
CC_droop
(
max
)
[0040] The resistor/capacitor filtering networks of C SNUB1 , R SNUB1 , C SNUB2 , and R SNUB2 are connected in shunt with the I/O ports of the PSE 20 and PD 24 and are used to damp the resonance of the inductors L 1 -L 4 and capacitors C 1 -C 4 .
[0041] In step 50 , the PSE logic 30 begins its detection/classification routine by transmitting digital codes to the PD logic 32 . The serial bits are transmitted to the PD logic 32 via the 1-wire serial link by controlling the pull-down MOSFET M 1 , and serial bits are transmitted to the PSE logic 30 by controlling the pull-down MOSFET M 2 . The PSE logic 30 includes circuitry for carrying out the detection and classification routine, such as a processor and a memory, or a state machine, or other logic circuits. The PSE logic 30 transmits the pertinent PSE PoDL characteristics and inquiries to the PD logic 32 and appropriately responds to the PD logic's transmitted PoDL characteristics and inquiries. Turning on the pull down MOSFETs M 1 and M 2 places a logical low voltage on the top wire of the wire pair 14 , while turning off the pull-down MOSFETs allows the voltage on the top wire to rise to a logical high voltage. The bit rate must be relatively slow, compared to the Ethernet bit rates, so that the bits are not filtered out by the low pass inductors L 1 and L 3 . Even with the relatively slow bit rate, the pertinent information for the detection and classification phase may be transmitted in less than 10 ms.
[0042] Prior to initiating communication with the PD 24 , the PSE 20 may choose to simply detect the presence of the PD 24 by applying the pull-up current I PUP and sensing the subsequent voltage V BUS across the wire pair 14 .
[0043] In step 52 , the pertinent information transmitted during the handshaking phase may include the PD's operating voltage requirement, the PD load current requirement, the serial number of the PD (or parallel PDs), and any other relevant operating parameters, including the ambient temperature of the PD 24 .
[0044] In step 56 , the PSE 20 may optionally determine the round trip resistance of the wire pair 14 by either controlling the pull-up current source 27 or the pull-down MOSFET M 1 to supply two different current levels and measuring the resulting voltages V BUS across the wire pair 14 . In other words, the PSE logic 30 or other circuitry in the PSE 20 may measure the total round-trip resistance between the PSE 20 and PD 24 by observing the incremental change in V BUS(HI) as I PUP is changed, as follows:
[0000]
R
PSE
-
PD
=
(
V
BUS
(
HI
)
,
1
-
V
BUS
(
HI
)
,
2
)
(
I
BUS
(
HI
)
,
1
-
I
BUS
(
HI
)
,
2
)
[0045] The resistance can then be used by the PSE 20 to raise or lower the level of the voltage source 22 such that the optimal voltage is received at the PD 24 . This may obviate the need for a DC/DC converter in the PD 24 . The voltage drop along the wire pair 14 becomes very significant for long lengths of the wire pair 14 .
[0046] The signals on the top wire of the wire pair 14 are supplied to the DATA_IN terminal of the PSE logic 30 via the driver 58 , and the signals on the top wire of the wire pair 14 are supplied to the DATA_IN terminal of the PD logic 32 via the driver 59 .
[0047] In step 60 , it is assumed that the detection/classification phase has been successful and the PSE 20 is ready to supply the full voltage V PSE across the wire pair 14 to power the PD load 62 and all other PD circuitry. The PSE logic 30 closes the switch SW 1 and the PD logic 32 closes the switch SW 2 so that the full V PSE is supplied to the PD load 62 and all other PD circuitry via the switch SW 1 , the inductors L 1 /L 2 , the wire pair 14 , the inductors L 3 /L 4 , and the switch SW 2 .
[0048] The master PHY 16 in the PSE 20 is powered by the voltage V PSE or another supply voltage, and the slave PHY 18 in the PD 24 is powered by the transmitted voltage V PSE . The capacitor C PD across the PD load 62 smooths the voltage V PSE . The PD load 62 may include a DC/DC converter for generating a target voltage for other circuitry in the PD load 62 .
[0049] In step 68 , in the event of a PD fault, where it is not desired for the PSE 20 to keep transmitting the voltage V PSE , the PSE logic 30 and the PD logic 32 may open the switches SW 1 and SW 2 , and the PD logic 32 may again be powered by the pull-up current source 27 , as previously described, to transmit status information via the 1-wire serial bus, such as the nature of the fault (e.g. temperature fault, over-current fault, or over-voltage fault).
[0050] In step 70 , the PD logic 32 and slave PHY 18 may be optionally powered by an auxiliary voltage source, via diodes D 2 and D 3 , generating V AUX . The auxiliary power source is not needed once the PSE 20 supplies the voltage V PSE to the PD 24 . By using the auxiliary power source, communication between the PD 24 and PSE 20 may be carried out via the PHYs 16 and 18 while the switches SW 1 and SW 2 are open.
[0051] In step 74 , the PD 24 is fully powered by the voltage V PSE and high speed differential Ethernet data may be transmitted through the wire pair 14 via the master PHY 16 , the slave PHY 18 , and the capacitors C 1 -C 4 . The PHY's 16 and 18 ensure the data has the correct characteristics for meeting the IEEE standards for T1 Ethernet. Any suitable host processing system and slave processing system may be coupled to the PHY's 16 and 18 for processing the Ethernet data. Since the voltage V PSE is DC, it is blocked by the capacitors C 1 -C 4 so does not affect the high speed differential Ethernet data into the PHYs 16 and 18 .
[0052] During the low current detection/classification phase, either the PSE 20 or PD 24 may limit the bus logic high voltage, but the preferred scheme discussed herein relies upon the PD clamping the bus voltage with the shunt regulator 46 . The shunt regulator 46 may also be used to present a constant voltage signature to the PSE 20 prior to serial communication as well as providing a virtual ground for the purpose of measuring round-trip resistance between the PSE 20 and PD 24 .
[0053] If an auxiliary power source is available to power the slave PHY 18 , the high frequency Ethernet link (using the PHYs 16 and 18 ) may operate simultaneously with the low frequency PSE/PD 1-wire serial bus (not using the PHYs 16 and 18 ) using the principal of frequency-division multiplexing (FDM).
[0054] During the detection/classification phase, the amount of time required for the 1-wire bus voltage to rise (t RISE ) is a function of the magnitude of I PUP and the impedance of the PoDL decoupling network. This rise time may limit the maximum rate at which serial data may be transmitted on the 1-wire bus.
[0055] The PD may current-limit the voltage being regulated by the shunt regulator 46 on the wire pair 14 in the event the PSE 20 attempts to overdrive the bus voltage.
[0056] After the detection and classification phase, the PSE 20 applies the V IN voltage to the V CC bus, and this increase in voltage above a predefined threshold is detected by the PD 24 , such as by a comparator. In response, the PD logic 32 shuts down the PD shunt regulator 46 (that limits the voltage to 4.5 volts), using the REG_EN signal, so the shunt regulator 46 becomes an open circuit during normal operation to avoid dissipating excessive power. Therefore, during normal operation, the shunt regulator 46 does not limit the voltage supplied to the V CC bus.
[0057] FIG. 4 illustrates an embodiment where the PSE 20 and PD 24 are similar to those in FIG. 2 but there are any number of additional devices 80 and 81 connected in parallel with the PD 24 . All the parallel devices can be powered by the PSE 20 and all can communicate on the wire pair 14 using differential Ethernet data. All the parallel devices can use the serial 1-wire bus in the manner discussed above during the detection/classification phase or at times when the PHYs 16 and 18 are not powered.
[0058] The parallel devices 80 and 81 may be connected to the PSE/PD 1-wire bus via a switch controlled by the associated device. The devices 80 and 81 need not necessarily require power from the PSE to operate.
[0059] One example of a parallel device may be a non-volatile memory which is used as a repository for PD power class and PHY operating parameter information. Parallel bus devices may have unique addresses that allow communication independent from the PD 24 . The PSE 20 may use the 1-wire bus protocol to determine the number of slave devices on the bus.
[0060] As seen, a low frequency data signal path (via inductors L 1 and L 3 ) is used by the PSE logic 30 and PD logic 32 during the low-power handshaking phase, and a separate high frequency, Ethernet differential data path is used by the master PHY 16 and slave PHY 18 (via capacitors C 1 -C 4 ) during the normal operation. Therefore, the two paths effectively use frequency division multiplexing (FDM) to communicate data over the wire pair 14 .
[0061] While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications.
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A PoDL system includes a PSE supplying DC power and Ethernet data over a single twisted wire pair to a PD. Prior to coupling the DC voltage source to the wire pair, the PD needs to receive sufficient power to perform a detection and classification routine with the PSE to determine whether the PD is PoDL-compatible. The PSE has a low current, pull-up current source coupled to a first wire in the wire pair via a first inductor. This pull-up current charges a capacitor in the PD to a desired operating voltage, and the operating voltage is used to power a PD logic circuit. The PD logic circuit and a PSE logic circuit then control pull-down transistors to communicate detection and classification data via the first wire. After the handshaking phase, the PSE then applies the DC voltage source across the wire pair to power the PD for normal operation.
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FIELD OF THE INVENTION
This invention relates to a method and apparatus for providing a uniform projection of light. More specifically, this invention relates to a method and apparatus for providing a uniform projection of light using an integrating sphere and a compound parabolic reflector.
BACKGROUND OF THE INVENTION
The uniform projection of light has traditionally been performed using the combination of a costly refractive lens and a parabolic concentrator. The concentrator is used to collect the light from a single lamp and direct it through a refractive lens system. The resulting distribution of light is governed by the geometry of the lamp element and the propagation of the light through the refractive optics. This method yields a light distribution with significant fluctuations in light intensity throughout the target plane. Enhancements such as refractive integrating and diffusing devices improve the output uniformity but reduce the overall efficiency of the system. Additionally, the spectral content of the light at the target plane and the total optical power projected are restricted since the optics are designed to use only a single lamp.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to overcome these and other drawbacks of the prior art.
It is another object of this invention to provide a method and apparatus for projecting a uniform distribution of light.
It is another object of this invention to provide a method and apparatus for projecting a uniform distribution of light using a plurality of light sources as inputs.
It is another object of this invention to provide a method and apparatus for projecting a uniform projection of light which selectively combines the light from a plurality of light sources to control characteristics (e.g., color) of the uniformly distributed light.
It is a further object of this invention to provide a uniform projection of light with a portable projector that is remote from the one or more light sources that feed that projector.
According to one embodiment of the present invention, these and other objects of the invention are achieved by providing a projection device that includes both a diffusive optic and a non-imaging optic. A diffusive optic, such as an integrating sphere, is used to mix or diffuse the output of one or more light sources. An exit port of the diffusive optic behaves as an extended light source for the non-imaging optic. The output from the diffusive optic fills the non-imaging optic, such as a compound parabolic concentrator, resulting in a uniform projection of the source light. The divergence of the light exiting the non-imaging optic can be determined from the collection angle of the non-imaging optic.
According to other aspects of the invention, the input to the projector can be one or more light sources or one or more fiber optics, the other end of the fiber optic(s) being fed by one or more light sources. In either case, the one or more light sources can have different characteristics (e.g., color, intensity, etc.) and can be selectively combined to control characteristics of the uniformly distributed output beam.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of one embodiment of an integrating projection optic according to the present invention.
FIG. 2 is a diagram of a compound parabolic concentrator.
FIG. 3 is a diagram of another embodiment of an integrating projection optic according to the present invention.
FIG. 4 is a diagram of another embodiment of present invention.
FIG. 5 is a diagram of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, an integrating projection optic 100 consists of a light source 110, a diffusive optic 120, and a non-imaging optic 130. The light source 110 may be, but is not limited to, a LED, a Xenon arc, Quartz Halogen filament, or a laser. The light beam 115 generated by the light source is directed to an input aperture 121 of the diffusive optic 120. Diffusive optic 120 uniformly disperses the light beam from the light source. Light exits diffusive optic 120 at exit aperture 122. This exiting light continues to disperse as it leaves diffusive optic 120.
Diffusive optic 120 may be an integrating sphere. The inner surface of the integrating sphere has a coating of a material with a Lambertian quality; that is, the surface has the directional characteristic of distributing the reflected light uniformly over the entire sphere's inner surface. Thus, once a light beam enters the sphere through its input aperture, the light beam is evenly distributed over the entire inner sphere surface, including the exit aperture.
The light flux passing through the exit aperture 122 preferably immediately enters the non-imaging optic 130 through its opening 131 and then exits through exit 132. Non-imaging optic 130 may be a compound parabolic concentrator (CPC). Referring to FIG. 2, the CPC 200 is a cone-shaped object, and consists of a large opening, referred to as the mouth 210 and having a radius r m , a smaller opening, referred to as the throat 220 and having a radius r t , and a specified length L. The ratio of r m to r t defines the collection angle, θ max of the CPC. The parameters r m , r t , L, and θ max are related by the equations:
θ.sub.max =sin.sup.-1 (r.sub.t /r.sub.m) (1)
and
L=(r.sub.t +r.sub.m)/tan(θ.sub.max) (2)
Therefore, the CPC can be designed to achieve a desired collection angle from equations (1) and (2). A smaller collection angle will result in a smaller divergence of light once the light leaves the CPC.
In operation, Lambertian light flux, such as the output of diffusive optic 120, fills the throat 220 of the CPC. The CPC acts as an angle limiter, preventing light passing herethrought from diverging with an angle greater than θ max . Referring again to FIG. 1, CPC 130 collects most or all of the Lambertian light flux from the output of diffusive optic 120. The reflective inner surface and geometry of CPC 130 converts the collected flux to a uniform field of light 140. The field of light 140 has a maximum divergence angle of θ max which is projected onto target 150.
In another embodiment of the invention, it is preferable that a plurality of light sources serve as inputs to the integrating sphere. One of the properties of an integrating sphere is its ability to mix the light from several sources into a uniform output. Referring to FIG. 3, multiple light sources 310 1 , 310 2 . . . 310 n provide multiple light beams 315 1 , 315 2 . . . 315 n which are directed into the input aperture 321 of integrating sphere 320. Input aperture 321 may comprise multiple input ports. The multiple light beams 315 1 , 315 2 . . . 315 n are then uniformly distributed over the sphere's inner surface in accordance with Lambert's Law. The output of the integrating sphere from exit aperture 322 is a Lambertian light flux which is polychromatic in proportion to the intensity of the light from each of light sources 310 1 , 310 2 . . . 310 n , and, as discussed earlier, diverges uniformly from the non-imaging optic 330 at an pre-designed angle, θ max . The reflective inner surface and geometry of CPC 330 converts the collected flux to a uniform field of light 340. The field of light 340 has a maximum divergence angle of θ max which is projected onto target 350. This characteristic makes this device very attractive for stage lighting, as one single device with multiple light sources can provide a plurality of colors. In addition, by varying the intensity of each light source, smooth transitions between colors can be achieved. Light source 310 1 -310 n intensity adjustment may be accomplished in any known manner as represented by intensity adjuster 360.
As shown in the embodiment of FIG. 4, the light beams from light sources 410 1 , 410 2 , . . . 410 n are provided to the diffusive optic 420 through a light guide such as fiber optic 415 1 , 415 2 , . . . 415 n . The light travels along the light guide or transparent materials which terminate at the input aperture of the diffusive optic. The reflective inner surface and geometry of CPC 430 converts the collected flux to a uniform field of light 440. The field of light 440 has a maximum divergence angle of θ max which is projected onto target 450.
There are several advantages to the embodiment shown in FIG. 4. First, the use of a transparent material to transmit light allows the input aperture size of the diffusive optic to be reduced, which increases the efficiency of the system. Second, the use of light guides promotes greater versatility. Large, remotely located light sources can be used while keeping the projection optics small, lightweight, and easily positioned
Referring to FIG. 5, in another embodiment of this invention, the projection device 500 is portable. The device 500 is equipped with a long light guide 510 for projecting the light of light source 520. This allows the user to use the device as a flashlight. In another embodiment of the invention, the light source is portable, possibly carried in a backpack. This allows for the power of the larger light source to be concentrated in a uniform beam.
There are many potential applications for uniform light projectors, such as uniform solar simulators used in exposure testing of electrical devices, a new projection optic for both high and low power illuminators such as flashlights and searchlights, combining multicolor lamps, delivery of uniform UV light for photo-polymerization applications, stage lighting, large-area IR illumination for unobtrusive searches from aircraft, ships, or terrestrial platforms in support of law enforcement, and area array calibration sources for terrestrial, airborne, or spaceborne platforms.
Although the present invention has been described in detail, it should be understood that various changes, substitutions, and alterations can be made without departing from the intended scope as defined by the appended claims.
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A method and apparatus for projecting a uniform projection of light by using a diffusive optic and non-imaging optic to receive light beams and uniformly distribute the light beams on a target. The uniform distribution of light diverges according to a pre-designed angle. The device allows for the use of multiple light sources which may be remotely located from the projection device. The projection device may be portable.
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FIELD OF THE INVENTION
The present invention relates to a method for producing intarsia knitted goods on a flat-bed knitting machine wherein, when one of the needle beds is traversed in one and/or the other lift direction by a carriage provided with one or a plurality of cams in the border area between two areas of intarsia, at least some of the yarn guides associated with each one of the intarsia areas and the respective needle bed are moved in a direction relative to each other and the yarn guides are being coupled or uncoupled within the intarsia area with or by means of the movement of the carriage. It also relates to a flat-bed knitting machine for implementing the method, having a carriage with at least one cam for both directions of lift along a needle bed arrangement, with a separate yarn guide for each intarsia area, the yarn guides being capable of being coupled or uncoupled within the intarsia area with or by means of the movement of the carriage, and where the yarn guides and the respective needle bed of the needle bed arrangement can be moved at least partially in a direction in relation towards each other in the border area between two intarsia areas.
BACKGROUND OF THE INVENTION
In such a method or with such a flat-bed knitting machine, known from German Published, Non-examined Patent Application DE-OS 27 30 306, the odd numbered areas of the individual intarsia areas which follow successively in a row of stitches are knitted by a preceding cam of a two-cam carriage and the even numbered areas are knitted by the succeeding cam. The yarn guide is provided with an arm, pivotably fixed on the yarn guide box, the end of which guiding the respective yarn is pivoted in the area between two adjacent intarsia areas out of the needle field of the respective intarsia area at the end of knitting operation and into the needle field of the respective intarsia area prior to the start of a knitting operation.
This is mechanically relatively complicated and expensive because of the multitude of yarn guides which must be used. Because of the pivoting mechanism, the speed possible for the carriage is also limited. Furthermore, mechanical control means must be provided which assure the pivoting of the yarn guides at exactly the corresponding times.
Additionally, in a method or with a flat-bed knitting machine of the type mentioned above, it is known from EP-A1 246 364 to couple the respective yarn guide operationally with a cover, which cover is displaced correspondingly in relation to the needle bed by means of a cable pull connected with the drive.
It is disadvantageous in this case that an additional drive is required to perform such a relative movement between the yarn guide and the needle bed.
Furthermore, a method or a flat-bed knitting machine of the previously described type is known from German Published, Non-examined Patent Application P 29 10 532 and German Published, Non-examined Patent Application P 32 45 233 in which the yarn guides are provided with yarn guide tubelets containing the yarn, which can be moved in a vertical sense in relation to the corresponding needle bed. The intarsia areas are produced according to the plating process, i.e. an overlapping process.
It is disadvantageous in this case that it is necessary to position each needle exactly, that space is limited for the yarn guide tubelets and that this design is limited to certain minimal needle spacings.
However, all of these known methods for producing intarsia knitted goods or of flat-bed knitting machines suitable for such production have the common disadvantage that, in the absence of an acceptance of the need for additional steps, it is only possible to produce as many different intarsia areas or colors as there are cams provided on the carriage used. If more intarsia areas or colors are to be knitted, further efforts or perhaps even the acceptance of idle passages or empty rows is required, depending on the pattern to b knitted, which results in a negative effect on the efficiency of the production.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for producing intarsia knitted goods on a flat-bed knitting machine and a flat-bed knitting machine for implementing the method of the type mentioned above, with which a larger amount of intarsia areas or colors can be knitted than corresponds to the number of cams in the carriage used, without requiring an effort which reduces the productive capacity and increases the costs.
The method and apparatus of the present invention make it easily possible to knit a plurality of colors or intarsia areas in each row of stitches as corresponds to the number of cams used in the carriage. The yarn guides with rigid arms, which have been customarily used and which can be made and used cost-effectively, can be employed. In accordance with the method, it is furthermore advantageously possible to manufacture a plurality of colors or intarsia areas with a carriage having only one cam. Additionally, in this method the movements of elements are used in an advantageous and cost-efficient manner, the drives of which are customarily already provided in a flat-bed knitting machine. This is not only true for the reversible drive of the carriage, but also for the drive of a needle bet displacement. Thus no additional drive elements are required. With all methods it is of advantage that the edge of the pattern can be freely designed without having to take into consideration, as was the case previously, the maximally possible and set pivot path of the yarn guide arm. Not only the short return lift of the reversible carriage, but also the displacement of the needle bed and the shaft can be variably selected and set as to their size.
Further details of the invention can be found in the description below, in which the invention is described in detail by means of the exemplary embodiments shown in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic and partial view of the area of a flat-bed knitting machine for producing intarsia knitted goods necessary to explain the invention in accordance with a first exemplary embodiment of the present invention in the form of a single cam-machine,
FIG. 2 shows, in a schematic view similar to that of FIG. 1, the various method steps for producing intarsia knitted goods in accordance with the first exemplary embodiment, but in connection with a multi-cam machine;
FIG. 3 is a view corresponding to FIG. 2, but in connection with a flat-bed knitting machine for producing intarsia knitted goods in accordance with a second exemplary embodiment of the present invention, and
FIG. 4 is a view corresponding to FIG. 2 of a flat-bed knitting machine for producing intarsia knitted goods, but in accordance with a third exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The flat-bed knitting machine 11/1, 11/2, 11' or 11", shown schematically in the drawings, in particular by means of the several method steps in accordance with the various exemplary embodiments, is used to produce intarsia knitted goods, the amount of colors or intarsia areas of which is greater and a multiple of the number of cams S provided in a knitting unit or carriage 16, 17, 18 or 19 used, without it being necessary to run idle passages. To the extent that they are not otherwise described, the flat-bed knitting machines 11/1, 11/2, 11' and 11" are of customary design. Only for reasons of clarity has the carriage 16 to 19 been placed above the needle bed and the yarn guides in the schematic views.
The flat-bed knitting machine 11/1, shown in FIG. 1 has, for example, a V-shaped carriage arrangement, the carriages 16 of which are each provided with a single knitting cam S. The two carriages 16, only one of which is schematically shown, are for example movable back and forth, as is customary, along a V-shaped needle bed arrangement consisting of affront and rear needle bed 20, only one of which is shown. In a manner, also not shown, the carriages 16 are provided with a reversible electric drive in a manner known per se, which makes it possible for the carriages 16, or the carriage arrangement, to reverse their lift direction at optional sites along the needle bed 20, or the needle bed arrangement, without it being required to make a needle selection in the needle bed or without the needles coming under the influence of the cams of the carriage. This can be accomplished, for example, by means of the known pressure cam technique. In the customary manner a yarn guide 22 can be moved back and forth along a plurality, in this case four, parallel guide rails 21. Also in the customary manner, the yarn guides 22 can be optionally connected ad disconnected with the movement of the carriage 16, so that they can be dropped off at optional sites of the needle area along the needle bed 20 and picked up again. The yarn guides 22 have arms 24, which can be connected with a yarn change box 23, through the ends 25 of which, provided with eyes, the respective yarn of the corresponding color is guided. With the aid of this single-cam flat-bed knitting machine 11/1 it is intended to produce an intarsia knitted piece consisting of four intarsia areas f, for example, different colors in the needle areas or needle fields 12/1 to 12/4 shown. It is to be understood that the boundaries or pattern edges between the individual intarsia areas may in general be of optional shape.
According to this exemplary embodiment, the flat-bed knitting machine is equipped with a total of four yarn guides 22 of which, at the beginning of a row of stitches, the yarn guide 22/1 is disposed ahead of the needle field 12/1, assigned to the first intarsia area, the yarn guide 22/2 is on the other side, looking in the direction of lift, of the boundary line 26 between the needle field 12/1 and 12/2. In the same manner as the yarn guide 22/2, the two yarn guides 22/3 and 22/4 are each disposed on the other side of the preceding needle field 12/2 or 12/3, i.e. in the area of the third or fourth intarsia area assigned to them and to be produced by them. This starting position is required, as in the method cited in the state of the art, because for the production of the respective preceding intarsia area the yarn guide to be used for the following intarsia area must be located outside of that needle field, in which the preceding intarsia area is to be knitted. This starting position can be seen in partial FIG. 1A.
If the carriage 16 with the single cam S and together with the first, in the direction of lift, yarn guide 22/1 are moved in the direction of the arrow A, one row of the first intarsia area is knitted in the respective color in the needle field 12/1, the needles being controlled in the customary manner by the cam S in the carriage 16 in one, for example the first, needle bed 20.
The knitting process takes place with the aid of the yarn guide 22/1 across the entire needle field 12/1 which is designed for this intarsia area. However, the first yarn guide 22/1 is taken along as far as the first rest position of the yarn guide 22/2, which is to be used for the following second intarsia area. There the second yarn guide 22/2 is connected with the yarn guide box 23, and the direction of movement of the carriage 16 is reversed. Thus the carriage 16 is returned by a short lift in the direction of the arrow B into the needle field 12/1 for the first intarsia area, at which position the first yarn guide 22/1 rests (Partial FIG. 1B). Then another lift reversal takes place, so that the carriage 16 continues to move in the direction of the arrow A, movably connected with the second yarn guide 22/2, from the position shown in partial FIG. 1C into the position shown in partial FIG. 1D and thus knits a line of stitches for the second intarsia area in the needle field 12/2.
Then the same method step takes place again, i.e. the carriage 16 moves with the second yarn guide 22/2 beyond the boundary 26 of the needle field 12/2 as far as the third needle guide 22/3, takes it and the second yarn guide 22/2 back into the needle field 12/2, leaves the second yarn guide 22/2 there and moves on with the third yarn guide 22/3 in the direction of the arrow A while knitting a row of stitches for the third intarsia area. This type of pilgrim-step movement is repeated until the carriage 16 with the fourth yarn guide 22/4 is disposed beyond the boundary 26 of the needle field 12/4 for the fourth intarsia area. There a lift reversal of the carriage 16 in the direction of the arrow B takes place, so that in this lift direction and in the corresponding reversed way, otherwise as described above, each one of a row of stitches of the fourth to the first intarsia areas is successively knitted in a reverse manner, the carriage 16 moving along the needle bed 20 in accordance with the pilgrim step technique.
A criterion for the size of the respective short reverse lift of the carriage 16 consists in that in the first place the yarn guides vacate the respective succeeding needle area or needle field and, in the second place, at least one needle of the preceding needle area or needle field has been reached to make a connection between the adjoining intarsia areas. For the latter case the lift distance depends on the size of the needle division. The reverse lift distance may be adjustably preset by a control. It may also be possible by means of this control to provide, via adjustable return lift distances, oblique pattern edges between adjoining intarsia areas having pitches of smaller or larger sizes.
FIG. 2 generally shows the same method for the production of intarsia knitted pieces along the needle areas or needle fields 13 of a needle bed 30, however, a carriage 17 is used with the flat-bed knitting machine 11/2, which is equipped with a plurality of knitting cams, in his case four, S1 to S4. Such four-cam carriages 17 also are standard items.
In accordance with partial FIG. 2A it is intended to produce, by means of the carriage 17 having four cams S1 to S4, two intarsia area groups of four intarsia areas each along the needle areas or needle fields 13/1 to 13/4 or 13/5 to 13/8, i.e. altogether eight intarsia areas of different colors. Altogether eight yarn guides 32 are provided which are, as in the exemplary embodiment of FIG. 1, movable along or on yarn guide rails and are connectable with the movement of the carriage 17 and disconnectable from it again in a manner not shown. The controllable connecting device for the yarn guides 32 can, in the same way as the one for the yarn guides 22 of FIG. 1, optionally be controllable by bipolar magnets, for example. In the starting position for the production of a row of stitches of an intarsia knitted piece provided with eight intarsia areas, the yarn guides 32 are disposed as shown in partial FIG. 2A, i.e. the yarn guides 32/1 to 32/4 for the first group for the first to the fourth intarsia areas are each disposed in front of the corresponding boundary 36 of the needle field for the respective succeeding intarsia area. This is also true for yarn guides 32/6 to 32/8 for the intarsia areas of the succeeding second group to be produced in the needle fields 13/6 to 13/8, with the exception of the yarn guide 32/5 which is disposed at the transition of the needle fields 13/4 and 13/5 for the first intarsia area group and the second intarsia area group and which is disposed there in the needle area 13/5 for the fifth intarsia area.
With the aid of the carriage 17, having a knitting unit consisting of the four cams S1 to S4, the first through fourth intarsia areas of the first intarsia area group are now knitted in the needle fields 13/1 through 13/4 in such a way, that the first knitting cam S1, which precedes in the direction of movement A, is assigned to the rear, in the direction of movement, needle field 13/4 for the fourth intarsia area of the first intarsia area group, the second cam S2 with the preceding needle field 13/3 for the third intarsia area, the cam S3, operating next to last in the direction of movement, with the needle field 13/2 for the second intarsia area and the succeeding, i.e. last, cam S4 with the front needle field 13/1 for the first intarsia area. In accordance with partial FIG. 2B, the carriage 17 is moved in the direction of movement A until a row of stitches of the first through fourth intarsia areas of the first intarsia area group has been knitted in the needle fields 13/1 to 13/4, so that the individual yarn guides 32/1 to 32/4, assigned to their cams S4 to S1, are successively taken along, starting with the yarn guide 32/4, in such a way that the respectively succeeding yarn guide 32/3, 32/2, 32/1 has been moved out prior to the arrival of the preceding yarn guide 32/1, 32/2 and 32/3. During this movement of the carriage 17 along this first movement sector across the needle fields 13/1 to 13/4, the yarn guides 32/1 to 32/4 are each dropped off on the other side of the boundaries 36 between the corresponding adjacent needle fields, the yarn guide 32/4 being carried along up to the yarn guide 32/5.
As in the exemplary embodiment of FIG. 1, the carriage is then reversed, in accordance with partial FIG. 2C, over a short lift distance, i.e. moved in the direction B, the two yarn guides 32/4 and 32/5 being carried along into the needle field 13/4, in which a row of the fourth intarsia area has been knitted. Then again a lift reversal takes place, so that the carriage 17 is again moved forward in the direction of the arrow A in order to be able to produce a row of stitches of the next, in this case second, intarsia area group with, for example again four intarsia areas, in the needle fields 13/5 to 13/8. The yarn guide 32/4 remains at the place in the needle field 13/4 shown in partial FIG. 2C. As described in connection with the yarn guides 32/1 to 32/4 and the first to fourth intarsia areas, the eighth to fifth intarsia areas are successively knitted and the yarn guides 32/8 to 32/5 are successively taken along and the yarn guides are dropped off in a corresponding manner, as shown in partial FIG. 2D.
Then a further row of stitches is knitted by the four-cam carriage 17 in the opposite direction according to arrow B in the same manner in the two intarsia area groups with four intarsia areas each during passage across the needle fields 13/8 to 12/1, as shown in partial FIGS. 2D to 2G. The pick-up and drop-off of the yarn guides and the association of the cams S1 to S4 to the needle fields for the respective intarsia areas takes place in a correspondingly reverse manner, such as is shown in the above mentioned partial Figs. During knitting in the direction B, too, a short lift reversal of the carriage 17 takes place at the boundary 36' between the two intarsia area groups, i.e. the needle fields 13/5 and 13/4, in order to bring the yarn guides 32/4 and 32/5 out of the needle area 13/4 for the succeeding intarsia area of the succeeding, in this case the first, intarsia area group.
The short lift reversal is, as described in FIG. 1, controlled in a corresponding and desired way, the same as the transition path of the yarn guides 13/1 to 13/4 or 13/5 and 13/6 to 13/8 for the shape of the pattern edge desired there.
In the exemplary embodiment illustrated in FIG. 3 the flat-bed knitting machine 11' is provided with a carriage 18 in the same manner as in the exemplary embodiment of FIG. 2, which is provided with four cams S1' to S4'. The design of this flat-bed knitting machine 11' and the manner of the assignment of the cams S1' to S4' to the individual needle fields 14/1 to 14/4 and 14/5 to 14/8 of the needle bed 40 for the first to eighth intarsia areas of the two intarsia areas groups is the same as in the exemplary embodiment of FIG. 2, so that in general only the differences relative to the above exemplary embodiment need to be discussed.
The important and, for all practical purposes, only two differences between this exemplary embodiment of FIG. 3 add the exemplary embodiment shown in FIG. 2 consist in that, firstly, in contrast to the yarn guides 42/1 to 42/5, which have the same initial position as the yarn guides 32/1 to 32/5 of the exemplary embodiment of FIG. 2, the remaining yarn guides 42/6 to 42/8 are disposed in the initial position in relation to the yarn guide 42/5, i.e. in the associated needle fields 14/6 to 14/8, and in that, secondly, the relative movement between the yarn guides 42/1 to 42/8 and the associated needle area 14/1 to 14/8 of the corresponding needle bed 40 does not take place by means of the reversal of the carriage 18, but by the corresponding needle bed 40 being displaced in the direction of the arrow A' or B'. In other words, preferably that needle bed 40 is displaced in the directions mentioned which is equipped with a corresponding device for the execution of a needle bed displacement anyway. In general it is possible by this to set the extent of the displacement. Thus, after a row of stitches has been knitted in the first to fourth intarsia areas of the first intarsia area group and the carriage 18 has attained the position shown in partial FIG. 3B, the needle bed 40 is displaced in the direction of the arrow A' in such a way that the yarn guides 42/4 and 42/5 are now disposed in the needle field 14/4 for the fourth intarsia area, instead of in the needle field 14/5 for the fifth intarsia area (partial FIG. 3C). At the same time the yarn guides 42/6 to 42/8 also reach the adjoining needle field 14/5 or 14/6 or 14/6, respectively, as is shown in partial FIG. 3A as initial position of the yarn guides 42/1 to 42/4.
After knitting a row of stitches for the second group of the fifth to eighth intarsia in the needle fields 14/5 to 14/8, a lift reversal of the carriage 18 takes place in accordance with partial FIG. 3D, so that it now moves in the direction of the arrow B' and initially knits a row of stitches of the second intarsia area group. After the carriage 18 has done this in accordance with partial FIG. 3E, another displacement of the needle bed takes place, but in a direction opposite the preceding displacement, i.e. in accordance with arrow B', so that the respective yarn guides 42/1 to 42/4, which have reached the associated needle areas 14/1 to 14/4 with the first needle bed displacement (partial FIG. C), together with the yarn guide 14/5, which is to be dropped off, reach a position in which they are disposed in front of the needle fields 14/1 to 14/4 in the knitting direction B', where a row of stitches is to be produced now for the first to fourth intarsia areas of he succeeding, in this case first, group. Partial FIG. 13G again illustrates the initial position for the start of a further row of stitches in the direction of movement A'.
In this exemplary embodiment the needle bed displacement is preferably performed during the lift movement of the carriage 18 and is synchronized with it, so that stopping the carriage is not necessary. Since both moves are in the same direction, this is possible. In this exemplary embodiment, as well as in the exemplary embodiment according to FIG. 2, cams are used which permit the performance of a relative movement between needle bed and cams without a needle selection. It is possible to use cams as described, for example, in German Published, Non-examined Patent Application DE-OS 35 41 171.
An exemplary embodiment of a flat-bed knitting machine 11" is illustrated in FIG. 4 which in general corresponds to those of exemplary embodiments of FIGS. 2 and 3. In general, the only difference from FIG. 2 is that the relative movement between the yarn guides 52/1 to 52/8 and the needle bed 50 or the needle fields 15/1 to 15/8 for the intarsia areas to be produced is performed in yet another way. Here, too, the carriage 19 has a total of four cams S1" to S4" and there are eight yarn guides 52/1 to 52/8 provided for producing two intarsia area groups with four intarsia areas each in the needle fields 15/1 to 15/8.
The initial position for the production of a row of stitches in the direction of the arrow A" corresponds, as far as the position of the yarn guides 52/1 to 52/8 in relation to the needle fields 15/1 to 15/8 for the production of the intarsia areas is concerned, to the exemplary embodiment of FIG. 2. Production of a row of stitches for the first intarsia group in the direction of movement A" of the carriage 19 takesplace in the way as was described in the exemplary embodiment of FIG. 2. In the transition position of the carriage 19 between the two intarsia area groups in accordance with FIG. 4B, the relative movement between the two yarn guides 52/4 and 52/5 and the needle bed 50 takes place in that one or two parallel yarn guide rails 51, on which the two yarn guides 52/4 and 52/5 can be fixed in this position, is/are displaced in the direction of the arrow B", i.e. opposite to the carriage direction A", by a certain amount in such a way, that the two yarn guides 52/4 and 52/5 are moved out of the needle area 15/5 in which the fifth intarsia area of the succeeding second intarsia area group is to be supplied with a row of stitches. In this, as in the other exemplary embodiments, the yarn guide 52/4 is dropped off. At the end of this row of stitches knitted in the direction of the arrow A" in accordance with partial FIG. 4D, positions of the yarn guides 52/1 to 52/8 in relation to the corresponding needle areas 15/1 to 15/8 result, which correspond to the positions of partial FIG. 2D.
Production of a row of stitches in the direction of movement B" takes place in a corresponding manner, a longitudinal displacement of the yarn guide rail 51 in the direction of the arrow A" in accordance with partial FIG. 4E taking place in the transition area of the boundary 56' between the two intarsia area groups in such a way, that the two yarn guides 52/4 and 52/5 are displaced out of the needle field 15/4 of the intarsia area now to be produced into the needle field 15/5 of the intarsia area which already was provided with a further stitch. Then the row of stitches in the needle fields 15/4 to 15/1 for the fourth to the first intarsia area can be successively knitted in the already described manner, while the yarn guide 52/5 remains dropped off.
The displacement of the needle bed 50 or the rail 51 of the exemplary embodiment of FIG. 3 or FIG. 4 can be controlled, adjustable as to its extent, in the same way as the lift reversal of the carriage in accordance with FIG. 1 or FIG. 2.
It should be understood that in the exemplary embodiments of FIGS. 2 to 4 the number of the cams assigned to a carriage as well as the number of the intarsia areas or intarsia area groups to be produced can be generally optional. Accordingly, in place of the eight intarsia areas to be produced shown, it would be possible, for example, to use a two or three cam carriage instead of a four cam carriage. It is to be understood that more than eight intarsia areas may be knitted and that the number of intarsia areas to be produced can be separated into various groups with the same or different numbers of intarsia areas.
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In a method for the production of intarsia knitted pieces on a flat-bed knitting machine, at least some of the yarn guides associated with each one of the intarsia areas and the respective needle bed are moved in a direction relative to each other when one of the needle beds is traversed in both lift directions by a carriage provided with one or a plurality of cams in the border area between two areas of intarsia, and the yarn guides are being coupled with the movement of the carriage in each intarsia area. At the end of a movement segment which extends at most across a number of intarsia areas corresponding to the number of cams, the carriage is reversed in its lift direction and returned, together with the yarn guide last used as well as with the yarn guide to be used for the following intarsia area, to the intarsia area last produced, without making a needle selection. In a further movement segment, a further number of intarsia areas corresponding at most to the number of cams is produced in the original lift direction. Becanuse of this a larger number of intarsia areas or colors can be knitted than corresponds to the number of cams in the carriage used without requiring steps which would reduce the production capacity and increase the costs.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 61/044,759, filed Apr. 14, 2008. The entire contents of that provisional application are incorporated herein by reference.
INTRODUCTION
Exemplary embodiments of the present invention are referred to herein as “Global COMPASS” or “Global Compass.” These embodiments aim to capture momentum in the slope of swap curves as signaled by dynamics in monetary policy regimes. The swap curve is the yield curve used to price interest rate swaps, reflecting both the general level of risk-free interest rates and the credit spread or swap spread in the interbank market attributable to the credit risk of default over the life of the swap.
Related embodiments comprise a Global COMPASS Index, which offers an attractive risk/return profile for investors: (a) a historical Sharpe Ratio of 1.15 since 1991 (after hedging costs) for at least one embodiment; (b) low historical correlation with asset class benchmarks to enhance portfolio diversification; and (c) maximum transparency: the Index is published daily on Bloomberg.
In one aspect, the present invention comprises a computer-implemented method comprising: (a) receiving with a first computer data regarding bank rates and swap rates for two or more currencies; (b) calculating with a second computer a swap curve for each of the two or more currencies; (c) calculating with a third computer one or more signals for each of the swap curves; and (d) based on the one or more signals, taking a position with respect to each of the swap curves and currencies, wherein the computers may be the same computer or different computers. In various embodiments: (1) the method further comprises calculating with a fourth computer a sub-index value for each of the currencies, the sub-index values based on returns for the positions; (2) the method further comprises weighting each of the sub-index values and calculating a value for an index, based on a combination of the sub-index values; (3) the weighting is based on relative gross domestic product values; (4) each signal is based on an average of a plurality of monetary policy indicators; (5) each of the monetary policy indicators has the value +1 or −1; (6) at least one of the monetary policy indicators is based on change in central bank target rate for a corresponding currency over a specified period of time; (7) at least one of the monetary policy indicators is a monetary policy surprise indicator; (8) each swap curve is based on data for a plurality of swap rates; (9) the data for the plurality of swap rates comprises 10 year swap rate data and 2 year swap rate data; (10) the signals are calculated on a weekly basis; and (11) the currencies comprise United States dollar, Euro, British pound, Japanese yen, and Canadian dollar.
In another aspect, the invention comprises a computer-implemented method comprising: (a) receiving with a first computer data regarding the above index; (b) calculating with a second computer a performance value for the index to be used in a derivative based on the index; and (c) calculating with a third computer an amount due to, or owed by, an investor in the derivative, based on the performance value, wherein the computers may be the same computer or different computers. In various embodiments: (1) the derivative is a total return swap; (2) the derivative combines a floating rate investment of limited duration risk with a leveraged exposure to the index; (3) the derivative comprises a liability structure; (4) the derivative comprises a constant proportion portfolio insurance note; (5) the derivative comprises a Euro medium term note; and (6) the derivative comprises a UCITS-compliant note.
In another aspect, the invention comprises an apparatus comprising a computer readable medium that stores data describing a derivative product based on an index, the index constructed by steps comprising: (a) receiving with a first computer data regarding bank rates and swap rates for two or more currencies; (b) calculating with a second computer a swap curve for each of the two or more currencies; (c) calculating with a third computer one or more signals for each of the swap curves; (d) based on the one or more signals, taking a position with respect to each of the swap curves and currencies; (e) calculating with a fourth computer a sub-index value for each of the currencies, the sub-index values based on returns for the positions; and (f) weighting each of the sub-index values and calculating a value for the index, based on a combination of the sub-index values, wherein the computers may be the same computer or different computers. In various embodiments: (1) the derivative product is a total return swap; (2) the derivative product combines a floating rate investment of limited duration risk with a leveraged exposure to the index; (3) the derivative comprises a liability structure; (4) the derivative product comprises a constant proportion portfolio insurance note; (5) the derivative product comprises a Euro medium term note; and (6) the derivative product comprises a UCITS-compliant note.
In another aspect, the invention comprises a computer system comprising: (a) a processor that electronically receives data regarding bank rates and swap rates for two or more currencies; (b) a processor that electronically calculates a swap curve for each of the two or more currencies; (c) a processor that electronically calculates one or more signals for each of the swap curves; and (d) a processor that electronically, based on the one or more signals, takes a position with respect to each of the swap curves and currencies, wherein the processors may be the same processor or different processors. In various embodiments: (1) the system further comprises a processor that calculates a sub-index value for each of the currencies, the sub-index values based on returns for the positions; (2) the system further comprises a processor that weights each of the sub-index values and calculates a value for an index, based on a combination of the sub-index values; (3) weighting is based on relative gross domestic product values; (4) each signal is based on an average of a plurality of monetary policy indicators; (5) each of the monetary policy indicators has the value +1 or −1; (6) at least one of the monetary policy indicators is based on change in central bank target rate for a corresponding currency over a specified period of time; (7) at least one of the monetary policy indicators is a monetary policy surprise indicator; (8) each swap curve is based on data for a plurality of swap rates; (9) the data for the plurality of swap rates comprises 10 year swap rate data and 2 year swap rate data; (10) the signals are calculated on a weekly basis; and (11) the currencies comprise United States dollar, Euro, British pound, Japanese yen, and Canadian dollar.
In another aspect, the invention comprises a computer system comprising: (a) a processor that receives data regarding an index as described above; (b) a processor that calculates a performance value for the index to be used in a derivative based on the index; and (c) a processor that calculates an amount due to, or owed by, an investor in the derivative, based on the performance value, wherein the processors may be the same processor or different processors. In various embodiments: (1) the derivative is a total return swap; (2) the derivative combines a floating rate investment of limited duration risk with a leveraged exposure to the index; (3) the derivative comprises a liability structure; (4) the derivative comprises a constant proportion portfolio insurance note; (5) the derivative comprises a Euro medium term note; and (6) the derivative comprises a UCITS-compliant note.
In another aspect, the invention comprises a program storage device readable by a machine, tangibly embodying a program of instructions executable by the machine to perform method steps comprising: (a) receiving with a first computer data regarding bank rates and swap rates for two or more currencies; (b) calculating with a second computer a swap curve for each of the two or more currencies; (c) calculating with a third computer one or more signals for each of the swap curves; and (d) based on the one or more signals, taking a position with respect to each of the swap curves and currencies, wherein the computers may be the same computer or different computers. In various embodiments: (1) the method steps further comprise calculating with a fourth computer a sub-index value for each of the currencies, the sub-index values based on returns for the positions; (2) the method steps further comprise weighting each of the sub-index values and calculating a value for an index, based on a combination of the sub-index values; (3) the weighting is based on relative gross domestic product values; (4) each signal is based on an average of a plurality of monetary policy indicators; (5) each of the monetary policy indicators has the value +1 or −1; (6) at least one of the monetary policy indicators is based on change in central bank target rate for a corresponding currency over a specified period of time; (7) at least one of the monetary policy indicators is a monetary policy surprise indicator; (8) each swap curve is based on data for a plurality of swap rates; (9) the data for the plurality of swap rates comprises 10 year swap rate data and 2 year swap rate data; (10) the signals are calculated on a weekly basis; and (11) the currencies comprise United States dollar, Euro, British pound, Japanese yen, and Canadian dollar.
In another aspect, the invention comprises a program storage device readable by a machine, tangibly embodying a program of instructions executable by the machine to perform method steps comprising: (a) receiving with a first computer data regarding an index as described above; (b) calculating with a second computer a performance value for the index to be used in a derivative based on the index; and (c) calculating with a third computer an amount due to, or owed by, an investor in the derivative, based on the performance value, wherein the computers may be the same computer or different computers. In various embodiments: (1) the derivative is a total return swap; (2) the derivative combines a floating rate investment of limited duration risk with a leveraged exposure to the index; (3) the derivative comprises a liability structure; (4) the derivative comprises a constant proportion portfolio insurance note; (5) the derivative comprises a Euro medium term note; and (6) the derivative comprises a UCITS-compliant note.
These and other aspects and embodiments will be apparent to those skilled in the art upon reviewing the description below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts historical performance of an exemplary U.S. Compass strategy.
FIG. 2 depicts U.S. Compass performance over three years.
FIG. 3 depicts an exemplary dynamic allocation mechanism.
FIG. 4 illustrates back-testing results.
FIG. 5 depicts negative correlation of Fed Funds rate and USD swap curve slope.
FIG. 6 depicts negative correlation of ECB policy rate and EUR swap curve slope.
FIG. 7 depicts negative correlation of BOJ policy rate and JPY swap curve slope.
FIG. 8 depicts negative correlation of BOE base rate and GBP swap curve slope.
FIG. 9 depicts negative correlation of BOC policy rate and CAD swap curve slope.
FIG. 10 illustrates signal determination of curve position taken by an exemplary embodiment (Global Compass index) of the invention.
FIG. 11 depicts historical performance of an exemplary Global Compass index.
FIG. 12 depicts an exemplary payoff diagram.
FIG. 13 depicts an exemplary dynamic allocation mechanism.
FIG. 14 illustrates a performance comparison of vanilla floater versus Global Compass note.
FIG. 15 depicts an exemplary payoff diagram.
FIG. 16 depicts a computer based system for processing data according to an embodiment of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Exemplary embodiments of the present invention are described in detail below.
Investors usually face a difficult choice between passive and active investment management: (a) investments based upon static market views may achieve poor performance during certain rate cycles or changes in rate cycles; and (b) the management cost in actively managed funds can be high and the regulatory treatment of such investments is not always optimal. A cost effective alternative is to invest in a dynamic strategy that changes according to the yield curve environment.
The U.S. COMPASS (or simply COMPASS, or Compass) Index is a liquid index based on a dynamic investment strategy that automatically adjusts itself over time in response to changes in the market. The underlying strategy is a steepener/flattener position on the US curve that is contingent on the changes in the Fed Funds rate. 1 The Index preferably is structured so as to offer minimal duration. The COMPASS Index is published on Bloomberg to offer maximum transparency to investors. 1 The yield curve is said to flatten when yields of shorter maturities rise relative to yields of longer maturities, and to steepen when yields of short maturities fall relative to yields of long maturities. Since short-term rates are always less than long-term rates, flattening means the two types of rates are converging, and steepening means the two types of rates are diverging—i.e., the spread is increasing.
The COMPASS Note is a EUR-denominated note with a dynamic allocation mechanism that gives participation in the COMPASS Index and provides enhanced returns through leverage while providing full capital protection. The note has historically outperformed Vanilla floater and offered low correlation with other fixed income asset classes.
COMPASS Index
The COMPASS Index invests in a USD steepener when the Fed Funds Target rate is falling (easing cycle) or a USD flattener strategy when the Fed Funds Target rate is increasing (tightening cycle).
Index Methodology
The COMPASS Index involves entering into a duration-weighted pair of USD forward-starting 10-year and 2-year swaps according to the evolution of the Fed Funds target rate. By choosing the Fed Funds target rate as a condition, the index captures changes in US monetary policy. The steepening/flattening Position for any quarter is conditional on the change in the Fed Funds rate during the previous 3-month period as defined below:
TABLE 1
Position
Curve View
Condition
+1
Steepening
Fed Funds t ≦ Fed Funds t−3m (“Easing Cycle”)
−1
Flattening
Fed Funds t > Fed Funds t−3m (“Tightening Cycle”)
For any day t within a Calculation Period, Index t is calculated by taking the Index at the end of the previous period, and multiplying it by a factor equal to:
One, plus the product of the Position (as defined above); the EUR/USD exchange rate at the start of the period divided by the EUR/USD exchange rate at day t; and the change in the 10y USD Swap less the change in the 2y USD Swap (duration-weighted; the forwards versus the actual rates). Historical COMPASS Index Performance
The COMPASS strategy would have outperformed standard Steepener or Flattener strategies in the past. FIG. 1 compares the performance of a Standard Steepener, a Standard Flattener and the COMPASS index from October 1987. The COMPASS strategy would have outperformed the other two strategies for most of the sample period. The indices show the return on a derivative-based strategy hence they do not include any accretion at Euribor. See FIG. 1 .
COMPASS and Benchmark Asset Class Indices
COMPASS has offered high return-to-risk and diversification benefits. Judging by risk adjusted historical returns, COMPASS has performed well in comparison to benchmark equity and fixed income asset class indices. COMPASS has also exhibited low correlation to these asset classes across business cycles. See FIG. 2 .
TABLE 2
Historical Average Excess Returns*
Tremont
Lehman
Lehman
DJ
Hedge
US Agg
Euro
S&P 500
EuroStoxx
Fund
COMPASS
Index
Agg Index
Index
50 Index
Index
Index
Annual
2.47%
1.76%
6.66%
6.01%
6.29%
0.48%
return
Annual st.
3.86%
3.04%
13.55%
18.43%
7.46%
0.55%
dev.
Sharpe
0.64
0.58
0.49
0.33
0.84
0.88
Ratio
Correlation
−0.03
0.05
−0.20
−0.17
−0.17
—
with
COMPASS
*Calculations are based on monthly data from January 1988 (or as far back as availalbe). Source: Bloomberg, Lehman Brothers calculations.
COMPASS Note
The COMPASS Note offers a structured participation on the COMPASS Index using a dynamic allocation approach. The redemption amount for the note is equal to 100% plus any coupon payable at maturity date. At the inception of the COMPASS Note, the Capital is equal to 100% of the Nominal. The Capital at the end of any calculation period “k” is then calculated as follows:
Capital at the Beginning Growing at the 3-Month Euribor Rate:
Capital k-1 ×(1+(3 m EURIBOR+spread)×Daycount Fraction k )
+
Leveraged Return Earned on the Capital Allocated to the Strategy:
Capital k-1 ×Exposure k ×Performance k
−
An Administrative Fee of 1.00% Per Annum:
Administration Fee×Daycount Fraction k
The Capital at the beginning of an Allocation period is then set equal to the Capital at the end of the immediately preceding Allocation Period. The Exposure is a function of the performance of the strategy during the preceding calculation period. It is described in further detail below. The Performance of the strategy during a calculation period is defined as the percentage return on the index over that quarter less the roll cost of 0.01% (representing the cost of changing the dynamic allocation).
Dynamic Allocation Mechanism
The dynamic allocation mechanism protects the value of the investment while enhancing the returns during periods of high index returns. The core principle of this mechanism is that the percentage allocated to the strategy is a function of the performance. If the strategy performs well, the Exposure is increased providing a higher leverage. If the performance decreases, the Exposure is reduced and under extreme scenarios, positions in the strategy might be totally unwound to preserve the capital guarantee at maturity.
The Exposure to the strategy at the beginning of any calculation period is defined as the product of the Multiplier and the Allocation. The Allocation is defined as the leveraged difference between the value of the Note and the Barrier. The Barrier represents at inception the present value of the guaranteed amount at maturity. This Barrier is fixed and rises linearly to 100% over the life of the note. The Barrier has therefore the appealing feature of being insensitive to interest rate movements.
Example of the Dynamic Allocation Mechanism
Exposure=Multiplier×Allocation
Multiplier=25 Allocation=2.70×(Distance from the Barrier) with a maximum of 150%. See FIG. 3 .
Historical Performance Analysis
The COMPASS Note would have outperformed a vanilla note over most periods. The performance has been analyzed (net of fees with Euribor flat issuer) of a 10y investment assuming that on each month of the back-testing period an equal amount is invested in the COMPASS note (as described above) and a Vanilla Floater. See FIG. 4 .
TABLE 3
COMPASS
COMPASS
Vanilla Floater
Matured Notes
Total Notes
(%)
Average Returns
14.33%
16.17%
3.63%
Min. return
7.80%
5.62%
2.70%
Max. return
18.18%
30.47%
6.03%
(*) For notes issued after November 1997 we show the realized IRR until November 2007. No suspension Events occurred on any of the backtested notes. The last note used in the backtest was issued in November 2006 to ensure that we have at least 12 months of data for the calculation of the IRR. Backtesting for short periods is less indicative of the performance of a 10-year note and more susceptible to variations which could be unrepresentative. For assumptions on the back-testing see below.
COMPASS Note Structure—Exemplary Indicative Terms of 10-Year Restructured COMPASS Note:
Principal:
10 m minimum
Tenor:
10 years
Issuer:
Lehman Brothers Treasury Co BV
Issue Price:
100%
Coupon:
Coupon = 0%. Alternative coupon
paying structures available
Redemption:
The greater of 100% and the Capital
value of the Notes
The redemption price is subject
to the Suspension Event
Suspension:
If on any day t, (Capital t − Barriers t ) is lower
than 5%, a Suspension
Event will be deemed to have occurred, in
which all open positions in
the strategy will be closed and the
Allocation will be deemed to be
zero from that point onwards
Allocation Period:
Quarterly, from and including one
Allocation Date to and including
the immediately following Allocation Date
Administration Fee:
1.00% per annum at all times
Performance Fee:
None
Summary of U.S. COMPASS
Investment Strategy
Historically, the USD forward curve tends to over-predict flattening suggesting that a steepening strategy would be profitable over long periods. However the slope of the curve is highly negatively correlated with the level of Fed Funds rate. COMPASS Index takes the advantages of these relationships to allow the investor to benefit in differing rate cycles.
Note Format
The structure could be classified as a bond rather than an investment in a hedge fund even though it employs strategies adopted by hedge funds, thus achieving greater transparency, favorable accounting and regulatory treatment
Market Access
The note provides an opportunity for investors who can not easily access markets to implement dynamic strategies and a minimum coupon
Note Performance
The dynamic allocation mechanism further enhances the return on the note by leveraging the returns while providing full capital protection The note has been structured so as to have minimal duration (other than via the Strategy itself and the minimum coupon) The note has historically outperformed a comparable vanilla structure particularly over the last few years
Downside Scenario
Possible breakdown of relationship between slope and the level of the curve could lead to underperformance of the Index and a complete de-leveraging of the Notes in the worst case resulting in a redemption at only 100%.
Glossary
Index Position
The Index Position determines whether the Index is on a steepener or a flattener strategy. It is set to +1 if the Fed Funds rate decreased or remained the same during the previous 3-month period. In this case, the Index is a steepener. It is set to −1 if the Fed Funds rate increases during the previous 3-month period. In this case it is a flattener.
Capital
The Capital is equal to 100% at inception and increases during subsequent quarters at Euribor plus or minus the performance of the index, less the fees.
Redemption Amount
The Redemption Amount is the Capital at maturity with a minimum redemption of 100%
Multiplier
The Multiplier factor is a constant factor equal to 25. The Multiplier is multiplied by the Allocation to calculate the leveraged return on the strategy.
Allocation
The Allocation is the percentage of the Capital (prior to any additional leverage) that is invested in the strategy. The Allocation at the beginning of any quarter “k” is calculated as:
Allocation
k
=
2.70
×
[
Capital
-
Barrier
Capital
]
.
Barrier
The Barrier is a pre-determined percentage that only changes with time. It does not vary with interest rate movements and is an essential element of the Dynamic Allocation mechanism to provide the capital protection at maturity
Barrier
t
=
Barrier
0
+
[
(
1
-
Barrier
0
)
×
t
T
]
.
Where
T is the Total number of days from the initial allocation date to but excluding the final allocation date Barrier 0 is the level of the Barrier at inception
Exemplary Methodology and Assumptions
Index Back-Testing Assumptions
Details of source:
Money market rates: British Bankers Association fixings provided by Bloomberg Fed Funds: Federal Reserve provided by Bloomberg Swap rates: ISDA fixings until October 1998, LehmanLive from 1987 to October 1998. Historical data for the 12-year swap rate was not available before November 1993. A synthetic rate has been created by assuming a linear interpolation between the 10-year swap rate and the 30-year swap rate (closest maturity available). When the 30-year swap rate was not available, we have carried out a linear interpolation between the 10-year Treasury and the 30-year Treasury and then have adjusted by the asset-swap spread
Forward rates have been determined by Lehman Brothers proprietary systems using historical swap curves
COMPASS Note Back-Testing
The internal rate of return (IRR) for a vanilla floater is defined as the interest rate at which the net present value of the cash flows received (quarterly 3-month Euribor cash flows plus redemption amount) equals the issue price The back-testing of the Compass Notes have been carried out on a monthly basis assuming that on each month of the back-testing period an equal amount is invested in the Compass note and a Vanilla Floater. The data and graph on this presentation are based on the IRR of theses returns for each month. For backtested notes we evaluated whether a suspension event occurred on each of the roll dates. The analysis found that no suspension event occurred on any of the roll dates of historically backtested notes. The value of the barrier for historically issued Notes is determined by using the yield curve as of the Note issue date (source: LehmanLive—data missing are omitted) For notes issued after November 1997 we show the realized IRR until November 2007. The last note used in the backtest was issued in November 2006 to ensure that we have at least 12 months of data for the calculation of the IRR. Backtesting for short periods is less indicative of the performance of a 10-year note and more susceptible to variations which could be unrepresentative.
Global COMPASS
Exemplary embodiments of the present invention comprise a Global COMPASS Index and/or a Global COMPASS Note. Global COMPASS is based on a dynamic investment strategy based on the slopes of swap curves. A wide range of formats is available to best suit the needs of investors: for example, CPPI, OTC Swaps, and UCITS III.
Exemplary Global COMPASS Strategy
Historically, the Fed Funds rate and the swap curve slope have been negatively correlated. See FIG. 5 . The same negative correlation can also be observed in other financial regions. See FIGS. 6-9 . An embodiment comprises a Global COMPASS Index that uses momentum in monetary policy regimes to determine the appropriate positioning in the slope of the yield curves.
Policy rates and yield curves are fundamentally linked. Central banks effect monetary policy by intervening in markets to set short term lending rates. The current level and expected future levels of short rates are a key influence on the shape of the yield curve.
Momentum in curve slopes can be exploited. Markets tend to chronically underestimate changes in policy regime, as well as cross market relationships (U.S. in particular). This creates momentum in the slope of the curve over the course of tightening and easing cycles.
Solid rationale underlies the market inefficiency. Business cycle dynamics are complex and difficult to predict. Thus markets tend to exhibit confirmation biases (i.e., to wait for further information to corroborate a potential change in the market environment) and herd mentality.
Computing Global COMPASS Signals
The positions in the slope of yield curves implemented are derived from the dynamics of monetary policy regimes. The signal for each currency is calculated as the average of three monetary policy indicators. More details are provided below.
Local Monetary Policy
The current local monetary policy regime (tightening vs. easing cycles) is assessed through the past quarter change in the local central bank target rate. Possible indicator values: +1, −1.
Fed Monetary Policy
The U.S. economy is the world's predominant economy and the Fed is a relatively proactive central bank. Hence Fed actions can potentially exhibit cross-momentum impact on other swap curves. The same methodology as that used for the local monetary signal is applied to compute this indicator. Possible indicator values: +1, −1.
Monetary Surprises
Steepeners tend to outperform in periods when there is a negative/downward surprise in short rates (as compared to what was expected by forwards). The monetary policy surprise indicator identifies the recent surprises in monetary policy by comparing short rates (3m) priced in by forwards 3-month ago with the actual realized short rates. Possible indicator vales: +1, −1.
Signals are calculated for each swap curve: USD, EUR, GBP, JPY and CAD. Each Signal determines the curve position taken by the Global COMPASS Index. See FIG. 10 .
Historical Global COMPASS Index Performance
We compute the historical Global COMPASS Index return based upon the strategy described above. FIG. 11 illustrates the performance on Index net of hedging costs. TABLE 4 shows that historically the Sharpe Ratio of the Strategy would have been attractive. The Index shows the return on the derivative-based strategy only (pure alpha) and does not reflect any accretion at Libor. Bloomberg ticker: LBGLCMEU<Index><Go>.
TABLE 4
Statistical Analysis(*)
Feb-
5
12
6
3
91
years
months
months
months
Avg Annual.
2.2%
1.6%
2.6%
4.8%
6.9%
Return
StDev Annual.
2.0%
1.7%
2.5%
3.5%
4.7%
Return
Sharpe Ratio
1.10
0.93
1.02
1.37
1.45
Maximum 1-
−1.0%
−0.7%
−0.7%
−0.7%
−0.7%
day fall
% of positive
53%
53%
54%
57%
62%
returns
% of negative
47%
47%
46%
43%
38%
returns
TABLE 5
Correlation of monthly Returns
Global Equity Index (**)
−24%
Lehman Global Aggregate Index [Bond]
−3%
Lehman Global Agg. Corporate Index [Credit]
−5%
Lehman Commodity Index
−19%
*Calculations are based on daily data from February 1991 to 14 March 2008
**GDP-weighted composite Index of the leading Equity indices in each of the 5 geographies covered by the Global COMPASS Index. Correlation numbers for the
Products Linked to the Global COMPASS Index
Delta 1: A simple and effective way to gain direct exposure to the Global COMPASS Index.
CCPI: CPPI structures offer a dynamic allocation mechanism that further enhances the return while providing capital protection at maturity. Constant proportion portfolio insurance (“CPPI”) is a technique for leveraging investments while providing full or partial protection. Credit CPPI notes, for example, are investments whose principal is protected by a low-risk portfolio consisting of zero-coupon bonds or a cash deposit, and whose return is increased by leveraging the exposure to a portfolio of credit default swap names.
Custom Payouts: It is possible to structure options ranging from vanilla call options to more exotic options on the Global COMPASS Index.
EMTN stands for Euro Medium Term Note. EMTN/Certificates are structured notes using, for example, Lehman Brothers as an issuer or a third party are a common and simple format. Different maturities and currencies are available.
OTC Derivatives: OTC Swaps or Options can embed the various payouts available to take exposure to the Global COMPASS Index. Liability structures to lower the cost of funding can be tailored to match needs.
Undertakings for Collective Investment in Transferable Securities (UCITS) are a set of European Union directives that aim to allow collective investment schemes to operate freely throughout the EU on the basis of a single authorisation from one member state. UCITS (for example, UCITS III) provides a transparent and consistent regulatory framework that provides improved liquidity.
Total Return Swap (Delta 1): in a Total Return Swap, at the end of every period, the investor receives or pays the actual performance of the Global COMPASS Index over the period minus fees. A positive performance of the index is received by the investor, while a negative performance is paid. Thus the investor is exposed to all the upside and downside of the index. A total return swap is an effective way to gain direct exposure to the Global COMPASS Index. See FIG. 12 .
TABLE 6
Indicative Terms and Conditions
Maturity
5 years
Currency
EUR (other currencies available)
Party A
Lehman Brothers
Party B
Client
Leverage × [(Index End /Index Start ) − 1] × Notional Amount
Periodic
If the result of the above is positive, Party A will pay this
Payments
amount to Party B, while if this amount is negative, its
absolute value will be paid by Party B to Party A
Index
Global COMPASS Index
Frequency
Quarterly
Basis
Act/360
Fees
To be determined
CPPI Notes/Swaps: CPPI Notes offer a structured participation using a dynamic allocation approach. A CPPI Investment combines a floating rate investment (limited duration risk) with a leveraged exposure into the Global COMPASS Index. The Capital is calculated on a daily basis as follows:
Capital growing at the Euribor Rate
+
Leveraged Return Earned on the Strategy
−
Fee
Dynamic Allocation Mechanism
The Exposure is usually a function of the performance of the strategy during the preceding calculation period:
Typically if the strategy underperforms, the Exposure is decreased providing a lower leverage and vice-versa. Under extreme conditions, the strategy might be totally unwound to preserve the capital guarantee at maturity.
Exposure=Multiplier×Allocation
where the Allocation is defined as the leveraged difference between the value of the Note and the Barrier with a cap. The Barrier represents at inception the present value of the guaranteed amount at maturity. This Barrier is fixed and rises linearly to 100% over the life of the note. The Barrier has therefore the appealing feature of being insensitive to interest rate movements. See FIG. 13 .
CPPI Notes/Swaps—Historical Performance
The Global COMPASS Note would have outperformed a vanilla floater over most periods. The performance is analyzed (net of fees with Euribor flat issuer) for an 8-year investment assuming that on each month of the back-testing period an equal amount is invested in the Global COMPASS note and a vanilla floater. See FIG. 14 .
TABLE 7
Global COMPASS
Global COMPASS
Vanilla
Matured Notes
Total Notes
Floater
Average Return
11.67%
12.31%
3.57%
Min. Return
7.62%
7.62%
2.82%
Max Return
16.16%
22.47%
5.18%
TABLE 8
Indicative Terms and Conditions
Maturity
8 years (Alternative: 5 years or more)
Currency
EUR (other currencies available)
Issuer
Euribor flat issuer
Issue Price
100%
Coupon
None
(Alternative: Coupon paying structures available)
Redemption
Max [100% , Capital End ]
For any month t:
Capital t
(i) Capital t−1 × (1 + Euribor × Daycount t ) +
(ii) Capital t−1 × Exposure t × Performance t −
(iii) Fees × Daycount t
Exposure t
[4.0] × Allocation t
Allocation t
[3.50] × (Capital t − Barrier t )/Capital t
with a maximum of [100%]
Barrier t
[71.25%] + [28.75%] × (t/T)
where:
T is the Total number of days from the Initial Allocation
Date to but excluding the Final Allocation Date
Fees
To be determined
Liability Structures
In a Liability Structure, at the end of the every period, the borrower receives 3m Euribor+Spread and pays: (Fixed rate−Leverage×Global COMPASS Index performance in the period). The payments are subject to a floor and a cap. This is an effective way to potentially reduce the cost of funding by taking exposure to the Global COMPASS Index. See FIG. 15 .
TABLE 9
Indicative Terms and Conditions
Maturity
5 years
Currency
EUR (other currencies available)
Party A
Lehman Brothers
Party B
Client
Party A Pays
3 m Euribor + Spread
Party B Pays
Fixed Rate − Leverage × Index Performance t
Floored at [TBD] % , capped at [TBD] %
Index Performance
(Index t /Index t −1 − 1 or (Index t /Index 0 ) − 1
Index
Global COMPASS Index
Frequency
Quarterly
Basis
Act/360
Index Backtesting Exemplary Methodology and Assumptions
Data Source (*) (*) Backtesting data source might slightly differ from the source used for the Index in production (i.e. data after [x] March 2008) Swap Curve Construction: Libor and swap rates preferably are obtained from the following sources (in order): 1-ISDA (provided by Bloomberg), 2-LehmanLive, 3-Bloomberg. For each calendar date, select all data points from a single source only if it contains:
(a) 2-year swap rate and 10-year swap rate (b) at least one swap rate point between 1 year and 10 years (excluding 2-year and 10-year points) (c) 1-month, 3-month and 6-month deposit rates. If one of these conditions is not met, use the next data source.
If none of these conditions is met, the date is assumed to be a non-trading day. The points (if available) considered to build the curves are: /deposits/ 1m, 2m, 3m, 6m, 12m /swaps/ 1y, 2y, 3y, 4y, 5y, 6y, 7y, 8y, 9y, 10y, 12y, 15y, 20y, 30y Libor fixings from LehmanLive may be used for the ISDA data source.
TABLE 10
ISDA
Bloomberg-deposits
Bloomberg-swaps
USD
11 am NY time
BBA fixing
Composite (LDN)
EUR
11 am FFT time
BBA fixing
Composite (LDN)
JPY
10 am TKY time
BBA fixing
Composite (LDN)
GBP
11 am LDN time
BBA fixing
Composite (LDN)
CAD
11 am EST
BBA fixing
Composite (LDN)
Signals:
Central bank rates data have been provided by Bloomberg:
USD: US Federal Reserve Rate Target (FDTR Index)
EUR: ECB Minimum Bid Refinancing Rate 1 Week (GRRP14LR Index)
GBP: UK Base Rate (UKBRBASE Index)
JPY: Bank of Japan Target Rate (BOJDTR Index)
CAD: Bank of Canada overnight Lending Rate (CABROVER Index)
The Monetary Policy Signal is assumed to be equal to +1 (steepener) when data are missing. There are only two cases:
For the period of 19 Mar. 2001 to 8 Mar. 2006 where there was no formal recommended target rate in Japan; For the period before December 1992 where data for the Bank of Canada overnight Lending Rate were missing.
Index Calculations
The first date of the Index is 25 Feb. 1991 when all 5 series are available. Foreign Exchange Data Source: Bloomberg—Composite London (USDDEm has been used for past data). Forward Calculations PV01 and forward rates may be determined using historical swap curves. Transaction costs: Two types of transaction costs are embedded in the Index:
Rolling hedge costs are applied on the percentage of the position which is rolled from on Calculation Period to another. This cost is equal to 0.10 bps (spread to mid) on the overall transaction. New hedge costs are applied on the net percentage of the position which is necessary to implement/unwind form one Calculation Period to another. This cost (spread to mid) is equal to:
USD: 0.50 bps EUR: 0.30 bps GBP: 0.75 bps JPY: 0.50 bps CAD: 2 bps Statistical Data: Sharpe ratio calculations may be done using the following formula:
(Average of Daily Returns×260)/(StDev of Daily Returns×sqrt(260)).
Correlations are done on a monthly basis and use end of month values.
Notes Backtesting Exemplary Methodology and Assumptions
The internal rate of return (IRR) for a Vanilla Floater is defined as the interest rate at which the net present value of the cash flows received (monthly 1-month Euribor cash flows plus redemption amount) equals the issue price. The back-testing of the Global Compass Notes have been carried out on a monthly basis assuming that on each month of the back-testing period an equal amount is invested in the Compass note and a Vanilla Floater. The data and graph on this presentation are based on the IRR of these returns for each month. For backtested notes we evaluated whether a suspension event occurred on each of the roll dates. The analysis found that no suspension event occurred on any of the roll dates of historically backtested notes. The value of the Barrier for historically issued notes is determined by using the yield curve as of the note issue date (source: Bloomberg).
Exemplary Terms and Conditions
As explained above, Global COMPASS Index embodiments aim to capture the changes in the slope of swap curves. The underlying strategies are steepeners or flatteners on the slope of the five swap curves of the largest financial geographies: United States (US), Euro-area (EU), Japan (UK), United Kingdom (UK) and Canada (CA).
Following the calculation of weekly signals based on the dynamics of the different monetary policy regimes, steepeners or flatteners positions are implemented in the respective curves. Sub-indices for the 5 geographies are created.
The returns of each of these sub-indices, with weights based on relative GDP figures, determine the returns of the Global COMPASS Index.
Roll Dates
Monday of each week subject to the Following Index Business Day Convention.
Calculation Period
From and excluding one Roll Date to but including the immediately following Roll Date.
Calculation of the Index commences on [●], which is also the start of the Initial Calculation Period.
Index Business Days
London, New York and Target.
Index Global,t
The Index Level on [●] shall be equal to 100. (Index GLOBAL, INITIAL ).
For any Index Business Day t,
Index
Global
,
t
=
{
42.50
%
×
(
Index
US
,
t
Index
US
,
t
-
1
-
1
)
+
33.00
%
×
(
Index
EU
,
t
Index
EU
,
t
-
1
-
1
)
+
13.50
%
×
(
Index
JN
,
t
Index
JN
,
t
-
1
-
1
)
+
7.00
%
×
(
Index
UK
,
t
Index
UK
,
t
-
1
-
1
)
+
4.00
%
×
(
Index
CA
,
t
Index
CA
,
t
-
1
-
1
)
}
US Sub-Index
Index US,t
The Index value on [●] shall be equal to 100. (Index US, [START] =100).
For any Calculation Period Index US, Previous shall be equal to the value of the Index US, Final for the immediately preceding Calculation Period.
For any Index Business Day t during a Calculation Period, Index US, t shall be:
Index
US
,
Previous
×
{
1
+
Signal
US
×
[
10
yFwd
US
,
1
m
-
t
t
-
10
yFwd
US
,
1
m
0
)
×
10
yPV
01
US
,
1
m
-
t
t
-
(
2
yFwd
US
,
1
m
-
t
t
-
2
yFwd
US
,
1
m
0
)
×
2
yPV
01
US
,
1
m
-
t
t
×
10
yPV
01
US
,
1
m
0
2
yPV
01
US
,
1
m
0
]
-
TC
US
}
For any Calculation Period, Index US, Final shall be equal to Index US, t where t is the Final Fixing Date for such Calculation Period.
For the purpose of evaluating whether a Suspension Event should occur the Index US may be valued intra-day by the Calculation Agent using current market data at that time to calculate the swap rates, but following the same formula and methodology as above.
TC US
The Transaction Costs will be charged based on the cost of rolling the position from one Calculation Period to another and the cost of implementation/unwinding new positions from one Calculation Period to another.
i) If the sign of Signal US Previous is different from the sign of Signal US :
TC US =|Signal US −Signal US Previous |×0.0050%×10 yPV 01 US,1m 0
ii) Otherwise,
TC
US
=
{
min
(
Signal
US
;
Signal
US
Previous
)
×
0.0010
%
+
Signal
US
-
Signal
US
Previous
×
0.0050
%
}
×
10
yPV
01
US
,
1
m
0
Where Signal US Previous is equal to Signal US for the previous Calculation Period (or zero in the case of the Initial Calculation Period).
Signal US
For any Calculation Period, the value of the US Global COMPASS signal calculated on or about [0.8.00 am London time] by the Calculation Agent one US Business Day before the Initial Fixing Date.
Initial Fixing Date
For any Calculation Period, the Final Fixing Date of the preceding Calculation Period subject to adjustment with the Following US Business Day Convention.
Final Fixing Date
For any Calculation Period, the last Index Business Day of such Calculation Period.
Forward Start Date US
For any Calculation Period, the day that is one month following the Initial Fixing Date for such Calculation Period subject to adjustment with the Following US Business Day Convention.
10yFwd US,1m 0
For any Calculation Period, the forward rate for a semi-annual USD swap transaction with a maturity of 10 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
10yFwd US,1m-t t
For any Index Business Day t during a Calculation Period (to and including the Final Fixing Date), the forward rate for a semi-annual USD swap transaction with a maturity of 10 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on such day.
For any Index Business Day t which is not a US Business Day, 10yFwd US,1m-t t will be equal to 10yFwd US,1m-(t-1) (t-1) .
2yFwd US,1m 0
For any Calculation Period, the forward rate for a semi-annual USD swap transaction with a maturity of 2 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
2yFwd US,1m-t t
For any Index Business Day t during a Calculation Period (to and including the Final Fixing Date), the forward rate for a semi-annual USD swap transaction with a maturity of 2 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on such day.
For any Index Business Day t which is not a US Business Day, 2yFwd US,1m-t t will be equal to 2yFwd US,1m-(t-1) (t-1) .
10yPV01 US,1m 0
For any Calculation Period, the present value in USD of USD 1 per annum paid semi-annually, 30/360, unadjusted, following, from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 10yFwd US,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
10yPV01 US,1m-t t
For any Index Business Day t during a Calculation Period, the present value in USD of USD 1 per annum paid semi-annually, 30/360, unadjusted, following from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 10yFwd US,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on that day.
For any Index Business Day t which is not a US Business Day, 10yPV01 US,1m-t t will be equal to 10yPV01 US,1m-(t-1) (t-1) .
2yPV01 US,1m 0
For any Calculation Period, the present value in USD of USD 1 per annum paid semi-annually, 30/360, unadjusted, following, from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 2yFwd US,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
2yPV01 US,1m-t t
For any Index Business Day t during a Calculation Period, the present value in USD of USD 1 per annum paid semi-annually, 30/360, unadjusted, following from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 2yFwd US,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on that day.
For any Index Business Day t which is not a US Business Day, 2yPV01 US,1m-t t will be equal to 2yPV01 US,1m-(t-1) (t-1) .
US Business Days
New York.
EU Sub-Index
Index EU,t
The Index value on [●] shall be equal to 100. (Index EU, [START] =100.
For any Calculation Period Index EU, Previous shall be equal to the value of the Index EU, Final for the immediately preceding Calculation Period.
For any Index Business Day t during a Calculation Period, Index EU, t shall be:
Index
EU
,
Previous
×
{
1
+
FX
EU
,
START
FX
EU
,
t
×
(
Signal
EU
×
[
10
yFwd
EU
,
1
m
-
t
t
-
10
yFwd
EU
,
1
m
0
)
×
10
yPV
01
EU
,
1
m
-
t
t
-
(
2
yFwd
EU
,
1
m
-
t
t
-
2
yFwd
EU
,
1
m
0
)
×
2
yPV
01
EU
,
1
m
-
t
t
×
10
yPV
01
EU
,
1
m
0
2
yPV
01
EU
,
1
m
0
]
-
TC
EU
)
}
For any Calculation Period, Index EU, Final shall be equal to Index EU, t where t is the Final Fixing Date for such Calculation Period.
For the purpose of evaluating whether a Suspension Event should occur the Index EU may be valued intra-day by the Calculation Agent using current market data at the time to calculate the swap rates, but following the same formula and methodology as above.
TC EU
The Transaction Costs will be charged based on the cost of rolling the position from one Calculation Period to another and the cost of implementing/unwinding new positions from one Calculation Period to another.
i) If the sign of Signal EU Previous is different from the sign of Signal EU :
TC EU =|Signal EU −Signal EU Previous |×0.0050%×10 yPV 01 EU,1m 0
ii) Otherwise,
TC
EU
=
{
min
(
Signal
EU
;
Signal
EU
Previous
)
×
0.0010
%
+
Signal
EU
-
Signal
EU
Previous
×
0.0050
%
}
×
10
yPV
01
EU
,
1
m
0
Where Signal EU Previous is equal to Signal EU for the previous Calculation Period (or zero in the case of the Initial Calculation Period).
FX EU, Start
For any Calculation Period, the exchange rate (quoted as the number of EUR per 1 unit of USD) as determined by the Calculation Agent with reference to market data observed as of [8:00 am London Time] one EU Business Day before the Initial Fixing Date.
FX EU, t
For any Index Business Day t, the exchange rate (quoted as the number of EUR per 1 unit of USD) as determined by the Calculation Agent with reference to market data observed as of [8:00 am London Time] on such day t.
Signal EU
For any Calculation Period, the value of the EU Global COMPASS signal calculated on or about [08:00 am London time] by the Calculation Agent one US Business Day before the Initial Fixing Date.
Initial Fixing Date
For any Calculation Period, the Final Fixing Date of the preceding Calculation Period subject to adjustment with the Following EU Business Day Convention.
Final Fixing Date
For any Calculation Period, the last Index Business Day of such Calculation Period.
Forward Start Date EU
For any Calculation Period, the day that is one month following the Initial Fixing Date for such Calculation Period subject to adjustment with the Following EU Business Day Convention.
10yFwd EU,1m 0
For any Calculation Period, the forward rate for a semi-annual EUR swap transaction with a maturity of 10 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am London Time on the Initial Fixing Date.
10yFwd EU,1m-t t
For any Index Business Day t during a Calculation Period (to and including the Final Fixing Date), the forward rate for a semi-annual EUR swap transaction with a maturity of 10 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am London Time on such day.
For any Index Business Day t which is not a EU Business Day, 10yFwd EU,1m-t t will be equal to 10yFwd EU,1m-(t-1) (t-1) .
2yFwd EU,1m 0
For any Calculation Period, the forward rate for a semi-annual EUR swap transaction with a maturity of 2 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am London Time on the Initial Fixing Date.
2yFwd EU,1m-t t
For any Index Business Day t during a Calculation Period (to and including the Final Fixing Date), the forward rate for a semi-annual USD swap transaction with a maturity of 2 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am London Time on such day.
For any Index Business Day t which is not a EU Business Day, 2yFwd EU,1m-t t will be equal to 2yFwd EU,1m-(t-1) (t-1) .
10yPV01 EU,1m 0
For any Calculation Period, the present value in EUR of EUR 1 per annum paid semi-annually, 30/360, unadjusted, following, from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 10yFwd EU,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am London Time on the Initial Fixing Date.
10yPV01 EU,1m-t t
For any Index Business Day t during a Calculation Period, the present value in EUR of EUR 1 per annum paid semi-annually, 30/360, unadjusted, following from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 10yFwd EU,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am London Time on that day.
For any Index Business Day t which is not a EUR Business Day, 10yPV01 EU,1m-t t will be equal to 10yPV01 EU,1m-(t-1) (t-1) .
2yPV01 EU,1m 0
For any Calculation Period, the present value in EUR of EUR 1 per annum paid semi-annually, 30/360, unadjusted, following, from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 2yFwd EU,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am London Time on the Initial Fixing Date.
2yPV01 EU,1m-t t
For any Index Business Day t during a Calculation Period, the present value in EUR of EUR 1 per annum paid semi-annually, 30/360, unadjusted, following from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 2yFwd EU,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am London Time on that day.
For any Index Business Day t which is not a EU Business Day, 2yPV01 EU,1m-t t will be equal to 2yPV01 EU,1m-(t-1) (t-1) .
EU Business Days
Target.
UK Sub-Index
Index UK,t
The Index value on [●] shall be equal to 100. (Index UK, [START] =100.
For any Calculation Period Index UK, Previous shall be equal to the value of the Index UK, Final for the immediately preceding Calculation Period.
For any Index Business Day t during a Calculation Period, Index UK, t shall be:
Index
UK
,
Previous
×
{
1
+
FX
UK
,
START
FX
UK
,
t
×
(
Signal
UK
×
[
10
yFwd
UK
,
1
m
-
t
t
-
10
yFwd
UK
,
1
m
0
)
×
10
yPV
01
UK
,
1
m
-
t
t
-
(
2
yFwd
UK
,
1
m
-
t
t
-
2
yFwd
UK
,
1
m
0
)
×
2
yPV
01
UK
,
1
m
-
t
t
×
10
yPV
01
UK
,
1
m
0
2
yPV
01
UK
,
1
m
0
]
-
TC
UK
)
}
For any Calculation Period, Index UK, Final shall be equal to Index UK, t where t is the Final Fixing Date for such Calculation Period.
For the purpose of evaluating whether a Suspension Event should occur the Index UK may be valued intra-day by the Calculation Agent using current market data at the time to calculate the swap rates, but following the same formula and methodology as above.
TC UK
The Transaction Costs will be charged based on the cost of rolling the position from one Calculation Period to another and the cost of implementing/unwinding new positions from one Calculation Period to another.
i) If the sign of Signal UK Previous is different from the sign of Signal UK :
TC UK =|Signal UK −Signal UK Previous |×0.0050%×10 yPV 01 UK,1m 0
ii) Otherwise,
TC
UK
=
{
min
(
Signal
UK
;
Signal
UK
Previous
)
×
0.0010
%
+
Signal
UK
-
Signal
UK
Previous
×
0.0050
%
}
×
10
yPV
01
UK
,
1
m
0
Where Signal UK Previous is equal to Signal UK for the previous Calculation Period (or zero in the case of the Initial Calculation Period).
FX UK,Start
For any Calculation Period, the exchange rate (quoted as the number of GBP per 1 unit of USD) as determined by the Calculation Agent with reference to market data observed as of 11:00 am London Time one UK Business Day before the Initial Fixing Date.
FX UK,t
For any Index Business Day t, the exchange rate (quoted as the number of GBP per 1 unit of USD) as determined by the Calculation Agent with reference to market data observed as of 11:00 am London Time on such day t.
Signal UK
For any Calculation Period, the value of the UK Global COMPASS signal calculated on or about [08:00 am London time] by the Calculation Agent one US Business Day before the Initial Fixing Date.
Initial Fixing Date
For any Calculation Period, the Final Fixing Date of the preceding Calculation Period subject to adjustment with the Following UK Business Day Convention.
Final Fixing Date
For any Calculation Period, the last Index Business Day of such Calculation Period.
Forward Start Date UK
For any Calculation Period, the day that is one month following the Initial Fixing Date for such Calculation Period subject to adjustment with the Following UK Business Day Convention.
10yFwd UK,1m 0
For any Calculation Period, the forward rate for a semi-annual GBP swap transaction with a maturity of 10 years on a Act/365 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am London Time] on the Initial Fixing Date.
10yFwd UK,1m-t 0
For any Index Business Day t during a Calculation Period (to and including the Final Fixing Date), the forward rate for a semi-annual GBP swap transaction with a maturity of 10 years on a Act/365 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am London Time on such day.
For any Index Business Day t which is not a UK Business Day, 10yFwd UK,1m-t t will be equal to 10yFwd UK,1m-(t-1) (t-1) .
2yFwd UK,1m 0
For any Calculation Period, the forward rate for a semi-annual GBP swap transaction with a maturity of 2 years on a Act/365 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am London Time on the Initial Fixing Date.
2yFwd UK,1m-t t
For any Index Business Day t during a Calculation Period (to and including the Final Fixing Date), the forward rate for a semi-annual GBP swap transaction with a maturity of 2 years on a Act/365 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am London Time on such day.
For any Index Business Day t which is not a UK Business Day, 2yFwd UK,1m-t t will be equal to 2yFwd UK,1m-(t-1) (t-1) .
10yPV01 UK,1m 0 For any Calculation Period, the present value in GBP of GBP 1 per annum paid semi-annually, Act/365, unadjusted, following, from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 10yFwd UK,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am London Time on the Initial Fixing Date.
10yPV01 UK,1m-t 0
For any Index Business Day t during a Calculation Period, the present value in GBP of GBP 1 per annum paid semi-annually, Act/365, unadjusted, following from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 10yFwd UK,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am London Time on that day.
For any Index Business Day t which is not a UK Business Day, 10yPV01 UK,1m-t t will be equal to 10yPV01 UK,1m-(t-1) (t-1)
2yPV01 UK,1m 0
For any Calculation Period, the present value in GBP of GBP 1 per annum paid semi-annually, Act/365, unadjusted, following, from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 2yFwd UK,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am London Time on the Initial Fixing Date.
2yPV01 UK,1m-t t
For any Index Business Day t during a Calculation Period, the present value in GBP of GBP 1 per annum paid semi-annually, Act/365, unadjusted, following from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 2yFwd UK,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am London Time on that day.
For any Index Business Day t which is not a UK Business Day, 2yPV01 UK,1m-t t will be equal to 2yPV01 UK,1m-(t-1) (t-1) .
UK Business Days
London.
JN Sub-Index
Index JN,t
The Index value on [●] shall be equal to 100. (Index JN, [START] =100.
For any Calculation Period Index JN, Previous shall be equal to the value of the Index JN, Final for the immediately preceding Calculation Period.
For any Index Business Day t during a Calculation Period, Index JN, t shall be:
Index
JN
,
Previous
×
{
1
+
FX
JN
,
START
FX
t
,
START
×
(
Signal
JN
×
[
10
yFwd
JN
,
1
m
-
t
t
-
10
yFwd
JN
,
1
m
0
)
×
10
yPV
01
JN
,
1
m
-
t
t
-
(
2
yFwd
JN
,
1
m
-
t
t
-
2
yFwd
JN
,
1
m
0
)
×
2
yPV
01
JN
,
1
m
-
t
t
×
10
yPV
01
JN
,
1
m
0
2
yPV
01
JN
,
1
m
0
]
-
TC
JN
)
}
For any Calculation Period, Index JN, Final shall be equal to Index JN, t where t is the Final Fixing Date for such Calculation Period.
For the purpose of evaluating whether a Suspension Event should occur the Index JN may be valued intra-day by the Calculation Agent using current market data at the time to calculate the swap rates, but following the same formula and methodology as above.
TC JN
The Transaction Costs will be charged based on the cost of rolling the position from one Calculation Period to another and the cost of implementing/unwinding new positions from one Calculation Period to another.
i) If the sign of Signal JN Previous is different from the sign of Signal US :
TC JN =|Signal JN −Signal JN Previous |×0.0050%×10 yPV 01 JP,1m 0
ii) Otherwise,
TC
JP
=
{
min
(
Signal
JN
;
Signal
JN
Previous
)
×
0.0010
%
+
Signal
JN
-
Signal
JN
Previous
×
0.0050
%
}
×
10
yPV
01
JN
,
1
m
0
Where Signal JN Previous is equal to Signal JN for the previous Calculation Period (or zero in the case of the Initial Calculation Period).
Signal JN
For any Calculation Period, the value of the JN Global COMPASS signal calculated on or about [08:00 am London time] by the Calculation Agent one JN Business Day before the Initial Fixing Date.
Initial Fixing Date
For any Calculation Period, the Final Fixing Date of the preceding Calculation Period subject to adjustment with the Following JN Business Day Convention.
Final Fixing Date
For any Calculation Period, the last Index Business Day of such Calculation Period.
Forward Start Date JN
For any Calculation Period, the day that is one month following the Initial Fixing Date for such Calculation Period subject to adjustment with the Following JN Business Day Convention.
10yFwd JN,1m 0
For any Calculation Period, the forward rate for a semi-annual JPY swap transaction with a maturity of 10 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
10yFwd JN,1m-t t
For any Index Business Day t during a Calculation Period (to and including the Final Fixing Date), the forward rate for a semi-annual JPY swap transaction with a maturity of 10 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on such day.
For any Index Business Day t which is not a JN Business Day, 10yFwd JN,1m-t t will be equal to 10yFwd JN,1m-(t-1) (t-1) .
2yFwd JN,1m 0
For any Calculation Period, the forward rate for a semi-annual JPY swap transaction with a maturity of 2 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
For any Index Business Day t during a Calculation Period (to and including the Final Fixing Date), the forward rate for a semi-annual JPY swap transaction with a maturity of 2 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on such day.
For any Index Business Day t which is not a JN Business Day, 2yFwd JN,1m-t t will be equal to 2yFwd JN,1m-(t-1) (t-1) .
10yPV01 JN,1m 0
For any Calculation Period, the present value in JPY of JPY 1 per annum paid semi-annually, 30/360, unadjusted, following, from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 10yFwd JN,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
10yPV01 JN,1m-t t
For any Index Business Day t during a Calculation Period, the present value in JPY of JPY 1 per annum paid semi-annually, 30/360, unadjusted, following from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 10yFwd JN,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on that day.
For any Index Business Day t which is not a JN Business Day, 10yPV01 JN,1m-t 1 will be equal to 10yPV01 JN,1m-(t-1) (t-1)
2yPV01 JN,1m 0
For any Calculation Period, the present value in JPY of JPY 1 per annum paid semi-annually, 30/360, unadjusted, following, from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 2yFwd JN,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
2yPV01 JN,1m-t t
For any Index Business Day t during a Calculation Period, the present value in JPY of JPY 1 per annum paid semi-annually, 30/360, unadjusted, following from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 2yFwd JN,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on that day.
For any Index Business Day t which is not a JN Business Day, 2yPV01 JN,1m-t t will be equal to 2yPV01 JN,1m-(t-1) (t-1) .
JN Business Days
Tokyo.
CA Sub-Index
Index CA,t
The Index value on [●] shall be equal to 100. (Index CA, [START] =100.
For any Calculation Period Index CA, Previous shall be equal to the value of the Index CA, Final for the immediately preceding Calculation Period.
For any Index Business Day t during a Calculation Period, Index CA, t shall be:
Index
CA
,
Previous
×
{
1
+
FX
CA
,
START
FX
CA
,
t
×
(
Signal
CA
×
[
10
yFwd
CA
,
1
m
-
t
t
-
10
yFwd
CA
,
1
m
0
)
×
10
yPV
01
CA
,
1
m
-
t
t
-
(
2
yFwd
CA
,
1
m
-
t
t
-
2
yFwd
CA
,
1
m
0
)
×
2
yPV
01
CA
,
1
m
-
t
t
×
10
yPV
01
CA
,
1
m
0
2
yPV
01
CA
,
1
m
0
]
-
TC
CA
)
}
For any Calculation Period, Index CA, Final shall be equal to Index CA, t where t is the Final Fixing Date for such Calculation Period.
For the purpose of evaluating whether a Suspension Event should occur the Index CA may be valued intra-day by the Calculation Agent using current market data at the time to calculate the swap rates, but following the same formula and methodology as above.
TC CA
The Transaction Costs will be charged based on the cost of rolling the position from one Calculation Period to another and the cost of implementing/unwinding new positions from one Calculation Period to another.
i) If the sign of Signal CA Previous is different from the sign of Signal US :
TC CA =|Signal CA −Signal CA Previous |×0.0050%×10 yPV 01 CA,1m 0
ii) Otherwise,
TC
CA
=
{
min
(
Signal
CA
;
Signal
CA
Previous
)
×
0.0010
%
+
Signal
CA
-
Signal
CA
Previous
×
0.0050
%
}
×
10
yPV
01
CA
,
1
m
0
Where Signal CA Previous is equal to Signal CA for the previous Calculation Period (or zero in the case of the Initial Calculation Period).
Signal CA
For any Calculation Period, the value of the CA Global COMPASS signal calculated on or about [08:00 am London time] by the Calculation Agent one CA Business Day before the Initial Fixing Date.
Initial Fixing Date
For any Calculation Period, the Final Fixing Date of the preceding Calculation Period subject to adjustment with the Following CA Business Day Convention.
Final Fixing Date
For any Calculation Period, the last Index Business Day of such Calculation Period.
Forward Start Date CA
For any Calculation Period, the day that is one month following the Initial Fixing Date for such Calculation Period subject to adjustment with the Following CA Business Day Convention.
10yFwd CA,1m 0
For any Calculation Period, the forward rate for a semi-annual CAD swap transaction with a maturity of 10 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
10yFwd CA,1m-t t
For any Index Business Day t during a Calculation Period (to and including the Final Fixing Date), the forward rate for a semi-annual CAD swap transaction with a maturity of 10 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on such day.
For any Index Business Day t which is not a CA Business Day, 10yFwd CA,1m-t t will be equal to 10yFwd CA,1m-(t-1) (t-1) .
2yFwd CA,1m 0
For any Calculation Period, the forward rate for a semi-annual CAD swap transaction with a maturity of 2 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
2yFwd CA,1m-t t
For any Index Business Day t during a Calculation Period (to and including the Final Fixing Date), the forward rate for a semi-annual CAD swap transaction with a maturity of 2 years on a 30/360 basis and with an effective date on the Forward Start Date, to be calculated by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on such day.
For any Index Business Day t which is not a CA Business Day, 2yFwd CA,1m-t t will be equal to 2yFwd CA,1m-(t-1) (t-1) .
10yPV01 CA,1m 0
For any Calculation Period, the present value in CAD of CAD 1 per annum paid semi-annually, 30/360, unadjusted, following, from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 10yFwd CA,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
10yPV01 CA,1m-t t
For any Index Business Day t during a Calculation Period, the present value in CAD of CAD 1 per annum paid semi-annually, 30/360, unadjusted, following from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 10yFwd CA,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on that day.
For any Index Business Day t which is not a CA Business Day, 10yPV01 CA,1m-t t will be equal to 10yPV01 CA,1m-(t-1) (t-1)
2yPV01 CA,1m 0
For any Calculation Period, the present value in CAD of CAD 1 per annum paid semi-annually, 30/360, unadjusted, following, from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 2yFwd CA,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on the Initial Fixing Date.
2yPV01 CA,1m-t t
For any Index Business Day t during a Calculation Period, the present value of 0.01% paid semi-annually, 30/360, unadjusted, following from and including the Forward Start Date for such Calculation Period to but excluding the maturity date of such 2yFwd CA,1m 0 as determined by the Calculation Agent with reference to market data observed as of 11:00 am New York Time on that day.
For any Index Business Day t which is not a CA Business Day, 2yPV01 CA,1m-t t will be equal to 2yPV01 CA,1m-(t-1) (t-1) .
CA Business Days
Toronto.
Global COMPASS Signals
As explained above, the Global COMPASS Index aims to capture the changes in the slope of swap curves. The underlying strategies are steepeners or flatteners on the slope of the six swap curves of the largest financial geographies: United States (US), Euro-area (EU), Japan (JN), United Kingdom (UK), Canada (CA), Australia (AU).
Following the calculation of weekly signals based on the dynamics of the different monetary policy regimes, steepener or flattener positions are implemented in the respective curves. Sub-indices for the various geographies are created. The returns of each of these sub-indices, with weights based on relative GDP figures, determine the returns of the Global COMPASS Index.
MP i,t
The Monetary Policy Indicator aims to assess the current local monetary policy regime (tightening vs. easing cycles) through the past quarter change in the Central Bank target rate—easing regimes are when there is considerable steepening of the yield curve.
For any Business Day, t, the Monetary Policy Signal for Currency i , MP i,t should be equal to:
MP
i
,
t
=
-
1
if
R
i
(
t
)
>
R
i
(
t
-
3
m
)
+
1
otherwise
Where:
R i (t) is defined as the value of the Central Bank Rate, on day t subject to adjustment with the Preceding Business Day i Convention as determined by the Calculation Agent with reference to Bloomberg Page i
R i (t−3m) is defined as the value of the Central Bank Rate, on a day that is 3 months prior to day t subject to adjustment with the Business Day i Convention as determined by the Calculation Agent.
MS i,t
The Monetary Policy Surprise Indicator identifies the recent surprises in monetary policy by the comparison of short rates priced in by forwards with actual realized short rates.
For any Business Day i t, the Monetary Policy Surprise Signal for Currency i , MS i,t should be equal to:
MS
i
,
t
=
-
1
if
N
suprise
,
i
(
t
)
>
0
0
if
N
suprise
,
i
(
t
)
=
0
+
1
if
N
suprise
,
i
(
t
)
<
0
P
suprise
,
i
(
t
)
3
mFwd
i
,
3
m
t
-
3
m
-
3
mLibor
i
t
N
suprise
,
i
(
t
)
For any Business Day i t, the normalised rate change N surprise,i (t) is defined as:
N surprise,i ( t )=( P surprise,i ( t )−Average{ P surprise,i ( t )}/Standard Deviation{ P surprise,i ( t )})
Where both the Average and Standard Deviation is computed from and excluding the day that is 10 years before day t subject to adjustment with the Business Day i Convention to and including such day t.
3mLibor i t
For any Business Day i t, the rate for deposits in Currency i for a period of 3 months on such day t.
3mFwd i,3m t-3m
For any Business Day, t, the 3-month forward rate for a 3-month deposit calculated by the Calculation Agent.
Signal i,t
For any Business Day i t, Signal i,t is defined as the average of the Local Monetary Policy Signal (MP i,t ), the US Monetary Policy Signal (MP l,t ) and the Local Monetary Policy Surprise (MS i,t ):
Signal i,t =⅓×( MP i,t +MP l,t +MS i,t )
TABLE 11
Other Definitions
Bloomberg
i
Currency i
Business Day i
Central Bank Rate: R i
Page i
1
USD
New York
Fed Funds Target Rate
FDTR Index
2
EUR
Target
ECB Minimum Bid
EURR002W
Refinancing Rate
Index
3
JPY
Tokyo
BoJ Target
BOJDTR Index
4
GBP
London
UK Base Rate
UKBRBASE
Index
5
CAD
Toronto
BoC Overnight Lending
CABROVER
Rate
Index
6
AUD
Sydney
RBA Cash Target Rate
RBACTRD
Index
Embodiments of the present invention comprise computer components and computer-implemented steps that will be apparent to those skilled in the art. For example, calculations and communications can be performed electronically. An exemplary system is depicted in FIG. 16 . As shown, computers 1600 communicate via network 1610 with a central server 1630 . A plurality of sources of data 1660 , 1670 relating to, for example, trading volume data, also communicate via network 1610 with a central server 1630 , processor 1650 , and/or other component to calculate and transmit, for example, volume forecast data. The server 1630 may be coupled to one or more storage devices 1640 , one or more processors 1650 , and software 1660 .
Other components and combinations of components may also be used to support processing data or other calculations described herein as will be evident to those skilled in the art. Server 1630 may facilitate communication of data from a storage device 1640 to and from processor 1650 , and communications to computers 1600 . Processor 1650 may optionally include local or networked storage (not shown) which may be used to store temporary information. Software 1660 can be installed locally at a computer 1600 , processor 1650 and/or centrally supported for facilitating calculations and applications.
For ease of exposition, not every step or element of the present invention is described herein as part of a computer system and/or software, but those skilled in the art will recognize that each step or element may have (and typically will have) a corresponding computer system or software component. Such computer system and/or software components are therefore enabled by describing their corresponding steps or elements (that is, their functionality), and are within the scope of the present invention.
Moreover, where a computer system is described or claimed as having a processor for performing a particular function, it will be understood by those skilled in the art that such usage should not be interpreted to exclude systems where a single processor, for example, performs some or all of the tasks delegated to the various processors. That is, any combination of, or all of, the processors specified in the description and/or claims could be the same processor. All such combinations are within the scope of the invention.
Alternatively, the processing and decision steps described herein can be performed by functionally equivalent circuits such as a digital signal processor circuit or an application specific integrated circuit. The details described herein do not specify the syntax of any particular programming language, but rather provide sufficient functional information to enable one of ordinary skill in the art to perform the functions/processes in accordance with the present invention. It should be noted that many routine program elements, such as initialization of loops and variables and the use of temporary variables are not shown herein since they are already well-understood by those skilled in the art. Such elements will be nevertheless be understood to be part of corresponding embodiments by those skilled in the art.
It will be appreciated by those of ordinary skill in the art that unless otherwise indicated herein, the particular sequence of steps described is illustrative only and can be varied without departing from the scope of the invention.
The present invention has been described by way of example only, and the invention is not limited by the specific embodiments described herein. As will be recognized by those skilled in the art, improvements and modifications may be made to the invention and the illustrative embodiments described herein without departing from the scope or spirit of the invention.
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In one aspect, the present invention comprises a method comprising: receiving data regarding bank rates and swap rates for two or more currencies; calculating a swap curve for each of the currencies; calculating signals for each of the swap curves; and based on the signals, taking a position with respect to each of the swap curves and currencies. In various embodiments, the method further comprises calculating a sub-index value for each of the currencies, the sub-index values based on returns for the positions; and weighting each sub-index value and calculating a value for an index, based on a combination of the sub-index values. In another aspect, the invention comprises: receiving data regarding the index; calculating a performance value for the index to be used in a derivative based on the index; and calculating an amount due to, or owed by, an investor in the derivative, based on the performance value.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 60/821,482 filed Aug. 4, 2006, which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a chemical genus of biphenyl heterocycle derivative inhibitors of LTA4H (leukotriene A4 hydrolase) useful for the treatment and prevention and prophylaxis of inflammatory diseases and disorders.
BACKGROUND OF THE INVENTION
[0003] The end products of the leukotriene pathway are potent inflammatory lipid mediators derived from arachidonic acid. They can potentially contribute to development of atherosclerosis and destabilization of atherosclerotic plaques through lipid oxidation and/or proinflammatory effects. As described elsewhere, a gene on chromosome 13q12 has been identified as playing a major role in myocardial infarction (MI), [Helgadottir et al., Nature Genetics doi: 10.1038/ng 1311, 8 Feb. 2004]. This gene (ALOX5AP), herein after referred to as an MI disease gene, comprises nucleic acid that encodes 5-lipoxygenase activating protein (FLAP), herein after referred to as FLAP. DNA variants in the FLAP gene increase risk for myocardial infarction by 1.8 fold and for stroke by 1.7 fold. The leukotriene pathway, through FLAP, leads to the production of leukotriene B4 by the enzyme leukotriene A4 hydrolase (LTA4H). Leukotriene B4 is one of the most potent chemokine mediators of arterial inflammation. Particular DNA variants in the gene encoding LTA4H also elevate risk for MI and stroke, as described elsewhere [Hakonarsson et al., J. Am. Med. Assoc. 293, 2245-2256 (2005)]. Individuals with a prior history of MI produce more leukotriene B4 when their isolated neutrophils are stimulated with ionomycin. Increased LTB4 production is particularly marked in male patients with a prior history of MI who carry risk variants in the FLAP gene [Helgadottir et al.]. The treatment (prophylactic and/or therapeutic) of certain diseases and conditions (e.g., MI, acute coronary syndrome (ACS), stroke, atherosclerosis) associated with FLAP or with LTA4H can be accomplished by inhibiting LTA4H. Inhibiting LTA4H is advantageous for methods of treatment for MI or susceptibility to MI; for ACS (e.g., unstable angina, non-ST-elevation myocardial infarction (NSTEMI) or ST-elevation myocardial infarction (STEMI)); for decreasing risk of a second MI; for stroke (including transient ischemic attack) or susceptibility to stroke; for atherosclerosis, such as for patients requiring treatment (e.g., angioplasty, stents, coronary artery bypass graft) to restore blood flow in coronary arteries, such as patients requiring treatment for peripheral vascular disease including peripheral occlusive arterial disease, critical limb ischemia (e.g., gangrene, ulceration), and intermittent claudication to restore blood flow in the lower limbs; for atherosclerotic reno-vascular disease; for abdominal aortic aneurysm; and/or for decreasing leukotriene synthesis (e.g., for treatment of MI).
[0004] US Patent Application Publication No. 20050043378 and 20050043379, relate to benzooxazol-2-yl, benzothiazol-2-yl and 1H-benzoimidazol-2-yl compounds and derivatives thereof useful as leukotriene A4 hydrolase (LTA4H) inhibitors in treating inflammation and disorders associated with inflammation. These disclosures are incorporated herein by reference as they relate to utility.
SUMMARY OF THE INVENTION
[0005] The present invention relates to compounds exhibiting LTA4H enzyme inhibition, having general formula:
wherein
R 1 is selected from the group consisting of H, alkyl, aryl, heteroaryl, aryl substituted with from one to three substituents independently selected from the group consisting of halogen, loweralkyl, loweracyl, loweralkoxy, fluoroloweralkyl, fluoroloweralkoxy, hydroxyloweralkyl, formyl, cyano, benzyl, benzyloxy, phenyl, heteroaryl, heterocyclylalkyl and nitro; and heteroaryl substituted with from one to three substituents independently selected from the group consisting of halogen, loweralkyl, loweracyl, loweralkoxy, fluoroloweralkyl, fluoroloweralkoxy, formyl, cyano, phenyl, heteroaryl, heterocyclylalkyl and nitro;
Q is (CH 2 ) 1-8 ; in which one or two (CH 2 ) may optionally be replaced by —O—, —NR 1 —, —SO—, —S(O) 2 —, —C(═O)— or —C═O(NH)—, provided that said —O—, —NR 1 —, —SO—, —S(O) 2 —, —C(═O)— or —C═O(NH)— are separated by at least one —(CH 2 )—; and when Het is a nitrogen-attached heterocycle, Q may additionally be a direct bond;
Het is a 5-7 membered non-aromatic nitrogen heterocycle;
Z is (CH 2 ) 1-10 ; in which one or two (CH 2 ) may optionally be replaced by —O—, —NR 1 —, —SO—, —S(O) 2 —, —C(═O)— or —C═O(NH)—, provided that said —O—, —NR 1 —, —SO—, —S(O) 2 —, —C(═O)— or —C═O(NH)— are not at the point of attachment to nitrogen and are separated by at least one —(CH 2 )—;
W is selected from acyl, hydroxyl, carboxyl, amino, carboxamido, aminoacyl, —COOalkyl, —CHO, sulfonamide, —C(O)fluoroalkyl, —C(O)CH 2 C(O)Oalkyl, —C(O)CH 2 C(O)Ofluoroalkyl, —SH, —C(O)NH(OH), —C(O)N(OH)R 4 , —N(OH)C(O)OH, —N(OH)C(O)R 4 , heterocyclyl, substituted aryl, and substituted heterocyclyl, or taken together ZW are H or —COOalkyl; and
R 4 is selected from the group consisting of H and lower alkyl.
[0006] In a second aspect the invention relates to pharmaceutical compositions comprising a pharmaceutically acceptable carrier and a therapeutically effective amount of at least one of the compounds as described herein.
[0007] In a third aspect, the invention relates to methods for the treatment and prevention or prophylaxis of a disease, condition or disorder associated with leukotriene A4 hydrolase. The methods comprise administering to a mammal a therapeutically effective amount of a compound described above. The disease or condition may be related to allergic, acute or chronic inflammation. The disease may be for example contact and atopic dermatitis, arthritis, allergic rhinitis, asthma or an autoimmune diseases such as Crohn's disease, psoriasis, ulcerative colitis, inflammatory bowel disease, multiple sclerosis, ankylosing spondylitis, and the like. Similarly, the compounds defined above can be used in preventing recurring inflammatory attacks. The compounds are also useful for treating and preventing atherosclerosis, thrombosis, stroke, acute coronary syndrome, stable angina, peripheral vascular disease, critical leg ischemia, intermittent claudication, abdominal aortic aneurysm and myocardial infarction.
DETAILED DESCRIPTION OF THE INVENTION
[0008] Throughout this specification the substituents are defined when introduced and retain their definitions.
[0009] In one aspect the invention relates to heterocycle derivatives useful as LTA4H enzyme inhibitors, having the general formula:
In some embodiments the compounds have the formula
wherein n is 1-4 and Het is chosen from pyrrolidine, piperidine and piperazine.
[0010] In other embodiments, Q is a direct bond and Het is a piperazine. These compounds have the formula
[0011] In many embodiments Z is (CH 2 ) 1-5 and W is COOH. In many other embodiments, R 1 is H, methyl, phenyl or substituted phenyl.
[0012] In another aspect the present invention provides pharmaceutical compositions comprising a pharmaceutically acceptable carrier and a therapeutically effective amount of at least one compound as described above.
[0013] Methods of the invention parallel the compositions and formulations. The methods comprise administering to a patient in need of treatment a therapeutically effective amount of a compound according to the invention.
[0014] The present invention provides a method for inhibiting leukotriene A4 hydrolase comprising contacting the LTA4H enzyme with a therapeutically effective amount of a compound according to the general formula.
[0015] Furthermore, the present invention provides a method for treating a disorder associated with leukotriene A4 hydrolase comprising administering to a mammal a therapeutically effective amount of a compound or a salt, hydrate or ester thereof according to the general formula given above. It may be found upon examination that additional species and genera not presently excluded are not patentable to the inventors in this application. In either case, the exclusion of species and genera in applicants' claims are to be considered artifacts of patent prosecution and not reflective of the inventors' concept or description of their invention. The invention, in a composition aspect, is all compounds of the general formula above, except those that are in the public's possession. The invention, in a method aspect, is a method employing compounds of the general formula above, except those methods that are in the public's possession.
[0016] In some embodiments the disorder is associated with inflammation. In some embodiments the disorder is selected from allergic inflammation, acute inflammation and chronic inflammation.
[0017] Compounds of the genus represented by the general formula above are inhibitors of LTA 4 H enzyme. As such they have utility in treating and preventing inflammatory diseases and disorders, as described above, particularly for such conditions as asthma, chronic obstructed pulmonary disease (COPD), atherosclerosis, rheumatoid arthritis, multiple sclerosis, inflammatory bowel diseases (IBD)—including Crohn's disease and ulcerative colitis—or psoriasis, which are each characterized by excessive or prolonged inflammation at some stage of the disease.
[0018] Recent research indicates that the compounds are also useful for treating and preventing atherosclerosis, thrombosis, stroke, acute coronary syndrome, stable angina, peripheral vascular disease, critical leg ischemia, intermittent claudication, abdominal aortic aneurysm and myocardial infarction.
[0019] The compounds may be presented as salts. The term “pharmaceutically acceptable salt” refers to salts whose counter ion derives from pharmaceutically acceptable non-toxic acids and bases. Suitable pharmaceutically acceptable base addition salts for the compounds of the present invention include, but are not limited to, metallic salts made from aluminum, calcium, lithium, magnesium, potassium, sodium and zinc or organic salts made from lysine, N,N-dialkyl amino acid derivatives (e.g. N,N-dimethylglycine, piperidine-1-acetic acid and morpholine-4-acetic acid), N,N′-dibenzylethylenediamine, chloroprocaine, choline, diethanolamine, ethylenediamine, meglumine (N-methylglucamine) and procaine. When the compounds contain a basic residue, suitable pharmaceutically acceptable base addition salts for the compounds of the present invention include inorganic acids and organic acids. Examples include acetate, benzenesulfonate (besylate), benzoate, bicarbonate, bisulfate, carbonate, camphorsulfonate, citrate, ethanesulfonate, fumarate, gluconate, glutamate, bromide, chloride, isethionate, lactate, maleate, malate, mandelate, methanesulfonate, mucate, nitrate, pamoate, pantothenate, phosphate, succinate, sulfate, tartrate, p-toluenesulfonate, and the like.
[0020] For convenience and clarity certain terms employed in the specification, examples and claims are described herein.
[0021] Alkyl is intended to include linear, branched, or cyclic hydrocarbon structures and combinations thereof. Lower alkyl refers to alkyl groups of from 1 to 6 carbon atoms. Examples of lower alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, s- and t-butyl and the like. Preferred alkyl groups are those of C 20 or below. Cycloalkyl is a subset of alkyl and includes cyclic hydrocarbon groups of from 3 to 8 carbon atoms. Examples of cycloalkyl groups include c-propyl, c-butyl, c-pentyl, norbornyl and the like.
[0022] C 1 to C 20 hydrocarbon includes alkyl, cycloalkyl, alkenyl, alkynyl, aryl, arylalkyl and combinations thereof. Examples include phenethyl, cyclohexylmethyl, camphoryl, adamantyl and naphthylethyl.
[0023] Alkoxy or alkoxyl refers to groups of from 1 to 8 carbon atoms of a straight, branched, cyclic configuration and combinations thereof attached to the parent structure through oxygen. Examples include methoxy, ethoxy, propoxy, isopropoxy, cyclopropyloxy, cyclohexyloxy and the like. Lower-alkoxy refers to groups containing one to four carbons.
[0024] Alkoxyalkyl refers to ether groups of from 3 to 8 atoms of a straight, branched, cyclic configuration and combinations thereof attached to the parent structure through an alkyl. Examples include methoxymethyl, methoxyethyl, ethoxypropyl, and the like.
[0025] Alkoxyaryl refers to alkoxy substituents attached to an aryl, wherein the aryl is attached to the parent structure. Arylalkoxy refers to aryl substituents attached to an oxygen, wherein the oxygen is attached to the parent structure. Substituted arylalkoxy refers to a substituted aryl substituent attached to an oxygen, wherein the oxygen is attached to the parent structure.
[0026] Acyl refers to groups of from 1 to 8 carbon atoms of a straight, branched, cyclic configuration, saturated, unsaturated and aromatic and combinations thereof, attached to the parent structure through a carbonyl functionality. One or more carbons in the acyl residue may be replaced by nitrogen, oxygen or sulfur as long as the point of attachment to the parent remains at the carbonyl. Examples include acetyl, benzoyl, propionyl, isobutyryl, t-butoxycarbonyl, benzyloxycarbonyl and the like. Lower-acyl refers to groups containing one to four carbons.
[0027] Aryl and heteroaryl mean a 5- or 6-membered aromatic or heteroaromatic ring containing 0-3 heteroatoms selected from O, N, or S; a bicyclic 9- or 10-membered aromatic or heteroaromatic ring system containing 0-3 heteroatoms selected from O, N, or S; or a tricyclic 13- or 14-membered aromatic or heteroaromatic ring system containing 0-3 heteroatoms selected from O, N, or S. The aromatic 6- to 14-membered carbocyclic rings include, e.g., benzene and naphthalene, and according to the invention benzoxalane and residues in which one or more rings are aromatic, but not all need be. The 5- to 10-membered aromatic heterocyclic rings include, e.g., imidazole, pyridine, indole, thiophene, benzopyranone, thiazole, furan, benzimidazole, quinoline, isoquinoline, quinoxaline, pyrimidine, pyrazine, tetrazole and pyrazole.
[0028] Arylalkyl refers to a substituent in which an aryl residue is attached to the parent structure through alkyl. Examples are benzyl, phenethyl and the like. Heteroarylalkyl refers to a substituent in which a heteroaryl residue is attached to the parent structure through alkyl. Examples include, e.g., pyridinylmethyl, pyrimidinylethyl and the like. Heterocyclylalkyl refers to a substituent in which a heterocyclyl residue is attached to the parent structure through alkyl. Examples include morpholinoethyl and pyrrolidinylmethyl.
[0029] Heterocycle means a cycloalkyl or aryl residue in which from one to three carbons is replaced by a heteroatom selected from the group consisting of N, O and S. The nitrogen and sulfur heteroatoms may optionally be oxidized, and the nitrogen heteroatom may optionally be quaternized. Examples of heterocycles include pyrrolidine, pyrazole, pyrrole, indole, quinoline, isoquinoline, tetrahydroisoquinoline, benzofuran, benzodioxan, benzodioxole (commonly referred to as methylenedioxyphenyl, when occurring as a substituent), tetrazole, morpholine, thiazole, pyridine, pyridazine, pyrimidine, thiophene, furan, oxazole, oxazoline, isoxazole, dioxane, tetrahydrofuran and the like. It is to be noted that heteroaryl is a subset of heterocycle in which the heterocycle is aromatic. Examples of heterocyclyl residues additionally include piperazinyl, 2-oxopiperazinyl, 2-oxopiperidinyl, 2-oxo-pyrrolidinyl, 2-oxoazepinyl, azepinyl, 4-piperidinyl, pyrazolidinyl, imidazolyl, imidazolinyl, imidazolidinyl, pyrazinyl, oxazolidinyl, isoxazolidinyl, thiazolidinyl, isothiazolyl, quinuclidinyl, isothiazolidinyl, benzimidazolyl, thiadiazolyl, benzopyranyl, benzothiazolyl, tetrahydrofuryl, tetrahydropyranyl, thienyl, benzothienyl, thiamorpholinyl, thiamorpholinylsulfoxide, thiamorpholinylsulfone, oxadiazolyl, triazolyl and tetrahydroquinolinyl.
[0030] An oxygen heterocycle is a heterocycle containing at least one oxygen in the ring; it may contain additional oxygens, as well as other heteroatoms. A sulphur heterocycle is a heterocycle containing at least one sulphur in the ring; it may contain additional sulphurs, as well as other heteroatoms. A nitrogen heterocycle is a heterocycle containing at least one nitrogen in the ring; it may contain additional nitrogens, as well as other heteroatoms. Oxygen heteroaryl is a subset of oxygen heterocycle; examples include furan and oxazole. Sulphur heteroaryl is a subset of sulphur heterocycle; examples include thiophene and thiazine. Nitrogen heteroaryl is a subset of nitrogen heterocycle; examples include pyrrole, pyridine and pyrazine. A saturated nitrogenous heterocycle is a subset of nitrogen heterocycle. Saturated nitrogenous heterocycle contain at least one nitrogen and may contain additional nitrogens, as well as other heteroatoms. Examples include pyrrolidine, pyrazolidine, piperidine, morpholine, and thiomorpholine.
[0031] Substituted alkyl, aryl, cycloalkyl, heterocyclyl etc. refer to alkyl, aryl, cycloalkyl, or heterocyclyl wherein up to three H atoms in each residue are replaced with halogen, haloalkyl, hydroxy, loweralkoxy, carboxy, carboalkoxy (also referred to as alkoxycarbonyl), carboxamido (also referred to as alkylaminocarbonyl), cyano, carbonyl, nitro, amino, alkylamino, dialkylamino, mercapto, alkylthio, sulfoxide, sulfone, acylamino, amidino, phenyl, benzyl, heteroaryl, phenoxy, benzyloxy, or heteroaryloxy.
[0032] The terms “halogen” and “halo” refer to fluorine, chlorine, bromine or iodine.
[0033] The term “prodrug” refers to a compound that is made more active in vivo. Activation in vivo may come about by chemical action or through the intermediacy of enzymes. Microflora in the GI tract may also contribute to activation in vivo.
[0034] It will be recognized that the compounds of this invention can exist in radiolabeled form, i.e., the compounds may contain one or more atoms containing an atomic mass or mass number different from the atomic mass or mass number usually found in nature. Radioisotopes of hydrogen, carbon, phosphorous, fluorine, and chlorine include 2 H, 3 H, 13 C, 14 C, 15 N, 35 S, 18 F, and 36 Cl, respectively. Compounds that contain those radioisotopes and/or other radioisotopes of other atoms are within the scope of this invention. Tritiated, i.e. 3 H, and carbon-14, i.e., 14 C, radioisotopes are particularly preferred for their ease in preparation and detectability. Radiolabeled compounds of formula of this invention and prodrugs thereof can generally be prepared by methods well known to those skilled in the art. Conveniently, such radiolabeled compounds can be prepared by carrying out the procedures disclosed in the Examples and Schemes by substituting a readily available radiolabeled reagent for a non-radiolabeled reagent.
[0035] As used herein, and as would be understood by the person of skill in the art, the recitation of “a compound” is intended to include salts, solvates, co-crystals and inclusion complexes of that compound.
[0036] The term “solvate” refers to a compound of formula I in the solid state, wherein molecules of a suitable solvent are incorporated in the crystal lattice. A suitable solvent for therapeutic administration is physiologically tolerable at the dosage administered. Examples of suitable solvents for therapeutic administration are ethanol and water. When water is the solvent, the solvate is referred to as a hydrate. In general, solvates are formed by dissolving the compound in the appropriate solvent and isolating the solvate by cooling or using an antisolvent. The solvate is typically dried or azeotroped under ambient conditions. Co-crystals are combinations of two or more distinct molecules arranged to create a unique crystal form whose physical properties are different from those of its pure constituents. Pharmaceutical co-crystals have recently become of considerable interest for improving the solubility, formulation and bioavailability of such drugs as itraconazole [see Remenar et al. J. Am. Chem. Soc. 125, 8456-8457 (2003)] and fluoxetine. Inclusion complexes are described in Remington: The Science and Practice of Pharmacy 19 th Ed. (1995) volume 1, page 176-177. The most commonly employed inclusion complexes are those with cyclodextrins, and all cyclodextrin complexes, natural and synthetic, with or without added additives and polymer(s), as described in U.S. Pat. Nos. 5,324,718 and 5,472,954, are specifically encompassed within the claims. The disclosures of Remington and the '718 and '954 patents are incorporated herein by reference.
[0037] [The compounds described herein may contain asymmetric centers and may thus give rise to enantiomers, diastereomers, and other stereoisomeric forms. Each chiral center may be defined, in terms of absolute stereochemistry, as (R)— or (S)—. The present invention is meant to include all such possible isomers, as well as, their racemic and optically pure forms. Optically active (R)— and (S)— isomers may be prepared using chiral synthons or chiral reagents, or resolved using conventional techniques. The prefix “rac” refers to a racemate. When the compounds described herein contain olefinic double bonds or other centers of geometric asymmetry, and unless specified otherwise, it is intended that the compounds include both E and Z geometric isomers. The representation of the configuration of any carbon-carbon double bond appearing herein is selected for convenience only, and unless explicitly stated, is not intended to designate a particular configuration. Thus a carbon-carbon double bond depicted arbitrarily as E may be Z E, or a mixture of the two in any proportion. Likewise, all tautomeric forms are also intended to be included.
[0038] The graphic representations of racemic, ambiscalemic and scalemic or enantiomerically pure compounds used herein are taken from Maehr J. Chem. Ed. 62, 114-120 (1985): solid and broken wedges are used to denote the absolute configuration of a chiral element; wavy lines and single thin lines indicate disavowal of any stereochemical implication which the bond it represents could generate; solid and broken bold lines are geometric descriptors indicating the relative configuration shown but denoting racemic character; and wedge outlines and dotted or broken lines denote enantiomerically pure compounds of indeterminate absolute configuration.
[0039] Terminology related to “protecting”, “deprotecting” and “protected” functionalities occurs throughout this application. Such terminology is well understood by persons of skill in the art and is used in the context of processes that involve sequential treatment with a series of reagents. In that context, a protecting group refers to a group, which is used to mask a functionality during a process step in which it would otherwise react, but in which reaction is undesirable. The protecting group prevents reaction at that step, but may be subsequently removed to expose the original functionality. The removal or “deprotection” occurs after the completion of the reaction or reactions in which the functionality would interfere. Thus, when a sequence of reagents is specified, as it is in the processes of the invention, the person of ordinary skill can readily envision those groups that would be suitable as “protecting groups”. Suitable groups for that purpose are discussed in standard textbooks in the field of chemistry, such as Protective Groups in Organic Synthesis by T. W. Greene [John Wiley & Sons, New York, 1991], which is incorporated herein by reference.
[0040] A comprehensive list of abbreviations utilized by organic chemists appears in the first issue of each volume of the Journal of Organic Chemistry. The list, which is typically presented in a table entitled “Standard List of Abbreviations”, is incorporated herein by reference.
[0041] In general, the compounds of the present invention may be prepared by the methods illustrated in the general reaction schemes as, for example, described below, or by modifications thereof, using readily available starting materials, reagents and conventional synthesis procedures.
EXAMPLES
[0042]
Example 1
[0043]
[0044] Step 1:
2-(4-Benzyloxy-phenoxymethyl)-pyrrolidine-1-carboxylic acid tert-butyl ester
[0045] To a 15 mL of anhydrous DMF was added NaH (60% dispersion in oil, 338 mg, 8.44 mmol), and the resulting reaction mixture was cooled to 0° C. p-benzyloxy phenol (1.41 g, 7.03 mmol) was added and the reaction mixture was stirred at rt for 45 min. It was then cooled to −5° C., and (R)-Boc-prolinol tosylate (2.5 g, 7.03 mmol) in anhydrous DMF (5 mL) was cooled in a separate ice-bath and added dropwise to the reaction mixture. It was then allowed to warm to rt and stirred at 92° C. for 5 h and at rt overnight. The resulting mixture was poured into 200 mL ice/water and stirred for an hour. The resulting precipitate was filtered, washed with ether, dried over MgSO 4 , concentrated, recrystallized with ether/hexane to give shiny yellow crystals (1.5 g, 55%).
[0046] Step 2:
2-(4-Hydroxy-phenoxymethyl)-pyrrolidine-1-carboxylic acid tert-butyl ester
[0047] A solution of the product from step 1, in THF (1 ml), EtOH (25 ml), Pd—C (1.17 g, 10% wt) in a round bottom flask was charged with H 2 -balloon after flushing with hydrogen 3 times. The resulting solution was stirred overnight at rt. The reaction mixture was then filtered, washed with THF (30 ml), EtOH (25 ml) and dried over anhydrous MgSO 4 . After removal of the solvent in vacuo, the product was obtained as an orange oil (1.0 g, 95%).
[0048] Step 3:
2-(4-Prop-2-ynyloxy-phenoxymethyl)-pyrrolidine-1-carboxylic acid tert-butyl ester
[0049] To a solution of the product from step 2 (2.0 g, 6.82 mmol) in anhydrous DMF (50 mL) was added dry K 2 CO 3 (4.6 g, 33 mmol) and allowed to stir for 15 min. Propargyl bromide (1.214 g, 10.20 mmol) in anhydrous DMF (10 mL) was added and the reaction mixture stirred at 50° C. for 6 h, then at rt for 48 h. The reaction mixture was concentrated, taken up in EtOAc, washed with water, dried over anhydrous MgSO 4 and the solvent removed in vacuo. The product was purified by silica gel flash chromatography using EtOAc/hexane to obtain the title compound (2.0 g, 88%).
[0050] Step 4:
(R)-2-(4-Prop-2-ynyloxy-phenoxymethyl)-pyrrolidine hydrochloride
[0051] To a solution of the product from step 3 (100 mg) was added 2M HCl in dioxane (4 mL) and the resulting mixture was stirred for 2 h, and the solvent was removed in vacuo. Crude material was triturated with ether to obtain the title product (70 mg, 100%); LCMS; 97%, m/z 232.1 (M+1); 1 H NMR (DMSO-d 6 , 400 MHz) δ 1.70 (1H, m), 1.95 (2H, m), 2.10 (2H, m), 3.20 (2H, m), 3.53 (2H, m), 3.86 (1H, m), 4.07 (1H, dd, J1=8.0 Hz, J2=10.0 Hz), 4.18 (1H, dd, J1=4.0 Hz, J2=10.8 Hz), 6.94 (4H, s), 9.2 (2H, br s).
[0000] General Procedures for examples 2-4;
[0052] A: PdCl 2 (0.02 equiv), aryl iodide (1.0 equiv), H 2 O (0.07 equiv), and pyrrolidine (5 equiv) were added to a flask under aerobic conditions, and the resulting mixture was stirred at 50° C. for 5 min. To this solution was added 2-(4-prop-2-ynyloxy-phenoxymethyl)-pyrrolidine-1-carboxylic acid tert-butyl ester (1.2 equiv) and the reaction mixture was stirred at 50° C. for 24 h. The reaction mixture was then extracted with EtOAc and the combined organic layer was dried over anhydrous MgSO 4 . The solvent was removed under vacuum, and the residue was purified by flash chromatography.
[0053] B: The product from General Procedure A was dissolved in 4.0M HCl in dioxane (excess) the resulting mixture stirred for 2 h at rt. The solvent was removed in vacuo to obtain a thick oil. The oil was triturated with ether to obtain the product as the HCl salt.
Example 2
[0054]
[0055] Step 1:
2-[4-(3-Phenyl-prop-2-ynyloxy)-phenoxymethyl]-pyrrolidine-1-carboxylic acid tert-butyl ester
[0056] General procedure A was followed using the product from step 3, Example 1 (165 mg, 0.498 mmol), iodobenzene (85 mg, 0.416 mmol), PdCl 2 (2.5 mg, 0.014 mmol), pyrrolidine (0.2 mL, 2.37 mmol), water (0.53 mL) to give the title compound (30 mg, 15%).
[0057] Step 2:
2-[4-(3-Phenyl-prop-2-ynyloxy)-phenoxymethyl]-pyrrolidine
[0058] General procedure B was followed using the product from step 1, Example 2 (30 mg, 0.074 mmol) to give the title compound (13 mg, 51%); MS; m/z 308 (M+H) 99%; 1 H NMR (DMSO, 400 MHz) δ 1.68-2.12 (4H, m), 3.19 (2H, m), 4.98 (2H, s), 6.96 (2H, d, J=9.6 Hz), 7.01 (2H, d, J=5.2 Hz), 7.42 (4H, m), 6.96 (2H, d, J=9.6 Hz), 7.01 (2H, d, J=5.2 Hz), 7.42 (4H, m).
Example 3
[0059]
[0060] Step 1:
2-{4-[3-(4-Hydroxymethyl-phenyl)-prop-2-ynyloxy]-phenoxymethyl}-pyrrolidine-1-carboxylic acid tert-butyl ester
[0061] General procedure A was followed using the product from step 3 Example 1 (266 mg, 1.0546 mmol), p-iodobenzylalcohol (156.5 mg, 0.669 mmol), PdCl 2 (2.5 mg, 0.014 mmol), pyrrolidine (0.277 mL, 3.34 mmol), water (0.844 mL) to give the title compound (60 mg, 20.5%).
[0062] Step 2:
(4-{3-[4-(Pyrrolidin-2-ylmethoxy)-phenoxy]-prop-1-ynyl}-phenyl)-methanol
[0063] General procedure B was followed using the product from step 1, Example 3 (100 mg, 0.21 mmol) to give the title compound (30 mg, 54%); MS m/z 338 (M+H)>95%; 1 H NMR (DMSO-d 6 , 400 MHz) δ 1.68-2.11 (4H, m), 3.20 (2H, m), 3.87 (1H, m), 4.20 (1H, dd, J=4.0 Hz, 10.8 Hz), 4.50 (2H, d, J=5.6 Hz), 4.97 (2H, s), 5.28 (OH, t, J=5.6 Hz), 6.96 (2H, d, J=9.2 Hz), 7.01 (2H, d, J=6.4 Hz), 7.32 (2H, d, J=8.8 Hz), 7.38 (2H, d, J=8.0 Hz).
Example 4
[0064]
[0065] Step 1:
2-{4-[3-(4-Bromo-phenyl)-prop-2-ynyloxy]-phenoxymethyl}-pyrrolidine-1-carboxylic acid tert-butyl ester
[0066] General procedure A was followed using the product from step 3 Example 1 (266 mg, 0.803 mmol), p-bromo iodobenzene (156.5 mg, 0.669 mmol), PdCl 2 (2.5 mg, 0.014 mmol), pyrrolidine (0.277 mL, 3.34 mmol), water (0.844 mL) to give the title compound (110 mg, 33.8%).
[0067] Step 2:
2-{4-[3-(4-Bromo-phenyl)-prop-2-ynyloxy]-phenoxymethyl}-pyrrolidine hydrochloride
[0068] General procedure B was followed using the product from step 1, Example 4 (100 mg, 0.21 mmol) to give the title compound. (92 mg, 96%); MS m/z 423 (M+H) 99%: 1 H NMR (DMSO, 400 MHz) δ 1.68-2.13 (4H, m), 3.20 (2H, m), 3.85 (1H, m), 4.06 (1H, dd, J=4.0 Hz, 10.8 Hz), 4.20 (1H, dd, J=104 Hz, 3.6 Hz), 4.97 (2H, s), 6.95 (2H, d, J=8.8 Hz), 7.01 (2H, d, J=9.2 Hz), 7.37 (2H, d, J=8.4 Hz), 7.59 (2H, d, J=8.4 Hz).
Example 5
[0069]
[0070] Step 1:
3-[4-(4-Hydroxy-phenyl)-piperazin-1-yl]-butyric acid methyl ester
[0071] To a mixture of 4-piperazin-1-yl-phenol (2 g, 11.2 mmol) and methyl 3-bromo-butyrate (2.03 g, 11.2 mmol) in DMF (5 mL) was added triethylamine (4.5 mL, 11.53 mmol) dropwise and the reaction mixture was stirred at ambient temperature overnight. The mixture was poured onto water and extracted with ethyl acetate (50 ml×3). The combined organic layers were washed with brine, dried over anhydrous Na 2 SO 4 and evaporated under vacuum to dryness. The residue was purified by silica gel flash chromatography (1% methanol in CH 2 Cl 2 ) to furnish the title compound (1.85 g, 59.3%); MS; m/z 279 (M+H).
[0072] Step 2:
3-[4-(4-Prop-2-ynyloxy-phenyl)-piperazin-1-yl]-propionic acid methyl ester
[0073] To a mixture of the compound from step 1 (278 mg, 1.0 mmol) and K 2 CO 3 (152 mg, 1.1 mmol) in DMF (5 mL) was added 3-bromopropyne (130 mg, 1.1 mmol) dropwise at rt. The reaction mixture was stirred at rt overnight and then partitioned between water and ethyl acetate. The organic payers were combined and washed with brine, dried over anhydrous Na 2 SO 4 and evaporated under vacuum to give a brown oil. The crude product was purified by silica gel flash chromatography (30% ethyl acetate in hexane) to furnish the title compound (120 mg, 38%) as a light yellow solid; MS; m/z 317 (M+H).
[0074] Step 3:
3-[4-(4-Prop-2-ynyloxy-phenyl)-piperazin-1-yl]-propionic acid sodium salt
[0075] The compound from step 2 (175 mg, 0.55 mmol) was dissolved in methanol (4 mL) followed by addition of 1N NaOH aqueous solution (0.55 ml, 0.55 mmol). The reaction solution was stirred at 60-70° C. for 4 h and then evaporated under vacuum to dryness. The residue was stirred with ethyl acetate (4 mL) and the solid was collected by filtration and washed with ethyl acetate to give the title product as an off-white solid (75 mg, 42%); MS; m/z 289 (M+H).
Example 6
[0076]
[0077] Step 1:
4-But-2-ynyloxy-phenol
[0078] To a solution containing butynyl bromide (1 g, 7.5 mmol), hydroquinone (827 mg, 7.5 mmol), and K2CO3 (1.o4 g, 7.5 mmol) was refluxed for 10 h. Solvent was removed in vacuo and the crude product was dissolved in EtOAc and partitioned with water. Organic layer was separated and washed with water and dried over anhydrous Na2SO4. The solvent was removed in vacuo to obtain the crude product (0.3 g, 25%), which was used for the next step without further purification; LCMS 99%, m/z 162.2 (M + ).
[0079] Step 2:
1-[2-(4-But-2-ynyloxy-phenoxy)-ethyl]-piperidine
[0080] To a solution of the product from step 1 (200 mg, 1.23 mmol) in MeOH (10 mL) was added piperidine ethyl chloride hydrochloride (227 mg, 1.23 mmol), and K2CO3 (679 mg, 4.92 mmol), and the resulting mixture was refluxed for 10 h. Solvent was removed in vacuo and the crude product was dissolved in EtOAc and partitioned with water. Organic layer was separated and dried over anhydroua Na2SO4. Solvent was removed in vacuo to obtain a thick oil, which was added 2M HCl in ether. Solvent was decanted and the solid was triturated with ether to obtain the title product (100 mg, 30%); MS m/z 274.4 (M+H) 99%: 1 H NMR (DMSO-d 6 , 400 MHz) δ 1.39 (1H, m), 1.67-1.82 (8H, m), 2.97 (2H, m), 3.41-3.50 (1H, m), 3.75 (1H, br m), 4.31 (2H, d, J=5.2 Hz), 4.67 (2H, s).
[0081] In these reactions, it is also possible to make use of variants that are in themselves known, but are not mentioned here. The starting materials are either commercially available, synthesized as described in the examples or may be obtained by the methods well known to persons of skill in the art.
[0082] LTA4H inhibitors have been shown to be effective anti-inflammatory agents in pre-clinical studies. For example, oral administration of LTA4H inhibitor SC57461 to rodents resulted in the inhibition of ionophore-induced LTB4 production in mouse blood ex vivo, and in rat peritoneum in vivo (Kachur et al., 2002, J. Pharm. Exp. Ther. 300(2), 583-587). Furthermore, eight weeks of treatment with the same inhibitor compound significantly improved colitis symptoms in a primate model (Penning, 2001, Curr. Pharm. Des. 7(3): 163-179). The spontaneous colitis that develops in these animals is very similar to human IBD. Therefore persons of skill in the art accept that positive results in LTA4H models are predictive of therapeutic utility in this and other human inflammatory diseases.
[0083] The inflammatory response is characterized by pain, increased temperature, redness, swelling, or reduced function, or by a combination of two or more of these symptoms. The terms inflammation, inflammatory diseases or inflammation-mediated diseases or conditions include, but are not limited to, acute inflammation, allergic inflammation, and chronic inflammation.
[0084] Autoimmune diseases are associated with chronic inflammation. There are about 75 different autoimmune disorders known that may be classified into two types, organ-specific (directed mainly at one organ) and non-organ-specific (affecting multiple organs).
[0085] Examples of organ-specific autoimmune disorders are insulin-dependent diabetes (Type I) which affects the pancreas, Hashimoto's thyroiditis and Graves' disease which affect the thyroid gland, pernicious anemia which affects the stomach, Cushing's disease and Addison's disease which affect the adrenal glands, chronic active hepatitis which affects the liver; polycystic ovary syndrome (PCOS), celiac disease, psoriasis, inflammatory bowel disease (IBD) and ankylosing spondylitis.
[0086] Examples of non-organ-specific autoimmune disorders are rheumatoid arthritis, multiple sclerosis, systemic lupus and myasthenia gravis.
[0087] Furthermore, the compounds, compositions and methods of the present invention are useful in treating cancer. Leukotriene synthesis has been shown to be associated with different types of cancer including esophageal cancer, brain cancer, pancreatic cancer, and colon cancer.
[0088] The terms “methods of treating or preventing” mean amelioration, prevention or relief from the symptoms and/or effects associated with lipid disorders. The term “preventing” as used herein refers to administering a medicament beforehand to forestall or obtund an acute episode. The person of ordinary skill in the medical art (to which the present method claims are directed) recognizes that the term “prevent” is not an absolute term. In the medical art it is understood to refer to the prophylactic administration of a drug to substantially diminish the likelihood or seriousness of a condition, and this is the sense intended in applicants' claims. As used herein, reference to “treatment” of a patient is intended to include prophylaxis. Throughout this application, various references are referred to. The disclosures of these publications in their entireties are hereby incorporated by reference as if written herein.
[0089] The term “mammal” is used in its dictionary sense. Humans are included in the group of mammals, and humans would be the preferred subjects of the methods of.
[0090] While it may be possible for the compounds of the formula above to be administered as the raw chemical, it is preferable to present them as a pharmaceutical composition. According to a further aspect, the present invention provides a pharmaceutical composition comprising a compound of formula shown above, or a pharmaceutically acceptable salt or solvate thereof, together with one or more pharmaceutically carriers thereof and optionally one or more other therapeutic ingredients. The carrier(s) must be “acceptable” in the sense of being compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
[0091] The formulations include those suitable for oral, parenteral (including subcutaneous, intradermal, intramuscular, intravenous and intraarticular), rectal and topical (including dermal, buccal, sublingual and intraocular) administration. The most suitable route may depend upon the condition and disorder of the recipient. The formulations may conveniently be presented in unit dosage form and may be prepared by any of the methods well known in the art of pharmacy. All methods include the step of bringing into association a compound of the formula above or a pharmaceutically acceptable salt or solvate thereof (“active ingredient”) with the carrier, which constitutes one or more accessory ingredients. In general, the formulations are prepared by uniformly and intimately bringing into association the active ingredient with liquid carriers or finely divided solid carriers or both and then, if necessary, shaping the product into the desired formulation.
[0092] Formulations of the present invention suitable for oral administration may be presented as discrete units such as capsules, cachets or tablets each containing a predetermined amount of the active ingredient; as a powder (including micronized and nanoparticulate powders) or granules; as a solution or a suspension in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid emulsion or a water-in-oil liquid emulsion. The active ingredient may also be presented as a bolus, electuary or paste.
[0093] A tablet may be made by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active ingredient in a free-flowing form such as a powder or granules, optionally mixed with a binder, lubricant, inert diluent, lubricating, surface active or dispersing agent. Molded tablets may be made by molding in a suitable machine a mixture of the powdered compound moistened with an inert liquid diluent. The tablets may optionally be coated or scored and may be formulated so as to provide sustained, delayed or controlled release of the active ingredient therein.
[0094] The pharmaceutical compositions may include a “pharmaceutically acceptable inert carrier”, and this expression is intended to include one or more inert excipients, which include starches, polyols, granulating agents, microcrystalline cellulose, diluents, lubricants, binders, disintegrating agents, and the like. If desired, tablet dosages of the disclosed compositions may be coated by standard aqueous or nonaqueous techniques, “Pharmaceutically acceptable carrier” also encompasses controlled release means.
[0095] Compositions of the present invention may also optionally include other therapeutic ingredients, anti-caking agents, preservatives, sweetening agents, colorants, flavors, desiccants, plasticizers, dyes, and the like. Any such optional ingredient must, of course, be compatible with the compound of the invention to insure the stability of the formulation. The dose range for adult humans is generally from 0.1 μg to 10 g/day orally. Tablets or other forms of presentation provided in discrete units may conveniently contain an amount of compound of the invention which is effective at such dosage or as a multiple of the same, for instance, units containing 0.1 mg to 500 mg, usually around 5 mg to 200 mg. The precise amount of compound administered to a patient will be the responsibility of the attendant physician. However, the dose employed will depend on a number of factors, including the age and sex of the patient, the precise disorder being treated, and its severity. The frequency of administration will depend on the pharmacodynamics of the individual compound and the formulation of the dosage form, which may be optimized by methods well known in the art (e.g. controlled or extended release tablets, enteric coating etc.).
[0096] Combination therapy can be achieved by administering two or more agents, each of which is formulated and administered separately, or by administering two or more agents in a single formulation. Other combinations are also encompassed by combination therapy. For example, two agents can be formulated together and administered in conjunction with a separate formulation containing a third agent. While the two or more agents in the combination therapy can be administered simultaneously, they need not be. For example, administration of a first agent (or combination of agents) can precede administration of a second agent (or combination of agents) by minutes, hours, days, or weeks. Thus, the two or more agents can be administered within minutes of each other or within any number of hours of each other or within any number or days or weeks of each other. In some cases even longer intervals are possible.
[0097] While in many cases it is desirable that the two or more agents used in a combination therapy be present in within the patient's body at the same time, this need not be so. Combination therapy can also include two or more administrations of one or more of the agents used in the combination. For example, if agent X and agent Y are used in a combination, one could administer them sequentially in any combination one or more times, e.g., in the order X-Y-X, X-X-Y, Y-X-Y, Y-Y-X, X-X-Y-Y, etc.
[0098] As LTA4H inhibitors, the compounds of formula above have utility in treating and preventing inter alia inflammation. The compounds and compositions can be used advantageously in combination with other agents useful in treating and preventing inflammatory conditions and for treating and preventing atherosclerosis, thrombosis, stroke, acute coronary syndrome, stable angina, peripheral vascular disease, critical leg ischemia, intermittent claudication, abdominal aortic aneurysm and myocardial infarction.
[0000] Assays to Determine Potency of LTA 4 Hydrolase Inhibitors
[0099] (1) In vitro assay testing inhibitory activity against purified recombinant human LTA 4 hydroase:
[0100] A human LTA 4 hydrolase full-length cDNA clone (NM — 000895) was purchased from OriGene Technologies (Rockville, Md.). The gene was amplified by polymerase chain reaction and transferred via pDONR201 into the bacterial expression vector pDEST17 by recombination (both plasmids from Invitrogen, Carlsbad, Calif.). The resulting construct was transformed into Escherichia coli BL21-AI (Invitrogen), and expression was induced by chemical induction with arabinose. The recombinant enzyme was purified by chromatography on a FPLC system (Amersham Biosciences, Uppsala, Sweden) using immobilized metal affinity chromatography (Ni-NTA Superflow, Qiagen, Hilden, Germany) and anion exchange chromatography (MonoQ HR 10/10, Amersham Biosciences).
[0101] The compounds of the invention were incubated in a series of dilutions with 200 nM of recombinant enzyme in assay buffer (100 mM Tris-HCl, 100 mM NaCl, 5 mg/ml fatty-acid free BSA, 10% DMSO, pH 8.0) for 10 min at room temperature to allow binding between LTA 4 hydrolase and the inhibitors. LTA 4 was prepared by alkaline hydrolysis of LTA 4 methyl ester (Biomol, Plymouth Meeting, Pa., or Cayman Chemicals, Ann Arbor, Mich.). A solution of 10 μg of the ester was dried under a nitrogen stream and redissolved in 60 μl of a solution of 80% aceton and 20% 0.25 M NaOH. After incubation for 40 min at room temperature the resulting approximately 500 μM tock of LTA 4 was kept at −80° C. for no more than a few days prior to use.
[0102] Immediately before the assay, LTA 4 was diluted to a concentration of 10 μM in assay buffer (without DMSO) and added to the reaction mixture to a final concentration of 2 μM to initiate the enzyme reaction. After incubation for 120 sec at room temperature, the reaction was stopped by adding 2 volumes of chilled quenching buffer, containing acetonitril with 1% acetic acid and 225 nM LTB 4 -d 4 (Biomol). The samples were then kept at 4° C. over night to complete protein precipitation and centrifuged for 15 min at 1800 g. LTB 4 formed was measured by LC-MS/MS using LTB 4 -d 4 as an internal standard and an external LTB 4 standard (Biomol) as reference. Briefly, the analyte was separated from LTB 4 isomers formed by spontaneous hydrolysis of LTA 4 using isocratic elution (modified protocol from Mueller et al. (1996), J. Biol. Chem. 271, 24345-24348) on a HPLC system (Waters, Milford, Mass.) and analyzed on a tandem quadrupole mass spectrometer (Waters). MRM transitions followed on 2 channels were 335.2>195.3 (LTB 4 ) and 339.2>197.3 (LTB 4 -d 4 ). Based on the amounts of LTB 4 found at each inhibitor concentration, a dose-response curve was fitted to the data and an IC 50 value was calculated.
structure example IC50 (uM) 1 B 2 A 3 A 4 B 5 B 6 B A = <5 uM, B = 5-20 uM, C = 20-30 uM
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A chemical genus of biphenyl heterocycle derivative inhibitors of LTA4H (leukotriene A4 hydrolase) of the formula:
is disclosed. In these compounds Q and Z are (CH 2 ) 1-10 ; in which one or two (CH 2 ) may optionally be replaced by —O—, —NR 1 —, —SO—, —S(O) 2 —, —C(═O)— or —C═O(NH)—; Het is a 5-7 membered non-aromatic nitrogen heterocycle; and W is acyl, hydroxyl, carboxyl, amino, carboxamido, aminoacyl, —COOalkyl, —CHO, heterocyclyl, substituted aryl, or substituted heterocyclyl, or taken together ZW can be H or —COOalkyl. The compounds are useful for the treatment and prevention and prophylaxis of inflammatory diseases and disorders.
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This application is a divisional of U.S. patent application Ser. No. 10/722,460, filed Nov. 28, 2003, now U.S. Pat. No. 7,071,540.
BACKGROUND OF THE INVENTION
This non-provisional application claims priority under 35 U.S.C. § 119(a) from Korean Patent Application No. 2003-44119 filed on Jul. 1, 2003, the subject matter of which is herein incorporated by reference.
FIELD OF THE INVENTION
The present invention generally relates to siloxane-based resins and semiconductor interlayer insulating films using the same. More specifically, the present invention is directed to siloxane-based resins having a new structure, which is used to prepare a semiconductor interlayer insulating film.
DESCRIPTION OF THE RELATED ART
As the circuit density of multilevel integrated circuit devices increases, the performances of devices come to depend on a line rate. So, it needs reducing the capacitances of interlayer insulating films of the devices revealed methods to decrease the resistance and capacity of the line. Specifically, U.S. Pat. Nos. 3,615,272; 4,399,266; 4,756,977 and 4,999,397 disclose the formation of insulating films by the SOD (spin on deposition) method using polysilsesquioxanes having a dielectric constant of 2.5-3.1 as well as good planarization properties.
The hydrosilsesquioxanes as well as preparation methods thereof are well known in the art. For Example, U.S. Pat. No. 3,615,272 discloses a method of preparing a completely condensed, soluble hydrogensilsesquioxane resin, which comprises the steps of condensing trichlorosilanes in a sulfuric acid medium and washing the resulting resin with water or aqueous sulfuric acid. Also, U.S. Pat. No. 5,010,159 discloses a method of synthesizing a soluble condensed hydridosilicon resin, which includes the steps of hydrolyzing hydridosilanes in an arylsulfuric acid hydrate-containing a hydrolysis medium and contacting the resulting resin with a neutralizing agent. U.S. Pat. No. 6,232,424 describes a highly soluble silicon resin composition having excellent solution stability, which was prepared by hydrolyzing and polycondensing tetraalkoxysilane, organosilane and organotrialkoxysilane monomers in the presence of water and a catalyst. U.S. Pat. No. 6,000,339 describes that a silica-based compound is useful for improving the resistance to oxygen plasma and physical properties as well as thickness of a coating film, which can be obtained through reacting a monomer selected from the group consisting of alkoxysilane, fluorine-containing alkoxysilane and alkylalkoxysilane with a titanium- or zirconium-alkoxide compound in the presence of water and a catalyst. U.S. Pat. No. 5,853,808 describes that siloxane and silsesquioxane polymers, useful for forming SiO 2 -rich ceramic coatings, can be obtained from hydrolysis and polycondensation of organosilanes having a β-substituted alkyl group. Meanwhile, EP 0 997 497 A1 discloses that hydrolyzation and polycondensation of a certain combination of alkoxysilanes including mono-, di-, tri-, tetraalkoxysilane and trialkoxysilane dimers can provide resinous materials for insulating films.
SUMMARY OF THE INVENTION
The present invention features the production of a siloxane-based resin having excellent mechanical properties as well as very low dielectric constant, and the formation of a low dielectric insulating film using the siloxane-based resin.
One aspect of the present invention relates to a siloxane-based resin that is prepared by hydrolyzing and condensing a silane-based monomer having a radial structure of Formula 1 and at least one monomer selected from the group consisting of the compounds of Formulas 2 to 4, in organic solvent in the presence of an acid or alkaline catalyst with water:
Si[(CH 2 ) k SiY 1 Y 2 Y 3 ] 4 Formula 1
wherein, k is an integer of 1-10; and Y 1 , Y 2 and Y 3 are independently a C 1 -C 3 alkyl group, a C 1 -C 10 alkoxy group, or a halogen atom, provided that at least one of them is hydrolysable,
wherein,
R 1 is a C 1 -C 3 alkyl group, or a C 6 -C 15 aryl group;
X 1 , X 2 and X 3 are independently a hydrogen atom, a C 1 -C 3 alkyl group, a C 1 -C 10 alkoxy group, or a halogen atom, provided that at least one of them is hydrolyzable;
m is an integer of 0-10; and
p is an integer of 3-8,
wherein, R 2 is a C 1 -C 3 alkyl group, or a C 6 -C 15 aryl group;
X 4 is a hydrogen atom, or a C 1 -C 10 alkoxy group;
Y 1 is a hydrogen atom, a C 1 -C 3 alkyl group or a C 1 -C 10 alkoxy group; and
n is an integer of 0-10, and
R 3 SiX 5 X 6 X 7 Formula 4
wherein, R 3 is a C 1 -C 3 alkyl group, or a C 6 -C 15 aryl group; X 5 , X 6 and X 7 are independently a hydrogen atom, a C 1 -C 3 alkyl group, a C 1 -C 10 alkoxy group, or a halogen atom, provided that at least one of them is hydrolyzable.
Another aspect of the present invention relates to a method of forming a semiconductor interlayer insulating film, comprising the step of: providing a resin solution by dissolving the siloxane-based resin in an organic solvent; coating a silicon wafer with the resin solution; and heat-curing the resulting coating film.
Still another aspect of the present invention relates to an interlayer insulating film made using the above siloxane-based resin.
The present invention provides a siloxane-based resin with superior solubility through the condensation of a radial silane-based monomer of Formula 1 and at least one compound selected from the group consisting of compounds of Formulas 2 to 4.
The siloxane-based resin has a dielectric constant of 3.0 or less so that it is suitable for application as a low dielectric coating film.
Also, the present invention provides the method of preparing an insulating film by coating a silicon wafer with a solution containing the above siloxane-based resin in an organic solvent and heat-curing the resulting coating film.
According to the present invention, the combined use of a porogen with the inventive siloxane-based resin may further lower the dielectric constant of the final insulating film down to 2.50 or less. The present invention is represented by:
Si[(CH 2 ) k SiY 1 Y 2 Y 3 ] 4 Formula 1
wherein, k is an integer of 1-10; and Y 1 , Y 2 and Y 3 are independently a C 1 -C 3 alkyl group, a C 1 -C 10 alkoxy group, or a halogen atom, provided that at least one of them is hydrolyzable,
wherein,
R 1 is a C 1 -C 3 alkyl group, or a C 6 -C 15 aryl group;
X 1 , X 2 and X 3 are independently a hydrogen atom, a C 1 -C 3 alkyl group, a C 1 -C 10 alkoxy group, or a halogen atom, provided that at least one of them is hydrolyzable;
m is an integer of 0-10; and
p is an integer of 3-8,
wherein,
R 2 is a C 1 -C 3 alkyl group, or a C 6 -C 15 aryl group;
X 4 is a hydrogen atom, or a C 1 -C 10 alkoxy group;
Y 1 is a hydrogen atom, a C 1 -C 3 alkyl group or a C 1 -C 10 alkoxy group; and
n is an integer of 0-10, and
R 3 SiX 5 X 6 X 7 Formula 4
wherein,
R 3 is a C 1 -C 3 alkyl group, or a C 6 -C 15 aryl group;
X 5 , X 6 and X 7 are independently a hydrogen atom, a C 1 -C 3 alkyl group, a C 1 -C 10 alkoxy group, or a halogen atom, provided that at least one of them is hydrolyzable.
In the preparation of the above siloxane-based resin, the monomer of Formula 1 and the monomer selected from the group consisting of the compounds represented by Formulas 2 to 4 are mixed in a molar ratio of 1:99 to 99:1.
Preferable acid or base catalysts for the preparation of the inventive siloxane-based resin can be exemplified by, but are not limited to, hydrochloric acid, nitric acid, benzene sulfonic acid, oxalic acid, formic acid, potassium hydroxide, sodium hydroxide, triethylamine, sodium bicarbonate and pyridine. Such a catalyst is used so that molar ratio of the catalyst to the monomers is 0.000001:1-10:1.
The amount of water used in the preparation of the inventive siloxane-based resin is 1-1000 mol per 1 mol of the monomers, so that molar ratio of water to the monomers is 1:1-1000:1.
Non-limiting Examples of the organic solvent used in the preparation of the inventive siloxane-based resin include aliphatic hydrocarbon solvents such as hexane; aromatic hydrocarbon solvents such as anisole, mesitylene and xylene; ketone-based solvents such as methyl isobutyl ketone, 1-methyl-2-pyrrolidinone, cyclohexanone and acetone; ether-based solvents such as tetrahydrofuran and isopropyl ether; acetate-based solvents such as ethyl acetate, butyl acetate and propylene glycol methyl ether acetate; alcohol-based solvents such as isopropyl alcohol and butyl alcohol; amide-based solvents such as dimethylacetamide and dimethylformamide; silicon-based solvents; and mixtures thereof
According to the present invention, the hydrolysis and polycondensation reaction is carried out at a temperature of 0-200° C., preferably 50-110° C., for 0.1-100 hrs, preferably 5-48 hrs.
The siloxane-based resin thus prepared has Mw of 3,000-300,000. The Si—OR content in the entire terminal groups preferably amounts to more than 5 mol %.
The present invention also provides a method of forming an interlayer insulating film for a semiconductor device using the inventive siloxane-based resin.
The insulating film has a low dielectric property below 3.0 and shows excellent mechanical and heat resistance properties. According to the present invention, such an insulating film can be obtained by coating a silicon wafer with a solution containing the inventive siloxane-based resin in an organic solvent and heat-curing the resulting coating film. That is, the inventive siloxane-based resin dissolved in an organic solvent is applied onto a substrate. Then, the organic solvent is evaporated through simple air-drying or by subjecting the substrate, at the beginning or following the heat-curing step, to a vacuum condition or to mild heating at a temperature of 200° C. or less, so that a resinous coating film can be deposited on the surface of the substrate. Thereafter, the resinous coating film is cured by heating the substrate at a temperature of 150-600° C., preferably 200-450° C., for 1-150 minutes, so as to provide an insoluble, crack-free film. As used herein, by “crack-free film” is meant a film without any cracks that can be observed with an optical microscope at a magnification of 1000×. As used herein, by “insoluble film” is meant a film that is substantially insoluble in any solvent described as being useful for dissolving the inventive siloxane-based resin.
According to the present invention, the combined use of a porogen with the inventive siloxane-based resin may further lower the dielectric constant of the final insulating film down to 2.50 or less. As used herein, by “porogen” is meant any pore-generating compounds. In case of using a porogen, an additional step is required of heating the resinous film over the decomposition temperature of the porogen so that the porogen can be decomposed.
The porogen used in the present invention may be any of the pore-generating compounds well know in the art, which can be exemplified by, but are not limited to, cyclodextrin, polycaprolactone, and derivatives thereof. The porogen is mixed in content of 1-70 wt %, based on a solid content of the siloxane-based resin.
Preferred organic solvents for the dissolution of the siloxane-based resin or the porogen to provide a liquid coating composition can be exemplified by, but are not limited to, aliphatic hydrocarbon solvents such as hexane; aromatic hydrocarbon solvents such as anisole, mesitylene and xylene; ketone-based solvents such as methyl isobutyl ketone, 1-methyl-2-pyrrolidinone, cyclohexanone and acetone; ether-based solvents such as tetrahydrofuran and isopropyl ether; acetate-based solvents such as ethyl acetate, butyl acetate and propylene glycol methyl ether acetate; alcohol-based solvents such as isopropyl alcohol and butyl alcohol; amide-based solvents such as dimethylacetamide and dimethylformamide; silicon-based solvents; and mixtures thereof.
In the preparation of the liquid coating composition, the weight ratio of solid component containing the siloxane-based resin and the porogen is preferably 5-70 wt % based on the total composition. The organic solvent should be used in an amount sufficient to apply the solid components including the siloxane-based resin and the porogen evenly to the surface of a wafer. Thus, the organic solvent should amount to 20-99.9 wt %, preferably 70-95 wt % of the liquid coating composition. If the organic solvent content of the liquid coating composition is less than 20 wt %, part of the siloxane-based resin remains undissolved. On the other hand, if the organic solvent content is more than 99.9 wt %, the final resinous film is as thin as 1000 Å or less.
In the present invention, the liquid coating composition thus prepared can be applied to a silicon wafer according to various coating methods well known in the art. Non-limiting Examples of the coating method useful in the present invention include spin-coating, dip-coating, spray-coating, flow-coating and screen-printing, while spin-coating is most preferred.
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.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in more detail with reference to the following Examples. However, these Examples are given for the purpose of illustration only and should not to be construed as limiting the scope of the present invention.
EXAMPLE 1
Synthesis of Monomer
EXAMPLE 1-1
Synthesis of Monomer (A)
Monomer (A)
Si[CH 2 CH 2 SiCH 3 (OCH 3 )] 4
73.384 mmol (10.0 g) of tetravinylsilane and 0.2 g of platinum (0)-1,3-divinyl-1,1,3,3-tetramethyldisiloxane complex (solution in xylene) are introduced into a flask, and then diluted with 300 ml of tetrahydrofuran. Next, the flask is cooled to −78° C., and 322.888 mmol (37.145 g) of dichloromethylsilane is slowly added thereto, after which the reaction temperature is gradually elevated to room temperature. The reaction is continued at room temperature for 40 hours, and then volatile materials are removed from the reaction mixture under a reduced pressure of about 0.1 torr. To the reaction mixture is added with 100 ml of hexane and stirred for 1 hour, followed by filtering through celite to afford a colorless, clear solution. And then, hexane is removed from the resulting solution under a reduced pressure of 0.1 torr, to afford a liquid compound represented by the following Formula:
Si[CH 2 CH 2 SiCH 3 Cl 2 ] 4
16.778 mmol (10.0 g) of the above liquid compound is diluted with 500 ml of tetrahydrofuran, to which 150.999 mmol (15.28 g) of triethylamine is added. Then, the reaction temperature is cooled to −78° C., and 150.999 mmol (4.83 g) of methylalcohol is slowly added to the reaction solution, after which the reaction temperature is gradually elevated to room temperature. The reaction is continued at room temperature for 15 hrs, followed by filtering through celite, and then volatile materials are evaporated from the filtrate under reduced pressure of about 0.1 torr.
To the resulting solution is added 100 ml of hexane, and stirred for 1 hour, followed by filtering through the celite. Filtrate obtained from the filtration of the stirred solution is subjected to a reduced pressure to remove hexane therefrom and afford monomer (A) as a colorless liquid. The results obtained from NMR analysis of this monomer dissolved in CDCl 3 , are as follows:
1 H NMR(300 MHz) data; δ 0.09 (s, 12H, 4×-CH 3 ), 0.48-0.54 (m, 16H, 4×-CH 2 CH 2 —), 3.53 (s, 48H, 4×-[OCH 3 ] 8 )
EXAMPLE 1-2
Synthesis of Monomer (B)
Monomer (B)
29.014 mmol (10.0 g) of 2,4,6,8-tetramethyl-2,4,6,8-tetravinylcyclotetrasiloxane and 0.164 g of platinum (0)-1,3-divinyl-1,1,3,3-tetramethyldisiloxane complex (solution in xylene) are introduced into a flask, and then diluted with 300 ml of diethyl ether. Next, the flask is cooled to −78° C., and 127.66 mmol (17.29 g) of trichlorosilane is slowly added thereto, after which the reaction temperature is gradually elevated to room temperature. At room temperature, the reaction is continued for 40 hours, and then the volatile material is removed from the reaction mixture under a reduced pressure of 0.1 torr. To the resulting solution is added 100 ml of hexane, and stirred for 1 hour, and filtered through celite. Filtrate obtained from the filtration of the stirred solution is subjected to a reduced pressure to remove hexane therefrom under a reduced pressure of 0.1 torr, to afford a liquid compound represented by the following Formula:
11.28 mmol (10.0 g) of the above liquid compound is diluted with 500 ml of tetrahydrofuran, to which 136.71 mmol (13.83 g) of triethylamine is added. Then, the reaction temperature is cooled to −78° C., and 136.71 mmol (4.38 g) of methylalcohol is slowly added to the reaction solution, after which the reaction temperature is gradually elevated to room temperature. The reaction is continued at room temperature for 15 hours, and the reaction solution is filtered through celite. The volatile material is removed from the reaction mixture under a reduced pressure of 0.1 torr. To the remaining filtrate is added 100 ml of hexane and stirred for 1 hr, followed by filtering through celite. To the obtained filtrate is further added 5 g of activated carbon, and stirred for 10 hours, followed by filtering through celite. From the filtrate is then removed hexane under a reduced pressure to afford a colorless liquid monomer (B). The results obtained from NMR analysis of this monomer dissolved in CDCl 3 are as follows:
1 H NMR(300 MHz) data; δ 0.09 (s, 12H, 4×-CH 3 ), 0.52-0.64 (m, 16H, 4×-CH 2 CH 2 —), 3.58 (s, 36H, 4×-[OCH 3 ] 3 )
EXAMPLE 1-3
Synthesis of Siloxane-Based Monomer (C)
Monomer (C)
249.208 mmol (10.0 g) of 1,3-dichlorotetramethyldisiloxane is introduced into a flask, and then diluted with 500 ml of tetrahydrofuran. Next, the flask is cooled to −78° C., and 108.212 mmol (10.95 g) of triethylamine is added thereto. And then, 107.990 mmol (3.46 g) of methyl alcohol are slowly added to the flask, after which the reaction temperature is gradually elevated to room temperature. The reaction is continued at room temperature for 15 hours, and the reaction solution is filtered through celite. The volatile material is removed from the filtrate under a reduced pressure of 0.1 torr. To the remaining filtrate is added 100 ml of hexane, and stirred for 1 hour, followed by filtering through celite. And then, from the filtrate the hexane is removed under a reduced pressure to produce a colorless liquid. Colorless liquid monomer (C) is obtained from simple distillation of the liquid. The results obtained from NMR analysis of this monomer dissolved in CDCl 3 are as follows:
1 H NMR(300 MHz) data; δ 0.068(s, 12H, 4×-CH 3 ), 3.45(s, 6H, 2×-OCH 3 )
EXAMPLE 1-4
Synthesis of Siloxane-Based Monomer (D)
Monomer (D)
A monomer (D) is synthesized in the same manner as in Example 1-2, with the exception that 1,5-dichlorohexamethyltrisiloxane is used, instead of 1,3-dichlorotetramethyldisiloxane.
The results obtained from NMR analysis of the monomer (D) thus prepared and dissolved in CDCl 3 are as follows:
1 H NMR(300 MHz) data; δ 0.068 (s, 12H, 4×-CH 3 ), 0.077 (s, 3H, —CH 3 ), 3.44 (s, 6H, 2×-OCH 3 )
EXAMPLE 1-5
Synthesis of Siloxane-Based Monomer (E)
Monomer (E)
A monomer (E) is synthesized in the same manner as in Example 1-2, with the exception that 1,7-dichlorooctamethyltetrasiloxane is used, instead of 1,3-dichlorotetramethyldisiloxane.
The results obtained from NMR analysis of the monomer (E) thus prepared and dissolved in CDCl 3 are as follows:
1 H NMR(300 MHz) data; δ 0.068(s, 24H, 8×-CH 3 ), 3.45(s, 6H, 2×-OCH 3 )
EXAMPLE 1-6
Siloxane-Based Monomer (F)
Monomer (F)
The monomer (F), purchased from Sigma. Aldrich Co., USA, is used.
EXAMPLE 1-7
Siloxane-Based Monomer (G)
Monomer (G)
CH 3 Si(OCH 3 ) 3
The monomer (G), purchased from Sigma. Aldrich Co., USA, is used.
EXAMPLE 2
Synthesis of Siloxane Resin
The siloxane-based monomer (A) having a radial structure connected with organic groups, and at least one monomer of the monomers (B) through (G) are placed into a flask, and diluted with tetrahydrofuran 15 times as much as the total amounts of the monomers in the flask. Then, the flask is cooled to −78° C. At −78° C., predetermined amounts of hydrochloric acid (HCl) and water are added to the flask, after which the reaction temperature is gradually elevated to 70° C. The reaction is continued at 70° C. for 20 hours. At the completion of the reaction, the reaction mixture is transferred to a separatory funnel, followed by addition of diethylether and tetrahydrofuran as much as the tetrahydrofuran used in the previous dilution of the monomer. Then, 3×washing is conducted, each round with water one tenth as much as the total solution in the separatory funnel. After washing, volatile materials are evaporated from the remaining solution to produce white powdery polymers. The powder is completely dissolved in a small amount of acetone to obtain a clear solution, and this solution is filtered through a 0.2 μm syringe filter so as to remove impurities to provide a clear filtrate, to which is then slowly added deionized water. As a result, white powdery material is formed, which is then separated from the liquid phase (mixed solution of acetone and water) and dried for 10 hrs at a temperature of 0-20° C. under a reduced pressure of about 0.1 Torr to produce a fractionated siloxane-based resin.
TABLE 1
Silox-
ane
Monomer (mmol)
HCl
H 2 O
Final
Resin
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(mmol)
(mmol)
Resin (g)
(a)
8.402
3.599
0.110
368
3.45
(b)
4.798
4.799
0.096
320
2.87
(c)
2.569
5.999
0.098
308
2.95
(d)
10.703
4.587
0.095
316
3.52
(e)
10.703
4.587
0.095
316
3.46
(f)
10.703
4.587
0.095
316
3.35
(g)
10.703
4.587
0.104
578
3.97
(h)
12.487
5.351
0.116
386
3.62
(i)
12.487
12.487
0.138
457
3.56
(j)
10.703
24.973
0.160
534
3.41
(k)
8.919
80.271
0.312
1040
7.52
EXAMPLE 3
Composition Analysis
The respective siloxane-based resins obtained from the above Example 2 are analyzed for Si—OH, Si—OCH 3 , Si—CH 3 content, as described below. The results are set forth in Table 2.
TABLE 2
Siloxane Resin
Si—OH (%)
Si—OCH 3 (%)
Si—CH 3 (%)
(a)
33.9
2.1
64.0
(b)
39.2
1.3
59.5
(c)
35.7
0.8
63.5
(d)
24.9
1.5
73.6
(e)
27.1
1.0
71.9
(f)
27.5
1.0
71.5
(g)
25.9
0.9
73.2
(h)
27.7
6.6
65.7
(i)
21.5
5.1
73.4
(j)
24.9
4.5
70.6
(k)
24.3
2.7
73.0
Note: Si—OH content, Si—OCH 3 content, and Si—CH 3 content were analyzed by use of a nuclear magnetic resonance analyzer(Bruker Co.),and calculated from the following equations:
Si—OH(%) = Area(Si—OH) ÷ [Area(Si—OH) + Area(Si—OCH 3 )/3 + Area(Si—CH 3 )/3] × 100,
Si—OCH 3 (%) = Area(Si—OCH 3 )/3 ÷ [Area(Si—OH) + Area(Si—OCH 3 )/3 + Area(Si—CH 3 )/3] × 100,
Si—CH 3 (%) = Area(Si—CH 3 )/3 ÷ [Area(Si—OH) + Area(Si—OCH 3 )/3 + Area(Si—CH 3 )/3] × 100.
EXAMPLE 4
Measurement of Thickness and Refractive Index of Thin Film
The siloxane-based resins obtained from the above Example 2, and their mixture with heptakis(2,3,6-tri-O-methoxy)-β-cyclodextrin are dissolved in propylene glycol methyl ether acetate (PGMEA), respectively, so that final concentration of the solid matter in the resulting liquid coating compositions is 25 wt %. Each of the coating compositions is then spin-coated onto a silicon wafer for 30 seconds while maintaining the spin rate of 3,000 rpm. In a nitrogen atmosphere, the coated wafers are subjected to the sequential soft baking on a hot plate (1 min at 100° C. and another minute at 250° C.) so as to sufficiently evaporate the organic solvent. Thereafter, the temperature is elevated to 420° C. at a rate of 3° C./min under vacuum condition, at which temperature the coating films are allowed to cure for 1 hr to produce test pieces.
Each of the test pieces thus prepared is analyzed for film thickness and refractive index. The film thickness and the refractive index are measured at 5 different points every test piece by the use of a profiler and a prism coupler, respectively. The mean thickness and refractive index are set forth in Table 3 along with their uniformity.
TABLE 3
Composition of resinous film
Siloxane
Siloxane
Resin
Porogen
Thick.
Refractive
Uniformity
Uniformity of
Resin
(wt %)
(wt %)
(Å)
Index (R.I.)
of R.I. (%)
Thick. (%)
(a)
100
—
10230
1.4460
0.054
1.07
(a)
70
30
9879
1.3374
0.071
0.98
(b)
100
—
10255
1.4494
0.049
0.85
(b)
70
30
10030
1.3369
0.031
0.86
(c)
100
—
9876
1.4393
0.035
0.87
(c)
70
30
9580
1.3375
0.087
0.76
(d)
100
—
11030
1.4275
0.081
0.53
(d)
70
30
10090
1.3417
0.096
0.54
(e)
100
—
10200
1.4245
0.063
0.36
(e)
70
30
10010
1.3417
0.108
0.38
(f)
100
—
10650
1.4324
0.087
0.56
(f)
70
30
10030
1.3655
0.105
0.46
(g)
100
—
11200
1.4240
0.054
0.51
(g)
70
30
11000
1.3490
0.087
0.51
(h)
100
—
11050
1.4211
0.034
1.38
(h)
70
30
10060
1.3366
0.069
1.54
(i)
100
—
9980
1.4174
0.087
1.52
(i)
70
30
9750
1.3371
0.116
1.48
(j)
100
—
11020
1.4145
0.041
1.20
(j)
70
30
10200
1.3317
0.068
0.97
(k)
100
—
10135
1.4077
0.079
1.02
(k)
70
30
9980
1.3371
0.094
0.97
EXAMPLE 5
Measurement of Dielectric Constant
P-type silicon wafers doped with boron are coated with a 3000 Å thermally-oxidized silicon film, followed by sequential deposition of a 100 Å of titanium layer, a 2000 Å of aluminum layer and a 100 Å of titanium layer using a metal evaporator. On the surface of each of these wafers is formed a resinous film in the same manner as in the above Example 4. Subsequently, on the resinous film is deposited a circular electrode of 1 m diameter which consists of a 100 Å-thick titanium layer and a 5000 Å-thick aluminum layer through a hard mask so as to provide a test piece having MIM (metal-insulator-metal) structure. Test pieces thus prepared are subjected to measurement of capacitance at 100 kHz using PRECISION LCR METER (HP4284A) with Micromanipulator 6200 probe station. Dielectric constant of each test film is calculated from the following equation, wherein “d” value was obtained by the use of an ellipsometer:
k=C×d/ε o ×A
wherein,
k: dielectric constant
C: capacitance
ε o : dielectric constant in vacuum
d: the thickness of low dielectric film
A: the contact area of electrode
The calculated dielectric constants are set forth in Table 4.
TABLE 4
Thin Film Composition
Siloxane
Siloxane Resin
Porogen
Dielectric
Resin
(wt %)
(wt %)
Constant
(a)
100
—
2.79
(a)
70
30
2.26
(b)
100
—
2.78
(b)
70
30
2.28
(c)
100
—
2.74
(c)
70
30
2.31
(d)
100
—
2.70
(d)
70
30
2.30
(e)
100
—
2.71
(e)
70
30
2.31
(f)
100
—
2.75
(f)
70
30
2.27
(g)
100
—
2.76
(g)
70
30
2.28
(h)
100
—
2.70
(h)
70
30
2.25
(i)
100
—
2.76
(i)
70
30
2.27
(j)
100
—
2.72
(j)
70
30
2.28
(k)
100
—
2.76
(k)
70
30
2.30
EXAMPLE 6
Measurement of Hardness and Modulus
Test pieces prepared as in the above Example 4 are analyzed for hardness and elastic modulus using Nanoindenter II (MTS Co.). The resinous film of each test piece is indented until the indentation depth reached 10% of its whole thickness. At this time, to secure the reliability of this measurement, 6 points are indented every test piece, and mean hardness and modulus are taken. The results are set forth in Table 5.
TABLE 5
Thin Film Composition
Siloxane Resin
Hardness
Modulus
Siloxane Resin
(wt %)
Porogen (wt %)
(GPa)
(GPa)
(a)
100
—
1.05
5.47
(a)
70
30
0.61
3.15
(b)
100
—
0.97
4.78
(b)
70
30
0.54
2.72
(c)
100
—
0.87
4.33
(c)
70
30
0.41
2.64
(d)
100
—
0.87
3.74
(d)
70
30
0.44
2.37
(e)
100
—
0.90
3.27
(e)
70
30
0.48
2.40
(f)
100
—
0.87
3.84
(f)
70
30
0.42
2.51
(g)
100
—
0.94
3.97
(g)
70
30
0.47
2.60
(h)
100
—
0.76
4.01
(h)
70
30
0.32
2.82
(i)
100
—
0.78
3.87
(i)
70
30
0.34
2.71
(j)
100
—
0.75
3.81
(j)
70
30
0.32
2.55
(k)
100
—
0.76
3.89
(k)
70
30
0.34
2.51
Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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A siloxane-based resin having a novel structure and a semiconductor interlayer insulating film using the same. The siloxane-based resins have a low dielectric constant in addition to excellent mechanical properties and are useful materials in an insulating film between interconnect layers of a semiconductor device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] See Application Data Sheet.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR AS A TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB)
[0004] Not applicable.
STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR
[0005] Not applicable.
BACKGROUND OF THE INVENTION
[0006] 1. Field of the Invention
[0007] The present invention relates to the field of the detection of microorganisms in the growth phase.
[0008] The present invention will find its application primarily in the areas of the industrial and clinical microbiology, for example in the pharmaceutical, biotechnological, agro-food industries or also in the hospitals or medical analysis laboratories.
[0009] The invention relates more particularly to a device permitting an incubation and quick detection of the forming of colonies, from microorganisms present in a sample, at the surface of a membrane or a solid or semi-solid culture medium.
[0010] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
[0011] Many techniques are presently implemented to permit the detection of contaminants, for example bacteria, in a sample to be tested.
[0012] The most conventional and oldest method consists of a deposition on the surface of an agar growth medium, whereby the latter may be more or less selective for one or several types of microorganisms.
[0013] The medium is then incubated at the appropriate temperature for the growth of the micro-organism(s) looked for, for a period that can be of up to several days.
[0014] Such a method has the drawback of requiring a relatively long incubation period in order to permit a detection with the naked eye of the colonies that were formed on the culture medium.
[0015] It is also known from the prior art to perform a polymerization chain reaction, also referred to as PCR, in order to determine the presence of specific microorganisms within a sample, by amplifying a DNA or RNA sequence.
[0016] These methods have the disadvantage of requiring several DNA strands, i.e. several contaminating microorganisms, generally at least several dozens of micro-organisms. Such methods are therefore often less sensitive than the growth-based methods.
[0017] Also known is the possibility of using techniques consisting in marking the microorganisms so as to emphasize the contrast between the light emitted by the microorganisms and that emitted by the growth medium. The use of fluorescent viability markers such as CFDA (carboxyfluorescein diacetate) or non-fluorescent viability markers such as the TTC (tetrazolium chloride), or also of enzymes permitting to reveal the bioluminescence emitted for example by the ATP (adenosine triphosphate), permit an early detection of microorganisms, thanks to the use of optical systems sensitive to the characteristics of the emitted light, for example the wavelength or intensity.
[0018] Thus known is namely the United States patent application US 2003/0155528 that describes a method for detecting microorganisms, in which the latter are marked by suitable fluorescent reagents (such as fluorescein) permitting, on the one hand, to determine the amount microorganisms and, on the other, to judge whether they are viable or dead cells.
[0019] However, these techniques can prove cumbersome to be implemented and require the use of often expensive reagents and the presence of skilled labor forces. Moreover, they are not very suitable for detecting contaminants on a large number of samples, the marking operation being often difficult to be automated. In addition, these techniques have a risk of contamination of the sample. Indeed, the addition of reagents requires contacting said reagent with the microorganisms to be detected and is generally performed by opening the box containing the agar medium. Finally, contacting the reagent with the microorganisms has the risk of destructing the living cells forming a colony, especially when they are in early stages of growth (typically less than 100 cells).
[0020] From the prior art are also known methods based on a use of the light properties emitted naturally by microorganisms, for example by detecting the auto-fluorescence of said microorganisms. Thus, it is possible to facilitate the distinction of colonies using the contrast existing between the natural fluorescence emitted by said microorganisms and the non-fluorescent medium, on which they have been deposited.
[0021] A method using this principle is namely described in the international patent application WO 03/022999, in which certain optical properties of the colonies, such as auto-fluorescence, are used.
[0022] These techniques indeed permit to facilitate the detection of auto-fluorescent colonies or microorganisms, they then have a better contrast with the membrane or the culture medium. However, the level of naturally generated fluorescence is of a low magnitude, which does not permit to obtain fast detection times compared to a marking with a specific fluorophore, for example. In addition, the spurious emission of natural fluorescence by the culture medium or other particles present in the environment, such as dust, membrane fibers, or plastic particles from the medium, can cause a false positive result.
[0023] Finally, techniques using optical systems with high magnification can be used to visualize colonies in early stages of development: this is the case with microscopes, for example. However, these devices are limited to a detection on small surfaces, generally smaller than 1 mm2. Thus, the implementation of this type of techniques for the detection of one or more detection media, such as membranes or agar media, proves both long, of about several minutes per cm2, and expensive, due to the necessity of using scanning systems.
[0024] Also known from the prior art is patent WO 2013/110734, which provides a device for an early detection, and which can be automated, of the appearance of colonies on the surface of a growth medium, namely a membrane or an agar culture medium.
[0025] More particularly, in this device can be found a detection surface, on which rests a growth medium, for example a membrane or an agar medium, and a detection system, such as a linear scanner. This system includes at least one CCD sensor associated with an optical system.
[0026] This device is particularly interesting, because it namely permits to omit the use of expensive optical equipment or reagents. In addition, such a device permits to avoid any contamination by other microorganisms or particles, because the samples do not need to be moved during incubation, since the detection system is mobile.
[0027] However, it has been found that such a detection device, though very performant per se, could be further improved in its performance. It was also found that the developments made to such a detection device could also improve the performances of the incubation and detection devices that do not use a linear scanner, for example.
BRIEF SUMMARY OF THE INVENTION
[0028] To this end, the present invention relates to a device for the incubation and quick detection without fluorescence measurement of colonies resulting from the multiplication of microorganisms present in a sample to be tested, comprising:
[0029] a heating means,
[0030] a detection surface, on which is stationary arranged at least one receptacle closed with a transparent cover, in which a microorganism growth medium in the form of colonies is placed, this medium being of the type membrane or agar,
[0031] a detection system, comprising an optical system permitting to visualize said colonies.
[0032] Said device is characterized in that it includes in addition a system for preventing the formation of condensation in said receptacle, which comprises a means for regulating the temperature, comprised of:
[0033] a first temperature sensor operating above said receptacle,
[0034] a second temperature sensor operating below said receptacle,
[0035] said heating means, which acts above said receptacle,
[0036] a cooling means acting below said receptacle, and
[0037] management means capable of collecting and analyzing the information collected by said sensor means, and of controlling said heating and cooling means so as to generate the desired incubation temperature, on the one hand, and to permanently apply a temperature gradient onto the surface of said receptacle, on the other hand.
[0038] Advantageously, but not limited to, the detection system is of the linear scanner type and mounted flat to scan all or part of said surface, comprising at least one CCD or CMOS sensor, which is associated with an optical system comprised of at least one lighting and at least one optics, such as a lens.
[0039] The presence of the system for preventing the formation of condensation is particularly advantageous.
[0040] It permits indeed to prevent condensation from forming on the portion of the transparent cover inside the receptacle when the latter is closed. During the incubation of the receptacles, water droplets are indeed likely to form on the surface of the cover inside the receptacle, located on the side of the growth medium, whereby the latter may consist of a membrane placed on an agar medium or of only an agar medium, for example.
[0041] Condensation can prove particularly problematic in the systems for detecting colonies. Indeed, it causes the cover of the receptacle to become opaque and thus prevents any detection of microbial growth.
[0042] In the prior art, the solution chosen to be able to read the result on the agar or on the membrane consists in opening the receptacle, by removing the cover on which the condensation droplets are located. However, such a solution cannot be considered adequate, because it is highly likely to result into contamination of the culture medium placed in the receptacle by germs in the environment. It is then possible to get a false positive result, which can prove particularly problematic, even dangerous, namely in a clinical application.
[0043] The detection device according to the present invention, as described above, permits to cope with this problem.
[0044] In addition, the present device is particularly advantageous, because it permits to combine the functions of incubation of the sample and of detection of microorganisms present in said sample.
[0045] Such a combination has many advantages.
[0046] In particular, the analyzed sample is constantly kept at the right temperature, since it does not leave the device, which facilitates the growth of the microorganisms.
[0047] Moreover, such a device permits to avoid the handling errors of the receptacle containing the growth medium, whereby such errors are always possible with a robotic arm of an automated prior-art device. As a result, the risks of contamination of the sample are reduced, even suppressed with the device according to the invention.
[0048] Finally, the device associating the incubation of a sample and the detection of microorganisms also helps to reduce the condensation on the cover of the receptacle.
[0049] In a particular embodiment, the management means permit to apply a temperature gradient of at least 0.10° C. between the inside and the outside of the receptacle.
[0050] Such a temperature gradient permits, in a particularly optimal way, to prevent the formation of condensation at the level of the receptacle.
[0051] It should be noted that preferably the temperature measurement is performed by means of a thermocouple.
[0052] The incubation and detection device according to the invention preferably includes means for adjusting the position of the receptacle or receptacles, and thus of the growth medium or media, relative to the optical system.
[0053] The incubation and detection device according to the invention also includes means for automatically correcting the distance between the optical system of the receptacle or receptacles, and thus of the growth medium or media.
[0054] Such an embodiment permits a constant and accurate positioning of the receptacle relative to the optical system of the detection system, which will facilitate the detection of the colonies that develop on the growth medium, namely by ensuring that it is in the same field depth area of the optical system.
[0055] On the other hand, said incubation and detection device includes means for correcting the orientation of the receptacles, and thus of the growth medium or media, relative to the axis of the optical system.
[0056] This feature constitutes a particularly clever way to cope with the phenomena of optical aberrations that are likely to lead to the formation of images that are distorted. Such phenomena are due to the structure of the scanner. As a result, the growth media appear oval and some areas of said media are then not visible. Therefore, the detection system may not detect some colonies and therefore there is, because of the phenomena of optical aberrations, a significant risk of a false negative result.
[0057] Now, like a false positive result, a false negative result can be dangerous, especially when a patient must be diagnosed in clinical microbiology or the sterility of products such as drugs must be ensured in industrial microbiology.
[0058] Thus and advantageously, in the incubation and detection device according to the invention, each of the receptacle or receptacles rests on the detection surface through wedging means capable of inclining said receptacle and of providing same with the most favorable orientation relative to the optical system, depending on the position occupied by the receptacle during the detecting operation.
[0059] In an advantageous embodiment, the detection surface consists of a drawer slidably mounted in said device, capable of passing from an open position for receiving the closed receptacle or receptacles, to a closed position, in which a scanning of said receptacle or receptacles and thus of the growth medium or media can be performed by the detection system, said media being arranged directly in said drawer.
[0060] Still more advantageously, the receptacle or receptacles are arranged in the drawer through a removable tray.
[0061] Said removable tray is advantageously provided on the periphery and on the lower side with shims designed capable, when the drawer is in the closed position, of cooperating with adjustable depth stops said device includes internally, so as to bring, through lifting, and holding said tray, and thus the receptacle or receptacles it carries, at the right distance from the optical system.
[0062] In this particular embodiment, where the tray can accommodate several receptacles, the detection surface, on which the receptacles are arranged, includes recesses specifically dedicated to these receptacles, the bottom of each of said recesses has a determined inclination relative to the general plane of the tray, depending on the positioning of these recesses on said tray, so as to obtain the desired correction relative to the optical system.
[0063] Such a feature permits to cope with the phenomena of optical aberrations in a particularly satisfactory manner.
[0064] Thus and preferably, the detection surface, on which at least one receptacle is arranged, is configured to provide each of the receptacles with an inclination relative to the optical system.
[0065] Finally and also advantageously, the optical system of the incubation and detection device according to the invention includes a calibration system, which consists of a removable element for the purposes of cleaning and/or replacement.
[0066] Indeed, the detection systems of the linear scanner type need, in order to detect and adjust the level of white when taking pictures, to take a picture on a white strip, referred to as calibration strip, integrated into the detection system.
[0067] In case this calibration strip is soiled, for example by dust, which would be deposited on it, this results into deteriorating the quality of the images taken by the scanner, which have vertical color lines, preventing or potentially delaying the detection of micro-colonies located on these lines.
[0068] A contemplated solution consists in dismantling the entire apparatus in order to clean the white calibration strip. However, this solution is not satisfactory, because it is particularly tedious and long to be carried out. Another solution simply consists in replacing the apparatus in its entirety, which is expensive and environmentally unfriendly.
[0069] The solution provided in the detection device according to the invention permits to solve the problem arisen.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0070] Further features and advantages of the invention will become clear from the detailed description of non-restrictive embodiments of the invention, with reference to the attached figures.
[0071] FIG. 1 schematically shows a perspective view of an incubation and detection device according to the invention.
[0072] FIG. 2 shows a cross-sectional view along a vertical plane of the same detection device.
[0073] FIG. 3 a shows a perspective view of part of the same detection device.
[0074] FIG. 3 b shows a plan view of the same part.
[0075] FIG. 3 c shows a cross-sectional view along the axis AA′ of FIG. 3 b.
DETAILED DESCRIPTION OF THE INVENTION
[0076] When referring to FIG. 1 , we can see a device for incubating and detecting microorganisms according to the invention. It is in the form of a box 1 , provided with a drawer 2 , only the front 20 of which is visible.
[0077] When referring to FIG. 2 , we can see that the device according to the invention includes, inside the box 1 , a detection surface 3 for receiving a receptacle closed by means of a transparent cover, which generally consists of a Petri box, and contains the growth medium for the microorganisms, such as a membrane or an agar medium.
[0078] The detection surface 3 is associated with the tray 2 , so that the extraction of drawer 2 permits the loading and unloading of the detection surface 3 .
[0079] The box 1 also contains a detection system 4 , of the linear scanner type, movably mounted above the detection surface 3 when the drawer 2 is closed, so as to be able to scan at least part of the detection surface 3 , and preferably all of said surface 3 .
[0080] The receptacle is held stationary on the detection surface 3 in order to permit the reading of the result.
[0081] Preferably, several receptacles are arranged on the detection surface 3 of the device 1 , so as to permit a simultaneous detection of eventual contaminants in several different samples.
[0082] Thus, the receptacle(s) comprising a growth medium rest stationary on the detection surface 3 , while the detection system 4 is movable in order to permit the detection of the formation of colonies on said growth media. This permits to prevent a movement of the media, which could lead to errors in the results being obtained.
[0083] The detection system 4 preferably includes at least one CCD (Charge-Coupled Device) sensor or CMOS (Complementary Metal Oxide Semiconductor) sensor.
[0084] The CCD or CMOS sensor advantageously has a resolution higher than or equal to 2400 dpi (dots per inch). Yet more preferably, the resolution is higher than or equal to 4800 dpi.
[0085] Such a resolution permits the detection through imaging of colonies present on the growth mediums, agar or membranes, positioned in the receptacles, when said colonies have a diameter smaller than or equal to 100 μm, even smaller than 50 μm, and yet more preferably smaller than or equal to 30 μm, through a useful magnification higher than or equal to 60.
[0086] The detection system 4 advantageously permits to take an image at regular time intervals.
[0087] The CCD or CMOS sensor of the detection system 4 is associated with an optical system comprised of at least one lighting and at least one optics, for example such as a lens. Preferably, the optical system also includes at least one mirror.
[0088] The incubation and detection device according to the invention comprises heating means 6 arranged in the upper portion of the box 1 , above the detection surface 3 , and which consist, non-restrictively, of an aluminum plate 60 associated with an electrical resistor 61 . These heating means 6 are of course designed to maintain within the box 1 the desired incubation temperature.
[0089] The incubation and detection device according to the invention also comprises a system for preventing the formation of condensation. Indeed, as already mentioned above, the formation of condensation disturbs the reading of the surface of the agar or the membrane and does not permit to obtain satisfactory results.
[0090] It is therefore particularly important to solve this problem of formation of condensation that prevents a correct reading of the samples and can affect the accuracy of the results.
[0091] To this end, the system for preventing the formation of condensation includes cooling means 7 arranged in the lower portion of the box 1 , under the drawer 2 and therefore under the detection surface that carries the receptacles.
[0092] It should be noted that these cooling means 7 can preferably consist in Peltier-effect thermoelectric modules.
[0093] The system for preventing the condensation further includes a first temperature sensor 62 , which is positioned above the receptacle or receptacles, and a second temperature sensor 70 arranged below the detection surface 3 , and therefore below the receptacle or receptacles.
[0094] The system for preventing the condensation is complemented with management means that are capable of collecting and analyzing the data or information collected by the first sensor 62 and the second sensor 70 , and capable of controlling the heating 6 and cooling 7 means in order to, on the one hand, generate the desired incubation temperature and, on the other hand, constantly apply a temperature gradient to the surface of the receptacle or receptacles.
[0095] A privileged means for measuring the temperature is obtained by using a thermocouple permitting to measure in a contactless way the surface temperature of the receptacle.
[0096] The application of the temperature gradient will permit, in a particularly advantageous way, to avoid the formation of water droplets on the inner surface of the transparent cover of the receptacle. The reading of the growth of the colonies on the agar medium or the membrane will thus be facilitated.
[0097] In one advantageous embodiment, the temperature gradient applied by means of the system for preventing the condensation is at least 0.10° C.
[0098] This means that the temperature applied at the level of the cover of the receptacle, i.e. above said receptacle, is higher by at least 0.10° C. than the temperature, which is applied at the level of the bottom of the receptacle, i.e. below the latter.
[0099] Preferably, this gradient is between 0.10 and 1° C., and yet more preferably, this gradient is between 0.50 and 1° C.
[0100] Such a gradient is particularly optimal to prevent the formation of condensation on the cover of the receptacle.
[0101] When referring also to FIGS. 3 a , 3 b and 3 c , we can see a tray 8 , which constitutes the detecting surface aimed at receiving the receptacles, not shown.
[0102] This tray 8 is designed removable with respect to the drawer 2 . Thus, the tray 2 includes a frame 21 , partially visible in FIG. 2 , on which the tray 8 can rest by its peripheral edge 80 , or part thereof, when the drawer 2 is maintained extracted from the box 1 .
[0103] The tray 8 also comprises, on the lower side and on the periphery, shims 81 aimed at cooperating with adjustable stops 10 , of the type with a screw, for example, the case 1 includes below the space of evolution of the drawer 2 .
[0104] In operation, during the closing of the drawer 2 , the shims 81 rest against the adjustable stops 10 , and remain there during the incubation and the detections, the tray 8 then being released from the drawer 2 . The adjustment of the stops permits an accurate positioning of the tray 8 , and therefore of the receptacles it carries, relative to the detection system 4 , irrespective of the drawer 2 .
[0105] In FIGS. 3 a , 3 b and 3 c we can see that the tray 8 includes recesses 82 , in this case twelve in number, each aimed at receiving a receptacle, not shown.
[0106] These recesses 82 each consist of a hollow accommodation permitting to wedge the receptacle.
[0107] When referring more particularly to FIG. 3 c , we can see that depending on the position of the recess 82 on the tray 8 , the bottom 83 of the recess 82 has a particular inclination relative to the general plane of the tray 8 . Thus, the median recesses 82 , relative to the XX′ axis of movement of the detecting means relative to the tray 8 , have a bottom 83 parallel to the general plane of the tray 8 , while the side recesses 82 have a bottom 83 inclined towards the central line.
[0108] These configurations permit to avoid the optical aberrations likely to prevent or disturb a detection of the colonies.
[0109] Finally, it should be noted, as can be seen in FIG. 1 , that the detection system, such as a scanner, of the incubation and detection device according to the invention includes a calibration system having the particularity of being an element 9 extractable from the casing 1 , and preferably removable, for the purposes of cleaning and/or replacement.
[0110] The incubation and detection device according to the invention has the advantage, compared to those of the prior art, of a compactness and simplicity of manufacture.
[0111] It also provides the advantage of a possible modularity, since it can be dimensioned for processing a varying number of receptacles, by adjusting the tray 8 for example, but also because several boxes 1 can be stacked and/or juxtaposed, without therefore representing an important space.
[0112] These advantages are essentially due to the detection system being used as well as to how it is implemented. This detection system could however not be as performant without any, or all, of the various above-mentioned features.
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The incubation and detection device includes a heater, a detection surface with at least one receptacle including a growth medium, and a detection system. There is also a system for preventing the formation of condensation in the receptacle, which includes a temperature-control formed by temperature sensors, heaters, coolers, and management device capable of collecting and analyzing the information collected by the sensor and controlling the heater and cooler so as to generate the desired incubation temperature and permanently apply a temperature gradient to the surface of the receptacle.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a divisional application of U.S. patent application Ser. No. 11/121,708 filed on May 4, 2005, which is a continuation of International Application No. PCT/DK2003/000753 filed on Nov. 4, 2003 (Pub. No. WO2004/041330), which claims priority to Denmark Patent Application No. 200201702 filed on Nov. 5, 2002, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to wearable insulin dispensing devices.
In connection with injection of insulin for combating Type I and Type II Diabetes extremely important features are simplicity of operation, reliability, cost and flexibility, which all are related to the issue of compliance which particularly in the cases of relatively mild Type II diabetes is a problem with important consequences regarding the success rate in treating the patients.
SUMMARY OF THE INVENTION
The main object of the invention is to provide a wearable insulin dispensing device having features and operation characteristics supporting and easing compliance by the users of the device.
The present invention provides a disposable, wearable, self-contained insulin dispensing device comprising
a housing, an insulin source in said housing, a pump means in said housing and adapted for pumping insulin from said insulin source to a catheter for injection of said insulin in a user of the device and, said catheter being associated with said housing and projecting generally perpendicularly to a generally planar surface of said housing intended for abutting a skin surface of a user of the device, an adhesive layer provided on said planar surface for adhering said planar surface to said skin surface, and a removable release sheet covering said adhesive layer for protecting said adhesive layer prior to use of said dispensing device, said release sheet being provided with catheter protection means to enclose and protect an end portion of said catheter such that removal of said release sheet for exposing said adhesive layer exposes said end portion.
Hereby, in a simple, reliable and cost-effective manner a device is provided which is easy to apply and still in an effective manner protects the catheter against damage and contamination until use of the device is initiated.
In another aspect, the invention provides a disposable, wearable, self-contained insulin dispensing device comprising
a housing, an insulin source in said housing, a pump means in said housing and adapted for pumping insulin from said insulin source to a catheter for injection of said insulin in a user of the device and, said catheter being associated with said housing and projecting generally perpendicularly to a generally planar surface of said housing intended for abutting a skin surface of a user of the device, an adhesive layer provided on said planar surface for adhering said planar surface to said skin surface, a combined microphone and loudspeaker associated with said housing, preferably arranged inside said housing, and recording and play back means connected to said combined microphone and loudspeaker and associated with said housing, preferably arranged inside said housing, such that verbal messages may be recorded and played back by said dispensing device.
Hereby a device promoting simple communication between a health care provider and the user is provided with readily understandable operation and with good effect on the compliance rate.
In yet another aspect, the invention provides a disposable, wearable, self-contained insulin dispensing device comprising
a housing, an insulin source in said housing, a pump means in said housing and adapted for pumping insulin from said insulin source to a catheter for injection of said insulin in a user of the device, and an actuator for said pump means, said actuator comprising a shape memory alloy wire, said actuator preferably further comprising a ratchet gear or pawl wheel, a pawl adapted for cooperating with said pawl wheel and connected to one end of said shape memory alloy wire and a spring means connected to said pawl, the connections between said pawl and said wire and said pawl and said spring means being such that contraction of said wire rotates said pawl wheel against the spring force of said spring means.
Hereby a pump means requiring very low energy and with a high degree of reliability is provided at a relatively low cost.
In a yet further aspect, the invention relates to a disposable, wearable, self-contained insulin dispensing device comprising
a housing, an insulin source in said housing, a pump means in said housing and adapted for pumping insulin from said insulin source to a catheter for injection of said insulin in a user of the device, an actuator for said pump means, preferably an actuator comprising a shape memory alloy wire, and controlling means for controlling the operation of said actuator according to a program, said program consisting in a sequence of a certain amount of actuations of said actuator per 24 hour time periods, or, in connection with provision of a timing means connected to said controlling means said program consisting in a sequence of actuations of said actuator that varies according to the time of day or, in connection with provision of a timing means connected to said controlling means and an input device for inputting data to said controlling means, adapting said controlling means so as to be programmable by means of said data, or adapting said program of said controlling means to comprises algorithms for automatically altering the sequence of actuations of said actuator according to input of data relative to actual glucose level in the blood of the use of the device and/or intake of nutrients by said user.
Hereby, compliance is enhanced by providing a device with capabilities of rendering a very specific and well-tuned dosage which may be altered according to the specific development of the individual user.
In a yet further aspect, the invention relates provides a combination of a dispensing device as specified above and a programming controller, said dispensing device and said programming controller comprising cooperating transmission and/or receiving means for mutual communication of data, said programming controller preferably being a cellular telephone or a personal computer or a laptop computer or a hand held computer.
Moreover, the invention provides a method of controlling the operation of a disposable, wearable, self-contained insulin dispensing device comprising
a housing, an insulin source in said housing, a pump means in said housing and adapted for pumping insulin from said insulin source to a catheter for injection of said insulin in a user of the device, an actuator for said pump means, preferably an actuator comprising a shape memory alloy wire, and controlling means for controlling the operation of said actuator according to a program,
said method comprising the steps of:
providing said controlling means with data for generating and/or amending said program prior to and/or after initiation of use of said dispensing device.
Furthermore, in a yet other aspect, the invention also related to a method of controlling the operation of a disposable, wearable, self-contained insulin dispensing device comprising
a housing, an insulin source in said housing, a pump means in said housing and adapted for pumping insulin from said insulin source to a catheter for injection of said insulin in a user of the device and, said catheter being associated with said housing and projecting generally perpendicularly to a generally planar surface of said housing intended for abutting a skin surface of a user of the device, an adhesive layer provided on said planar surface for adhering said planar surface to said skin surface, a combined microphone and loudspeaker associated with said housing, preferably arranged inside said housing, recording and play back means connected to said combined microphone and loudspeaker and associated with said housing, preferably arranged inside said housing, such that verbal messages may be recorded and played back by said dispensing device, an manual operating means for manually controlling the operation of said dispensing device
said method comprising the steps of:
recording verbal instructions in said recording means for instructing the user of the device in the operation of said dispensing device, and playing back said verbal instructions.
Finally, the invention relates to a method of controlling the operation of a disposable, wearable, self-contained insulin dispensing device comprising
a housing, an insulin source in said housing, a pump means in said housing and adapted for pumping insulin from said insulin source to a catheter for injection of said insulin in a user of the device and, said catheter being associated with said housing and projecting generally perpendicularly to a generally planar surface of said housing intended for abutting a skin surface of a user of the device, an adhesive layer provided on said planar surface for adhering said planar surface to said skin surface, a combined microphone and loudspeaker associated with said housing, preferably arranged inside said housing, a programmable computing means associated with said housing, preferably arranged inside said housing, and signal conversion means connected to said combined microphone and loudspeaker and associated with said housing, preferably arranged inside said housing, and adapted for converting received audio signals into input signals for said computing means and for converting output signals from said computing means to audio signals,
said method comprising the steps of:
transmitting audio signals to said microphone for controlling the operation of said dispensing device, receiving audio signals from said loudspeaker for evaluating the operation of said dispensing device.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention will be described and explained more in detail in connection with a currently preferred insulin dispensing device according to the invention shown, solely by way of example, in the accompanying drawings where:
FIG. 1 is a schematic isometric view of a disposable insulin dispensing device according to the invention before the adhesive pad for adhering the device to a user has been mounted on the device,
FIG. 2 is a schematic isometric view of the device of FIG. 1 seen from another angle and with the adhesive pad mounted thereon,
FIG. 3 is a schematic isometric partly exploded view of the device of FIG. 2 ,
FIG. 4 is a schematic entirely exploded view of the device of FIG. 2 ,
FIG. 5 is a schematic isometric view of the device of FIG. 2 together with a programming device according to the invention,
FIG. 6 is a schematic enlarged scale exploded view of a shape memory alloy actuator mechanism according to the invention of the device of FIG. 2 , and
FIG. 7 is a schematic view corresponding to FIG. 6 with the elements of the shape memory actuator shown in interconnected operative relative positions.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 , a disposable insulin dispensing device according to the invention, generally referenced by the numeral 1 , comprises a water-tight generally cylindrical housing 2 provided with a push button 3 for activating and deactivating the device as well as for activating a so-called bolus operation as explained in the following.
The housing further comprises a transparent window 4 for inspecting the operation of the device and apertures 5 for transmission of sound waves as explained in the following.
At one end of the housing 2 there is provided a stiletto 6 having a sharp needle 7 extending through a catheter 8 connected to a not shown insulin container or capsule inside the housing 2 as explained in the following.
Referring now to FIGS. 2-3 , the housing 2 is fixedly received in a trough 9 of an adhesive pad 10 made of a combination of a plate 11 of skin-friendly adhesive material, for instance as well known in the field of ostomy pouches, see for instance European patent application no. 0413250 and European patent application no. 0092999, and a relatively compressible portion 10 a made of foam material attached to the plate 11 . The catheter 8 extends through the planar portion 11 of the pad 10 . The push button 3 is protected by the foam material 10 a so as to avoid inadvertent operation of the button for instance when the user is asleep.
A slip release film 12 is adhered to the bottom surface of the adhesive plate 11 for protecting the adhesive surface of the plate 11 such that the adhesive properties are intact when the pad is to be adhered to the skin of a user of the dispensing device. The release film 12 is provided with a protective hollow projection 13 for receiving the catheter 8 and the needle 7 of the stiletto 6 so that the needle 7 and the catheter 8 are protected by the projection 13 before use of the dispensing device 1 . The housing 2 is provided with and end cover 14 on which the catheter 8 is mounted by means of a communication bushing 15 provided with an internal not shown elastomer mass and a communication passage for communicating the catheter 8 with the interior of the housing 2 as explained in the following in connection with FIG. 4 .
In use, the user removes the protective release sheet 12 thereby exposing the tip of the needle 7 such that the needle may be inserted subcutaneously at the same time that the adhesive pad 10 a , 11 is adhered to the abdominal skin of the user. When the needle 7 and the catheter 8 have been inserted subcutaneously and the device has been adhered to the skin of the user, the stiletto 6 is removed whereby communication is established between the catheter 8 and the interior of the housing 2 for supplying insulin subcutaneously to the user of the device.
The elastomer mass in the bushing 15 seals the exit opening of the needle 7 when it is removed such that no insulin may leak through said exit opening but is constrained to flow solely from the capsule to the catheter 8 .
Referring now to FIG. 4 showing an exploded view of the components of the insulin dispensing device according to the invention, the housing 2 contains a container or a capsule 16 for storing and dispensing insulin. The container or capsule 16 is of a well-known type having a perforatable dispensing projection 17 for receiving a catheter 18 for communicating the interior of the container 16 with the catheter 8 through the communication bushing 15 when the needle 7 has been retracted from said elastomer mass inside the bushing 15 as explained above.
A spindle 19 provided with a piston 20 is received in the container 16 such that axial displacement of the spindle towards the dispensing projection 17 will press insulin through the catheter 18 to the catheter 8 . The spindle 19 is rotated and displaced by means of a shape memory alloy actuator described more in detail in the following with reference to FIG. 6 .
A battery 21 for supplying power to the shape memory actuator is provided adjacent an end cover 22 of the housing 2 .
The shape memory actuator comprises a pawl or ratchet wheel 23 , a guide bushing 24 , a spring wheel 25 and a shape memory wire 26 . The operation of the shape memory actuator will be described more in detail in the following with reference to FIGS. 6 and 7 .
A printed circuit board 27 is provided for controlling the function of the dispensing device and the various operational steps thereof as described in the following.
Finally a combined microphone/loudspeaker 28 is arranged inside the housing 2 adjacent the apertures 5 for receiving and emitting sound waves for the purposes described below.
Referring now to FIG. 5 , a programming device or controller 29 having programming keys 30 and a display 31 is shown proximate the dispensing device for communicating with a not shown receiver/transmitter arranged inside the housing 2 . The communication may take place by infra red signals or other suitable signals transmitted from and to an opening 32 leading to a transmitter/receiver inside the controller 29 to and from, respectively an opening 33 (see FIG. 2 ) in the end cover 22 of the housing 2 leading to said not shown transmitter/receiver inside the housing 2 .
Referring now to FIGS. 6 and 7 , the spindle 19 is displaced axially in the direction of the arrow R 1 by counter-clockwise rotation of the pawl wheel 23 in the direction of the R 2 whereby the thread 36 meshing with the internal thread 37 results in said axial displacement whereby the piston 20 is displaced further into the carpule 16 to dispense insulin through the catheter 18 to the catheter 8 ( FIG. 4 ).
Rotation of the pawl wheel 23 is accomplished by means of the shape memory alloy (for instance Nitinol) wire 26 attached to electrically conductive rods 38 and 39 that are fixed in recesses 40 and 41 , respectively, in the electrically non-conductive guide bushing 24 and the electrically conductive spring wheel 25 , respectively.
The recess 40 is provided with not shown electrical contacts for electrically connecting the rod 39 to the battery 21 for supplying electrical current to the shape memory alloy (SMA) wire 26 to heat it in a manner and sequence controlled by the program elements in the printed circuit board 27 .
The spring wheel 25 has U-shaped spring arms 44 and 45 for exerting a spring force on the ends 46 and 47 thereof, respectively, in a direction towards the center of the pawl wheel 23 such that the ends 46 and 47 are constantly biased to enter into engagement with the teeth of the pawl wheel 23 .
The stop pins 42 and 43 are electrically connected to the printed circuit board 27 for emitting an electrical signal thereto when the spring wheel arm 48 contacts said stop pins.
The rod 38 is as mentioned above electrically connected to the power source such that an electrical current may be passed through the rod 38 , the wire 26 , the rod 39 , the loop recess 41 and the spring wheel 25 to heat the wire 26 to cause the wire to contract and rotate the pawl wheel the distance of one tooth in the direction of arrow R 2 by means of the arm end 46 engaging a tooth of the wheel until the arm 48 contacts the stop pin 42 that emits a signal to the control printed circuit board 27 whereby the current through the wire 26 is interrupted and the SMA wire 26 cools off and expands.
The other arm end 47 engages a tooth of the wheel 23 as a pawl and prevents the wheel 23 from rotating clock-wise. The spring effect of the spring wheel 25 in the tangential direction causes the arm 42 to move back into contact with the stop pin 43 thereby tightening the expanded SMA wire 26 .
The signals from the stop pins 42 and 43 are also utilized to indicate correct functioning of the pump and as an indication of the number of doses administered through the catheter 8 .
A dispensing device or insulin pump according to the invention may function in several different manners depending on the design and programming of the various control elements of the circuit board 27 :
1. Stand Alone Pump with Constant Flow:
The pump functions as a constant flow pump and may be designed for different flow rates, for instance 20 units/24 hours, 30 units/24 hours, etc. By depressing the bolus button 3 and holding it down, the pumping program is initiated and by again pressing the button 3 down and holding it, the pumping programme is terminated while a short duration pressure on the bolus button 3 activates a bolus additional dosage of insulin of a certain magnitude.
2. Stand Alone Pump with Varying Flow:
A timing device is incorporated in the printed circuit board 27 so that a standard program controls the flow dispensed by the pump during recurring 24 hour periods. The pre-programmed operating instructions may for example result in a lower dosage at night than during the day and an extra dosage at mealtimes.
3. Programmable Pump Type 1:
The pump is not provided with a predetermined program, but is provided with a programmable unit in the printed circuit board 27 and can be programmed by the user or a doctor by means of a controller 29 . The programming must be able to take place through the packing material in which the dispensing device is supplied so that the user can transport the device in a sterilized out packaging on vacations or the like without having to carry the controller along. The controller is a dedicated unit that for instance via a USB plug can be connected to a PC or it can be provided with cellular telephone capability for transmission of data. The controller can thus be programmed by a doctor or a user and be used for programming of the functioning of all subsequently used disposable dispensing devices.
4. Programmable Pump Type 2:
This pump functions in the same manner as programmable pump type 1, but the controller is a personal data device such as the type marketed under the trademark PALM PILOT®, or a laptop PC. This gives the additional advantage that the user may input health information and glucose level measurement results directly into the controller or programming unit and thus communicate such information to the doctor who may use this information when deciding whether the programming function of the controller or the programming unit is to be altered for subsequently used disposable dispensing devices.
5. Programmable Pump with Audio Input and Output:
By providing the dispensing device with the microphone/loudspeaker 28 and a suitable recording/play-back chip in the printed circuit 27 , short messages may be recorded by the dispensing device, and the short messages may be emitted by the device upon suitable manipulation of the bolus push button 3 or a separate recording button (not shown) mounted on the housing 2 .
By means of this audio capability the user may record verbally formulated information regarding glucose levels, meal composition, exercise, etc. A timer may record the timing of each recorded message. A doctor may then use these recorded messages together with information about number and timing of bolus dosages, pumping stops and the program utilized for the dispensing of the insulin so as to evaluate the treatment and decide upon any changes in the programming and instructions to the patient which may be recorded by the doctor via a mobile telephone or the like such that messages are automatically delivered to the user at predetermined times. Such a message could for example be ‘remember to measure your glucose level’ (message program to be delivered by the dispensing device to the user each morning at 8 o'clock) and so on.
Furthermore, standard instructions can be included in the programming circuit so that the pump may deliver verbal messages to the user instead of audio signals such as beep sounds. The message could for instance be: ‘Pump is stopped’ or ‘This is your third bolus in a row and you have taken a total of eight bolus dosages today’ or ‘The pump will be empty in two hours’ and so on. Generally speaking, the audio capability described above will render the dispensing device provided with such capability much more user-friendly, especially for users initiating a treatment or not very disciplined as regards compliance.
6 Closed Loop Re-Programmable Pump:
Either the controller or the computing unit mounted in the printed circuit 27 may be programmed to react to information regarding actual glucose blood level inputted by the user perhaps together with other information, such as data regarding the timing and constitution of the last meal, to alter the program of the dispensing flow or dosage to take into consideration this information such that the dispensing device to a certain extent constitutes a closed loop, fuzzy logic, semi-automatic self re-programming insulin dispensing device.
The programming controller 29 may be a mobile wire-less communication device such as a cellular telephone communicating with the dispensing device by audio signals transmitted to and received from the transmitter/receiver 28 . The transmissions should be preceded and terminated by an identification code to avoid disruption of the programming of the device by extraneous audio signals. Other signal identification or protection procedures such as encryption may be utilized. The audio signals may be converted to controlling signals for altering the programming of the re-programmable computing unit mounted in the circuit board 27 .
Signal conversion means may be provided for converting the audio signals received by the receiver into input signals for the computing means and for converting output signals from the computing means into audio signal for being transmitted by the loudspeaker.
So-called SMS signals may also be utilized for transferring information between a wire-less mobile communications unit and the dispensing device, for instance by means of IR signals or so-called Bluetooth communication technology.
Although the basic concept of the invention is that the entire device is disposable, a variation may be that the receiver/transmitter unit 28 with recording and play back components and corresponding battery and perhaps circuit board with computing means is reusable and may be releasably received in a holder provided on the disposable portion of the device.
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A wearable insulin dispensing device has features and operation characteristics supporting and easing compliance by the users of the device. For example, the device may provide capabilities of rendering a very specific and well-tuned dosage which may be altered according to the specific development of the individual user.
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This is a continuation-in-part of copending application Ser. No. 07/556,054 filed on Jul. 20, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of explosive compounds. More particularly, this invention relates to an improved method for the preparation of 7-amino-4,6-dinitrobenzofuroxan.
2. Description of Related Art
Energetic materials useful as components in solid propellants and explosives as well as methods for preparing same are well known in the art.
The synthesis and characterization of 7-amino-4,6-dinitrobenzofuroxan has been reported in United States Statutory Invention Registration No. H476 (incorporated by reference) wherein monochloro-4,6-dinitrobenzofuroxan in CH 2 Cl 2 is stirred under an ammonia atmosphere to precipitate the ammonium salt of 7-amino-4,6-dinitrobenzofuroxan. Treatment with dilute hydrochloric acid yields 7-amino-4,6-dinitrobenzofuroxan.
SUMMARY OF THE INVENTION
This invention provides the compound 7-amino-4,6-dinitrobenzofuroxan, useful in solid propellants and the like.
The method of making the compound comprises the nitration of 3-nitroaniline to produce 2,3,4,6-tetranitroaniline followed by reaction with sodium azide in acetic acid to produce 7-amino-4,6-dinitrobenzofuroxan.
OBJECTS OF THE INVENTION
It is an object of this invention to provide a novel and inherently more stable method for the production of 7-amino-4,6-dinitrobenzofuroxan.
This and other objects of the invention will become more readily apparent from the following detailed description.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention discloses a novel method for the preparation of 7-amino-4,6-dinitrobenzofuroxan: ##STR1##
The compound 7-amino-4,6-dinitrobenzofuroxan is an insensitive, thermally stable explosive. The physical and chemical properties of 7-amino-4,6-dinitrobenzofuroxan are presented in Table 1:
TABLE 1______________________________________PROPERTIES MEASUREMENTS______________________________________Molecular formula C.sub.6 H.sub.3 N.sub.3 O.sub.6Molecular weight 241.12Density 1.902 ± 0.008 g/cm.sub.3Melting point (DSC. 10°/min) 270° (decomposition)Oxygen balance (CO) -10Percent nitrogen 29.1Detonation velocity (calculated) 7.91 mm/μsDetonation pressure (calculated) 282 KbarImpact sensitivity (H.sub.30)* 100 cm (TNT ± 75 cm)Heat of formation +36.79% 0.72 Kcal/mol______________________________________ *Bureau of Mines
The production of 7-amino-4,6-dinitrobenzofuroxan is traditionally prepared by nitration of 3-nitroaniline to produce 2,3,4,6-tetranitroaniline followed by reaction with sodium azide in acetic acid to produce 7-amino-4,6-dinitrobenzofuroxan (ADNBF). The existing method utilizes a mixed nitrating acid of 30% oleum and 98% nitric acid for the first step followed by the addition of solid sodium azide. By using anhydrous nitric acid in place of the aforementioned mixed nitric acid complex, and an aqueous solution of sodium azide in the second step, the novel method of the present invention is effected.
Conversion of the 2,3,4,6-tetranitroaniline (TNA) to 7-amino-4,6-dinitrobenzofuroxan (ADNBF), shown in more detail below, is effected by means of displacing a nitro group from TNA with an azide ion. This reaction is carried out in an acetic acid slurry with aqueous sodium azide. The exothermic reaction is easily controlled by means of varying the rate of addition of the sodium azide solution. Excess sodium azide reacts with the side product nitrite ion to form gaseous N 2 O and N 2 . The intermediate 3-azido-2,4,6-trinitroaniline formed is thermally decomposed without isolation to from nitrogen gas and an unstable nitrene which cyclizes with an adjacent nitro group to form the product.
To aid in the understanding of the present method for the production of 7-amino-4,6-dinitrobenzofuroxan, the following example is provided.
EXAMPLE 1
Preparation of 2,3,4,6-Tetranitroaniline (TNA)
A 5,000 ml three-necked round bottom flask with a mechanical stirrer, thermometer, and 250 ml addition funnel was charged with 107 g (0.78 mol) of 3-nitroaniline in 1000 ml of concentrated sulfuric acid and warmed to 60° C. by means of an electric heating mantle. The mantle was removed and 190 ml of anhydrous nitric acid (285 g; 4.52 mol) was added slowly dropwise. The addition rate was adjusted along with an eternal ice water bath to maintain the reaction temperature at 65±3° C. during the addition. After the addition was completed, the mixture was stirred without external heating or cooling for 20 minutes as the reaction temperature subsided slowly. An ice bath was used to then lower the temperature to 40° C. and the thick slurry of product in acid was filtered through a fritted glass Buchner funnel. The flask and filter cake were rinsed with 50% sulfuric acid and then with water, and the yellow-green cake was left to dry on the funnel. The yield was 157 g (74%) as a slightly damp solid which was suitable for the next step without further purification. A small sample was dried to determine the melting point (mp=226° C. with decomposition) and infrared spectrum of this material which were identical with authentic samples.
EXAMPLE 2
Preparation of 7-Amino-4,6-dinitrobenzofuroxan (ADNBF)
In a 5000 ml three-necked round bottom flask equipped with a mechanical stirrer, thermometer, and addition funnel vented to a gas bubbler, the damp filter cake from the TNA preparation (157 g; 0.58 mol max.) was suspended in 700 ml of glacial acetic acid at room temperature. Conversion of the suspended TNA to 3-azido-2,4,6-trinitroaniline was effected by addition of a solution of 76.4 grams (1.18 moles) of sodium azide in 200 ml of water. The temperature was maintained at 20-28° C. by adjusting the addition rate and by use of external cooling. Gas evolution from the reaction of azide ions with the displace nitrate ions to form N 2 O and N 2 was evident when about one-third of the sodium azide solution had been added and remained smooth until the addition was complete (about 40 minutes). Without isolation of the intermediate 3-azido-2,4,6-trinitroaniline, the reaction flask was heated to 80° C. slowly. Gas evolution from decomposition of the azido group to a nitrene and gaseous nitrogen became vigorous at about 60° C. and ceased after about 30 minutes at 80° C. The nitrene spontaneously cyclizes with the adjacent nitro group to form the product. The reaction was held at 80° C. for a total of 60 minutes and was cooled to room temperature overnight. The product was filtered, washed well with water, and left to air dry on the funnel. The solid product (127 g; ca. 90% yield) was stored damp. A small sample was dried for infrared spectral analysis and melting point (mp=274-275° C., with decomposition) which were identical to those of authentic samples.
The subject invention has been described in detail sufficient to inform one skilled in the art with the method of manufacture with reference to a preferred embodiment thereof. However, it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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The compound 7-amino-4,6-dinitrobenzofuroxan is prepared by reacting 2,3,4,6-tetranitroaniline in a solvent with aqueous sodium azide under controlled exotherm conditions.
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RELATED APPLICATIONS
[0001] This application is a division of U.S. patent application Ser. No. 10/221,066, filed May 6, 2003, currently pending, which is a national stage filing under 35 U.S.C. §371 of international application PCT/GB01/01027, filed Mar. 9, 2001, which was published under PCT Article 21(2) in English, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an improved mode of administration for cannabis and its natural and synthetic derivatives. The term cannabis is used herein to refer to all physiologically active substances derived from the cannabis family of plants and synthetic cannabis analogues and derivatives, precursors, metabolites etc., or related substances having cannabis-like physiological effects.
BACKGROUND OF THE INVENTION
[0003] The medicinal and psychoactive properties of the cannabis plant have been known for centuries. At present, cannabis is not legally available. However, there is growing pressure on politicians to legalise its use, especially for medicinal purposes.
[0004] Evidence suggests that cannabis is a safe, versatile and potentially inexpensive drug. It has been reported as being beneficial to patients suffering from a wide range of symptoms experienced in connection with various, often very serious, medical conditions. For example, cannabis has been used to alleviate symptoms associated with cancer, anorexia, AIDS, chronic pain, spacicity, glaucoma, arthritis, migraine and many other illnesses.
[0005] Cannabis is recognised as having anti-emetic properties and has been successfully used to treat nausea and vomiting in cancer patients undergoing chemotherapy.
[0006] Studies also report use of cannabis in treating the weight loss syndrome of AIDS and in reducing intraocular pressure for the treatment of glaucoma. Cannabis is also reported to have muscle relaxing effects and anti-convulsant effects.
[0007] However, it is also well documented that these medicinal effects of cannabis come at the cost of less desirable effects. It is alleged that the administration of cannabis causes changes in mood, perception and motivation. The common euphoric effects have led to the use of cannabis as a recreational, “soft” drug and its criminalisation. The psychoactive effects are said to vary with dose, with the typical cannabis smoker experiencing a “high” which lasts about 2 hours, during which there is impairment of cognitive functions, perception, reaction time, learning and memory. These side effects clearly have implications, such as for the operation of machinery, and in particular for driving. These effects also make cannabis less attractive for widespread, mainstream use, as it can reduce a patient's ability to perform relatively simple tasks during treatment.
[0008] The euphoric effects of cannabis may also constitute an undesirable side effect for patients using the drug for medicinal purposes, especially for “naive” cannabis users. Furthermore, here have been reports of unpleasant reactions to cannabis, such as anxiety, panic or hallucinations. It is believed that these undesirable effects are most commonly associated with higher doses of cannabis.
[0009] Despite these effects, years of research have failed to show that cannabis is dangerous. In fact, the results appear to have proved the opposite. Cannabis has been shown to be safer, with fewer serious side effects than most prescription drugs currently used as anti-emetics, muscle relaxants, hypnotics and analgesics, etc.
[0010] The physiological and pharmacological effects of cannabis depend upon a number of factors, including the dosage level and the route of administration.
[0011] There are currently two main methods of cannabis delivery. Lung delivery is most commonly achieved by smoking cannabis. Unfortunately, there are concerns about the effect of this mode of administration on the lungs. Cannabis smoke carries even more tars and other particulate matter than tobacco, and so may be a cause of lung cancer. Furthermore, many patients find the act of smoking unappealing, as well as generally unhealthy. It is, known that some of the chemicals produced by smoking cannabis are aggressive and smoking has been shown to cause the gradual dissolving of teeth. For these reasons, smoking is not an approved medical means of administration for any drug.
[0012] Attempts have been made to overcome some of the problems associated with smoking both cannabis and tobacco by providing various smokeless inhalable aerosol formulations for lung delivery. A self-propelled inhalable aerosol of delta-9-tetrahydrocannabinol was developed as long ago as 1975 as a bronchodilator. Inhalable aerosol formulations were made comprising either only liquid components and or including a solid particulate component carrying the active agent, such as the cannabis. The various formulations were found to be of varying effectiveness in delivering the active agent to the alveoli of the lungs in the same manner as smoke.
[0013] However, both methods of lung delivery discussed above have been found to cause a pronounced and involuntary cough, possibly from irritation of the trachea and lungs. This unpleasant side effect is not overcome by the smoke-free method of lung delivery.
[0014] An oral dosage form of cannabis is available in the United States as a Schedule II drug. The capsules contain a synthetic version of delta-9-tetrahydrocannabinol (delta-9-THC), the main active substance in cannabis, and they have had limited success for a number of reasons. Firstly, in light of its anti-emetic properties, the capsules are commonly used to treat nausea and vomiting. Clearly, an oral administration is not ideal as the patient may well have difficulty keeping the capsule down long enough for it to take effect. It has also been found that orally administered THC is erratically and slowly absorbed into the bloodstream, making the dose and duration of action difficult to control. Furthermore, the oral dose is less effective than smoked cannabis and therefore larger doses are required in order to achieve a desired therapeutic effect.
SUMMARY OF THE INVENTION
[0015] The applicants have discovered that an alternative mode of administration allows the clinical or medicinal effects of cannabis to be maximised, whilst reducing the above discussed unpleasant and negative side effects. According to the present invention, the cannabis is formulated for sublingual delivery in aerosol or spray form, which offers unexpected advantages over known modes of cannabis delivery. The invention also relates to a device for delivering such a composition as an aerosol or spray.
[0016] Formulations according to the invention may include a propellant or may be dispensed using a pump spray device. The spray or aerosol devices may have upright or inverted valves. Furthermore, the aerosol or spray device may be adapted specifically for sublingual delivery. For example, the mouthpiece of the device may be adapted to direct the sprayed dose towards the sublingual mucosa. The device may also be adapted to dispense particles of a particular size, thereby optimising the sublingual uptake.
[0017] It is known that sublingual delivery of a pharmaceutically active agent results in fast uptake. The active agent is administered to the sublingual mucosa, from which it is rapidly absorbed into the bloodstream. Sublingual delivery also avoids first-pass metabolism of the active agent.
[0018] Aerosol or spray delivery of a composition to the sublingual area is particularly convenient and effective, and promotes fast-uptake. The sprayed composition will be thinly spread over the sublingual area, so that more of the dispensed composition will be absorbed and will be absorbed more quickly than where sublingual delivery is by some other mode, such as, for example, allowing a tablet to dissolve under the tongue.
[0019] The fast onset of the therapeutic effects of sublingually administered cannabis has the advantage of providing fast relief from the symptoms to be treated. It also has the advantage of reducing the risk of excessive doses being administered in an attempt to get immediate relief from symptoms, which is often observed in connection with slow-acting active agents and means of administration and which is potentially dangerous.
[0020] Sublingual delivery is clearly more attractive than injection, as alternative method of delivery offering fast uptake. Injection is painful, especially when regular administration is required. It can also be difficult for a patient to inject themselves, especially if weak or lacking co-ordination, often making it necessary for someone other than the patient to perform the administration.
[0021] Sublingual delivery also has advantages over oral delivery. It is well suited for administration of anti-emetics, it having rapid onset and delivery is not affected by nausea and vomiting. A sublingual dose is also absorbed at a predictable rate and so its administration can be accurately controlled. Devices with metered valves may be used to dispense the active agents sublingually, allowing accurate volumes, and therefore accurate doses, to be dispensed.
[0022] Sublingual delivery also avoids the negative effects associated with smoking. The risk of lung cancer due to the tar and impurities drawn into the lung by smoking will be avoided. Furthermore, the pronounced and involuntary cough associated with lung delivery of cannabis is not experienced with sublingual delivery.
[0023] A further and unexpected advantage associated with sublingual delivery of cannabis is that it is significantly more effective than smoking (which in turn is known to be significantly more effective than oral delivery). This is surprising in light of the huge surface area of the lungs which would be expected to allow much greater uptake of the cannabis than sublingual delivery which exposes a much smaller surface area to the active agent.
[0024] This effectiveness allows some of the undesirable effects of cannabis administration to be avoided, these effects being mainly associated with larger doses. Indeed, the applicants have discovered that the sublingual delivery of cannabis allows the beneficial medicinal effects of cannabis to be enjoyed whilst minimising the negative effects, such as the euphoria and impairment of faculties. That said, the sublingual administration of doses of cannabis large enough to produce said euphoric effect is still possible, if desired.
[0025] In one of the preferred embodiments of the present invention, a pharmaceutical composition suitable for sublingual delivery is provided comprising a pharmaceutically active agent which is cannabis and a propellant. The propellant may be, for example, 1,1,1,2-tetrafluoroethane (HFC-134a), 1,1,1,2,3,3,3-heptafluoropropane (HFC-227) or butane. Most preferably, the propellant included in the composition is HFC-134a or HFC-227.
[0026] In the past, aerosol or spray formulations frequently included one or more chlorofluorocarbon as a propellant, dichloro-difluoromethane being commonly used. It is well documented that chlorofluorocarbons are implicated in the depletion of the ozone layer and their production, therefore, is being phased out. 1,1,1,2-tetrafluoroethane (HFC-134a) and 1,1,1,2,3,3,3-heptafluoropropane (HFC227) are significantly less harmful to the ozone layer and they are of low toxicity and of suitable vapour pressure for use as aerosol propellants, making then suitable for use in pharmaceutical aerosols. An additional benefit is that HFC-134a and HFC227 can be used in combination with many pharmaceutically active agents, without causing any degradation to them or reducing their physiological activity. They are also not flammable.
[0027] Preferably, the composition of the present invention includes a carrier. In a preferred embodiment of the invention, the carrier is a lower alkyl (C 1 -C 4 ) alcohol, a polyol, or a (poly)alkoxy derivative. In embodiments, the carrier is a C 1 -C 4 alkyl alcohol or a lanolin alcohol and, preferably, is ethanol or isopropyl alcohol. The most preferred alcohol is ethanol.
[0028] The preferred polyols include propylene glycol and glycerol and the preferred (poly)alkoxy derivatives include polyalkoxy alcohols, in particular 2-(2-ethoxyethoxy)ethanol (available under the Trademark Transcutol®).
[0029] Further preferred (poly)alkoxy derivatives include polyoxyalkyl ethers and esters, such as polyoxyethylene ethers or esters. The preferred polyoxyethylene ethers and esters are polyoxyethylene alkyl ethers, polyoxyethylene castor oil derivatives, polyoxyethylene sorbitan fatty acid esters and polyoxyethylene stearates.
[0030] The preferred fatty acid alkyl esters are ethyl oleate, isopropyl myristate and isopropyl palmitate. The preferred polyalkylene glycol is polyethylene glycol.
[0031] In preferred embodiments, the inventive composition can comprise up to 50% or, preferably, 25% w/w carrier. More preferred embodiments include between 3% and 15% w/w, or between 4 and 10% w/w carrier. The pharmaceutical compositions can comprise between 50% and 99% w/w, preferably between 75% and 99% w/w, and, more preferably, between 88% and 95% w/w HFC-134a or HFC-227.
[0032] In further embodiments, compositions used in the present invention can comprise a plurality of different carriers.
[0033] Further excipients can be included in the formulations employed in the present invention. For example, neutral oils as well as surfactants (the latter for aiding the smooth operation of the valve), as are well known to those skilled in the art, may be included.
[0034] Thus, in further preferred embodiments, compositions employed in the invention can comprise an organic surfactant. The preferred organic surfactant is oleyl alcohol, although others can be employed, including sorbitan trioleate, sorbitan mono-oleate, sorbitan monolaurate, polyoxyethylene (20) sorbitan monolaurate, polyoxyethylene (20) sorbitan mono-oleate, natural lecithin, oleyl polyoxytheylene (2) ether, stearyl polyoxyethylene (2) ether, lauryl polyoxyethylene (4) ether, block copolymers of oxyethylene and oxypropylene, oleic acid, synthetic lecithin, diethylene glycol dioleate, tetrahydrofurfuryl oleate, ethyl oleate, isopropyl myristate, glyceryl mono-oleate, glyceryl monostearate, glyceryl monoricinoleate, cetyl alcohol, stearyl alcohol, cetyl pyridinium chloride, olive oil, glyceryl monolaurate, corn oil, cotton seed oil or sunflower seed oil.
[0035] It is preferable to include a flavouring oil in a formulation to be delivered sublingually. The preferred flavouring oil is peppermint oil, although it is clear that other flavour oils may be used, according to preference.
[0036] Some of the preferred compositions for the sublingual delivery according to the present invention contain tetrahydrocannabinols (THCs), such as delta-9tetrahydrocannabinol, the major active constituent of cannabis.
[0037] Many of the readily available substances derived from the cannabis plant are extracted in liquid form which may itself be directly sprayed using a pump spray or which may be soluble directly in the propellant, whilst other cannabis forms need to be solubilised in a co-solvent, such as ethanol, thus causing or allowing all or a proportion of the active agent present in the composition to dissolve and/or remain in solution, even after it has been dispensed.
[0038] The pharmaceutical compositions can be partial solutions in which only a proportion of the pharmaceutically active agent present therein is dissolved in the propellant and co-solvent, with the remainder being in suspension or suspendible. The exact proportions of dissolved and suspended active agent will depend upon the active agent concerned, its concentration and the identity and quantity of the co-solvent (s) used. In preferred embodiments the compositions are in the form of liquid solutions when maintained under pressure in devices in accordance with the invention.
[0039] In a particularly preferred embodiment of the invention the composition comprises a solution of delta-9-tetrahydrocannabinol in ethanol as a co-solvent and HFC-134a as a propellant.
[0040] The compositions of the present invention may also comprise cannabis in combination with other pharmaceutically active agents. For example, a formulation particularly suitable for providing improved anti-emetic effect comprises cannabis as the primary agent, with corticosteroid as a supplemental agent. In order to decrease toxicity of the primary agent, cannabis may be formulated together with the supplemental agent phenothiazine. Concurrent use of cannabis with prochlorperazine in low doses can reduce incidence of dysphoria which can accompany the administration of cannabis.
[0041] According to a further aspect of the invention, devices for delivering the cannabis compositions of the first aspect of the invention are provided.
[0042] Devices for administering metered aerosol doses of pharmaceutical preparations are well known in the art. Such devices include those disclosed in WO 92/11190, U.S. Pat. No. 4,819,834 and U.S. Pat. No. 4,407,481. Many of these devices include metering valves having components formed from plastic materials, such as the valves available from Bespak PLC of Bergen Way, Kings Lynn, Norfolk PE30 2JJ, United Kingdom, in which the valve core, metering chamber and some other structural components are formed from plastic materials. The plastic materials currently used for forming these structural parts in valves employed with many chlorofluorocarbon containing formulations include certain acetal co-polymers.
[0043] Although the plastics employed to manufacture metering valves, including the aforementioned acetal co-polymers, have also been found to be stable in the presence of HFC-134a alone, the applicants, to their surprise, have determined that many of these plastics materials can be caused to swell in the presence of formulations which include certain carriers or active agent solubilising co-solvents with HFC-134a. When such swelling takes place in a valve, the fit of mutually slidable components, such as metering chambers and valve cores, is adversely effected and they can bind together or become loose, causing the valve to leak or cease functioning altogether.
[0044] This problem has now been solved by using a device for providing pharmaceutical doses comprising a container, filled with a pharmaceutical composition including a pharmaceutically active agent in a solution of liquefied HFC-134a, or HFC-227, and a carrier selected from pharmaceutically acceptable alcohols, polyols, (poly)alkoxy derivatives, fatty acid alkyl esters, polyalkylene glycols, and dimethylsulphoxide, and valve means arranged for delivering aerosol doses of said pharmaceutical composition to the exterior of the container, wherein at least a portion of the device is formed from a polyester. Preferably, the valve means includes at least one component formed from a polyester, which component, more preferably, is a metering chamber and/or a valve core.
[0045] In further embodiments, the container comprises a polyester and, preferably, consists of metal lined with a polyester. The canister cap can also be so formed.
[0046] Apart from allowing the aforementioned swelling problem to be solved, an advantage of this aspect of the present invention is that use of expensive metal valve components can be avoided.
[0047] The preferred polyesters are polyalkylene benzene dicarboxylates, more preferably polyalkylene terephthalates and, most preferably, a polybutylene terephthalate.
[0048] Such materials, preferably, have a density of about 1.3 g/cm 3 and a water absorption of about 0.6% (23° C. saturation). The polyesters, also, are preferably partially crystalline in nature and have a crystalline melting range of 220-225° C.
[0049] Examples of suitable polybutylene terephthalates include those available under the Trademark Celanex® from Hoechst UK Limited, Walton Manner, Milton Keynes, Bucks MK7 7AJ, United Kingdom. Particularly preferred are Celanex® 2500 and Celanex® 500/2.
[0050] A variety of types of conventional spray devices exist are able to dispense very accurate volumes. However, this alone cannot ensure administration of a specific dose.
[0051] When pharmaceutical compositions are administered sublingually, it is particularly important that they are accurately delivered to the sublingual area. The sublingual area is relatively small and can be hard to reach because of the position under the tongue. If the composition does not come into contact with the sublingual mucosa, it will not be quickly absorbed and, indeed, may not be directly absorbed at all. This will clearly lead to an inaccurate dose being administered and the patient not receiving the desired amount of pharmaceutically active agent.
[0052] Therefore, a problem associated with sublingual administration of pharmaceutical compositions is the difficulty ensuring that a predictable dose is brought in contact with the sublingual mucosa. This can be particularly problematic where the composition is delivered by spray delivery. There are various factors which particularly influence the ability to ensure that a dispensed composition contacts the relatively small area of the sublingual mucosa.
[0053] Firstly, the direction and spread of the sprayed composition are clearly relevant. If the sprayed composition spreads or disperses upon leaving the aerosol or spray device, it is likely to contact a large area of the oral cavity other than the sublingual mucosa. This will make it unlikely that all of the composition will be absorbed and some of the active agent will not have an effect, thereby effectively reducing the dose administered.
[0054] Secondly, the velocity at which the composition is dispensed will also play a role, as the sublingual mucosa will be relatively close to the dispensing device when in use. If the composition is travelling at high velocity when it enters the oral cavity, it is more likely to spread around the cavity, rather than coming into contact almost exclusively with the sublingual mucosa, as desired.
[0055] At present there are no bespoke spray devices for sublingual administration. Rather, conventional spray devices of various types are generally used, and the user must attempt to direct the spray to the sublingual area.
[0056] The majority of known, conventional spray devices basically comprise a container in which the composition is stored, the composition being dispensed from an orifice or outlet, wherefrom it is allowed to generally disperse, often creating a cloud of droplets of dispensed composition. When using such devices for sublingual delivery, the user can, at best, attempt to control the general direction in which the composition is dispensed by pointing the device as a whole in a certain direction. However, it will be difficult, if not impossible, to target a small area like the sublingual mucosa, especially as it is positioned under the tongue.
[0057] Many conventional spray devices use a propellant, wherein the composition is dispensed through a single orifice. This generally results in the composition being dispensed at high velocity which, as discussed above, is undesirable in sublingual spray delivery.
[0058] An example of a conventional spray device generally capable of dispensing accurate doses is device is a so-called metered dose inhaler, or MDI device, frequently used to dispense pharmaceuticals for the treatment of asthma or angina and which has an inverted valve. A conventional MDI device comprises a pressurised aerosol container, carrying the composition to be administered for inhalation therapy. The container is encased in a housing which includes a mouthpiece and a passage leading from the orifice or outlet of the container to the mouthpiece. The mouthpiece is shaped to be comfortably held between the lips when the pharmaceutical composition is dispensed.
[0059] The MDI devices currently available are specifically intended for lung delivery. The dispensed composition is directed to the back of the throat, and inhalation by the patient results in the composition being drawn into the lungs from the oral cavity. Whilst MDI devices can dispense accurate and reproducible doses, such devices are not well suited to sublingual delivery for two reasons. Firstly, the devices are shaped to direct the dispensed substance to the back of the throat and not under the tongue. Secondly, because the substance is inhaled, it is dispensed at high velocity.
[0060] Thus, in a preferred embodiment of the present application, a spray or aerosol device has a bespoke mouthpiece, the mouthpiece being adapted to channel and direct the dispensed composition according to the present invention from an orifice of the device, towards the sublingual area of the user. Such a mouthpiece could be used in conjunction with a conventional spray device, such as one of the types discussed above.
[0061] Preferably, the mouthpiece of the dispensing device is angled in relation to the main body of the device, so that the mouthpiece directs the dispensed composition to the sublingual mucosa when the device is activated whilst held in the normal position for use.
[0062] Such a mouthpiece could be used in conjunction with devices having either an upright or an inverted valve. In a preferred embodiment, the device has an inverted valve, such devices generally being capable of dispensing accurate volumes of composition.
[0063] According to a further preferred embodiment, the mouthpiece for directing the dispensed composition to the sublingual area is part of a housing in which the main body, including the container, of the spray device is held. The mouthpiece could be rigidly fixed with respect to the housing, or the connection between the housing and the mouthpiece could be flexible, allowing the angle of the mouthpiece relative to the main body of the device to be adjusted.
[0064] In a further embodiment, the mouthpiece is shaped in such a way that it assists directional dispensing of the composition to the sublingual area of the mouth.
[0065] Preferably, the mouthpiece is long enough to allow the opening of the mouthpiece to sit under the tongue when the composition is dispensed. This will reduce the amount of composition being dispensed to parts of the oral cavity other than the sublingual area. Even more preferably, for greater comfort and greater ease of use, the mouthpiece is also a slim shape, fitting comfortably under the tongue or being comfortably held to direct the spray towards the sublingual area.
[0066] Additionally, the mouthpiece may also be shaped in such a way that it discourages the spread of the dispensed composition after it leaves the mouthpiece. As discussed above, when a composition is dispensed by a conventional spray device it will generally spread, forming a cloud. This is undesirable where a small area of the oral cavity is to be targeted. In a preferred embodiment, the mouthpiece opening is no larger than the average size of the sublingual area. This means that, despite some degree of spreading of the dispensed composition after it has left the mouthpiece, the spread will be limited to ensure that the area of the oral cavity contacted by the dispensed composition will correspond generally to the sublingual area, provided the composition is dispensed in the correct direction.
[0067] It is also advantageous for the dispensing device to be adapted to reduce or control the velocity at which the dispensed composition leaves the device. This will help to ensure that the composition comes into contact with the sublingual mucosa and stays in contact for long enough for the pharmaceutically active agent to be absorbed. Such control may be provided, to an extent, by the shape of the mouthpiece of the dispensing device.
[0068] Thus, in accordance with a further preferred embodiment of the present invention, the mouthpiece of the spray device has a cross-sectional area which first gradually increases, and then decreases. The resultant “duckbill” shape will both control the velocity of the dispensed composition and limit its spread. It is clear that a variety of mouthpiece shapes may be used to reduce the velocity of the dispensed composition.
[0069] In another preferred embodiment, the velocity with which the composition is dispensed is also reduced by providing the device with a plurality of orifices through which the composition is released. The provision of more than one orifice will reduce the force with which the dispensed composition is released from the main body of the device, thereby reducing its exit velocity. The more orifices through which the composition is dispensed, the slower the velocity of the substance dispensed.
[0070] In a yet more preferred embodiment, in a device having a plurality of orifices these orifices may be shaped and positioned to be directional, preferably serving to direct the individual jets of dispensed composition toward on another, to avoid unnecessary and undesirable spreading of the composition around the oral cavity.
[0071] Most preferably, the orifices are directed so that jets of dispensed composition converge at a point which is approximately the same distance from the nozzle of the device as the sublingual area will be from the nozzle when the device is used. Thus, the composition should contact a relatively small area, avoiding wastage caused by the composition being dispensed to areas other than the sublingual mucosa.
[0072] In a preferred embodiment of the invention, the orifices of the device are further adapted to dispense particles of a particular size, thereby optimising absorption across the sublingual mucosa.
[0073] A problem sometimes encountered with conventional spray and aerosol devices is that there is some degree of interaction between the container and the composition stored therein. This interaction can be in the form of corrosion of the container by the composition, or leaching of materials from the container into the composition, both of which are clearly undesirable. Such interaction between the container and its contents can significantly curtail the shelf life of the container. Furthermore, resultant contamination of the composition can be dangerous. Even seemingly inert compositions may eventually interact with their container when stored for prolonged periods.
[0074] Such interaction between the container and the contents thereof is a particular problem with the compositions of the present invention because cannabis and its analogues and derivatives are highly corrosive. Thus, these compositions cannot be stored in convention metal containers for any significant length of time.
[0075] It has been found that glass containers are considerably more resistant to interaction with compositions than the conventionally used metal and plastic containers. Therefore, in a further preferred embodiment of the present invention, the devices for spray dispensing the compositions of the invention include glass containers within which the composition is stored.
[0076] Preferably, in order to provide additional protection against interaction, the internal surface of the glass container may be coated. The coated containers will have surface properties like quartz, being highly inert. In a particularly preferred embodiment, the surface of the glass container is coated with a chemically bonded, ultra thin layer of pure silicone oxide. The thickness of such a layer would preferably be between 0.1 and 0.2 microns. Such a layer may be applied by a process whereby the inner surface of the container is first activated using pure oxygen. Next, silicone oxide coating gas is introduced into the container. Then, a plasma reaction is initiated by microwave energy, leading to the formation of a silicon oxide layer on the inner surface of the glass container.
[0077] Clearly, other inert coatings applied to the glass container surface may also protect the glass from interaction with the composition to be stored therein. The effect of such coatings is particularly apparent over time, the coating providing an inert barrier between the glass container and the composition stored therein.
[0078] A further advantage of glass containers is that it is much harder to tamper with them than with conventional containers. The provision of a tamper-proof container for pharmaceutical compositions as it will make it very difficult to gain access to the composition. It is particularly desirable to prevent extraction of the composition from the container where the pharmaceutical composition is one which is open to abuse, like the compositions of the present invention.
[0079] Containers made from conventional materials such as metals, such as aluminium, or plastics, are vulnerable to tampering. These materials may be punctured, for example with a syringe, and the pharmaceutical composition within the container can be extracted or material can be added to the contents of the container. In some circumstances, such tampering may even go unnoticed.
[0080] In contrast, glass cannot be punctured in this manner. Indeed, due to its tendency to break or shatter, it will be very difficult, if not impossible to tamper with a glass container, without destroying the container. A pressurised glass container in an aerosol or spray device will be particularly difficult to tamper with. Such containers will be pressurised, for example to a pressure of 6-8 bar and are prone to actually explode if tampered with, as the glass having a tendency to crack or shatter, as discussed above. This will make it virtually impossible for the contents of the container to be collected.
[0081] In order to reduce the risk of accidentally breaking of the relatively fragile glass container during normal use, it is preferably encased in a protective housing. Such a housing will reduce the risk of the container breaking by accident, for example when dropped.
[0082] One further advantage obviously afforded by using a container made from glass is the fact that it is transparent. Thus, the contents of the container are potentially visible. When the container is encased in a housing, the housing could be provided with a window, or could be transparent itself, in order to allow the container contents to be viewed.
[0083] Being able to see the amount of the composition left in the container can be very useful, especially where the composition is one which the user relies upon heavily, so that it would be highly undesirable for the composition to unexpectedly run out. For example, where the container contains a strong painkiller, it would be highly undesirable for the patient to only realise that the composition has run out when they require a further dose which is not available. Where the patient can see the composition inside the container, it will be easier to ascertain when the supply of composition is about to run out and when it will be necessary to obtain more.
[0084] According to a preferred embodiment of the present invention, to further assist monitoring of the amount of composition left in a container, the container is provided with markings to show how many doses are left inside the container. Thus for example, a warning line is provided, indicating that it is time to obtain more composition when the level inside the container reaches that line. Alternatively, where the container is encased in a housing, the markings are on the housing, preferably adjacent to the container.
[0085] Some examples of devices for sublingual delivery of cannabis will now be described, by way of example only, and with reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0086] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
[0087] FIG. 1 is a cross sectional view of an embodiment of a device in accordance with the invention, the device having an upright valve.
[0088] FIG. 2 is a cross sectional view of an embodiment of a housing, including a mouthpiece, for an inverted valve device, in accordance with the present invention.
[0089] FIG. 3 is a view of the underside of the housing shown in FIG. 2 .
[0090] FIG. 4 is a perspective view of the housing shown in FIG. 2 .
[0091] FIG. 5 is a view down the mouthpiece of the housing shown in FIG. 2 , the housing containing a spray device with a nozzle having three orifices.
[0092] FIG. 6 is a side view of a device with an upright valve, and a mouthpiece according to the present invention.
[0093] FIG. 7 is a perspective view of the device shown in FIG. 6 , wherein the spray device is being activated by downward pressure on the top of the device.
DETAILED DESCRIPTION OF THE INVENTION
[0094] The device 1 , shown in FIG. 1 , comprises a substantially cylindrical canister 2 sealed with a cap 3 . Both the canister 2 and the cap 3 may be manufactured from a variety of materials. Preferably, the canister and cap are formed from stainless steel or glass. This is because some of the cannabis substances which may be used in the present invention are “aggressive” chemicals and can attack “weaker” container materials. The canister and cap may be lined with a polyester (such as Celanex® 2500) or a lacquer (not shown).
[0095] A valve body moulding 4 comprises a cylindrical portion 5 , which defines a metering chamber 6 and a stepped flange portion 7 , and is formed by injection moulding from Celanex® 2500. The stepped flange portion 7 defines a first and outwardly facing annular seat 8 and a second, inwardly facing annular seat 9 . The first annular seat 8 accommodates an annular sealing ring 10 and the second annular seat 9 accommodates a first sealing washer 11 . The first sealing washer 11 is located so as to cooperate with the cylindrical portion 5 of the valve body moulding 4 , in defining the metering chamber 6 .
[0096] A base 12 of the cylindrical portion 5 of the valve body moulding 4 completes the boundary to the metering chamber 6 and provides a seat for a second sealing washer 13 .
[0097] The sealing ring 10 and the first and second sealing washers 11 and 13 can be formed from a butyl rubber, neoprene or one of the elastomers disclosed for such purposes in WO 92/11190.
[0098] An elongate, substantially cylindrical and partially hollow valve core 14 is slidably located within the first and second sealing washers 11 and 13 and extends through an orifice 15 , defined in the base 12 . The valve core 14 is formed by injection moulding from Celanex® 2500.
[0099] A stepped inlet passage 16 communicates between a first end 17 of the valve core 14 and an inlet orifice 18 , formed through the side of the valve core 14 . In a likewise manner, an outlet passage 19 communicates between the second end 20 of the valve core 14 and an outlet orifice 21 formed through the side of the valve core 14 . An annular flange 22 extends radially outwardly from the valve core 14 between the inlet and outlet orifices 18 and 21 and adjacent to the outlet orifice 21 .
[0100] A stainless steel compression coil spring 23 acts between the annular flange 22 and the second sealing washer 13 , urging the annular flange 22 into contact with the first sealing washer 11 , such that the outlet orifice 21 lies inside the first sealing washer 11 and is thereby isolated from the metering chamber 6 . In this position, as shown in FIG. 1 , the inlet orifice 18 is located within the metering chamber 6 . A flexible tube 24 is engaged within the stepped inlet passage 16 and extends from the valve core 14 to the base of the canister 2 (as shown in FIG. 1 ). Thus, the inlet orifice 18 is in communication with a region within the canister 2 adjacent to its base 12 .
[0101] The cap 3 is firmly attached to the canister 2 by crimping and, thus, holds the assembly of the valve body moulding 4 , valve core 14 , coil spring 23 , sealing washers 11 and 13 and sealing ring 10 in place as shown in FIG. 1 , with the sealing ring 10 and first sealing washer 11 sufficiently compressed to seal the interior of the device 1 and prevent the egress of its contents.
[0102] Downward movement of the valve core, in the direction of arrow A, against the action of the spring 22 will bring the outlet orifice 21 into the metering chamber immediately after the first orifice 18 has been sealed from the metering chamber 6 by the second sealing washer 13 .
[0103] When filled with a composition in accordance with the present invention, as shown at 25 , the device 1 will provide metered doses of the composition when used as follows. The device 1 should be held in the position shown in FIG. 1 , so that the composition 25 , by virtue of its pressure, enters the metering chamber 6 via the tube 24 , the inlet passage 16 and the inlet orifice 18 . Subsequent depression of the valve core 14 , in the direction of arrow A, seals the inlet orifice 18 and hence the remainder of the canister 2 , from the metering chamber 6 and opens the outlet passage to the metering chamber 6 , via the outlet orifice 21 . Since the composition 25 in the metering chamber 6 is pressurised with the propellant, it will be expelled from the metering chamber 6 through the outlet orifice 21 and the outlet passage 19 . If the valve core 14 is then allowed to return to the position shown in FIG. 1 , under the influence of the spring 22 , the outlet orifice 21 is again sealed from the metering chamber 6 and the metering chamber 6 will be filled with pressurised composition 25 from the canister 2 , via the tube 24 , stepped inlet passage 16 and inlet orifice 18 .
[0104] Whilst the foregoing description relates to a device having an upright valve, it is clear that devices with inverted valves may also be used to dispense the compositions of the present invention. Typical suppliers of inverted valves include Bespak plc, King's Lynn, UK, 3M Neotechnic, Clitheroe, UK and Valois Pharm, Le Vaudreuil, France.
[0105] FIGS. 2 to 7 show a mouthpiece according to a preferred embodiment of the present invention. In FIGS. 2 to 5 , the mouthpiece 100 is illustrated as being part of the housing 102 which is used to house an inverted valve spray device. In FIGS. 6 and 7 , the mouthpiece 200 is used with a conventional upright valve device 202 and is affixed to the moveable button part 204 of the dispensing device.
[0106] Thus, when the device is in use, the moveable button 204 is depressed and the mouthpiece will also move relative to the main body of the dispensing device.
[0107] Upon activating either type of spray device illustrated in the figures, the composition held within the container is dispensed from the spray device. As it leaves the spray device, the dispensed composition enters the mouthpiece. The mouthpiece then channels the composition to the opening of the mouthpiece 106 .
[0108] In use, the mouthpiece is preferably placed under the tongue, with the opening of the mouthpiece adjacent to the sublingual area. This ensures that the dispensed composition contacts, almost exclusively, the sublingual area when it leaves the mouthpiece.
[0109] The figures illustrate the preferred shape of the mouthpiece. The mouthpiece has a smooth shape, with a gradually increasing cross-sectional area which then decreases again towards the opening.
[0110] In FIG. 5 , the orifices 300 of the dispensing device are shown. There are three orifices, and each is directional, so that the jets of composition dispensed therefrom converge at a predetermined distance from the outlets themselves.
[0111] There now follow some examples of compositions according to the present invention.
Example 1
[0112] A composition comprising delta-9-tetrahydrocannabinol (delta-9-THC) with HFC134a suitable for use in a device as described above can be formulated from the following ingredients:
[0000]
Component
percent w/w
g/can
Delta-9-THC
0.7
0.099
Ethanol 96% BP
13.2
1.866
Peppermint oil
1.4
0.205
HFC-134a
84.7
12.02
Total
100
14.19
[0113] The peppermint oil is added to the delta-9-THC/ethanol solution and mixed thoroughly. 2.17 g of the resulting solution is then placed in the canister 2 and the valve assembly, comprising the valve body moulding 4 , first sealing washer 11 , second sealing washer 13 , spring 22 , tube 23 , and annular seal 10 are then sealed onto the canister 2 as shown in FIG. 1 by the cap 3 . The propellant is then added to the canister by being forced through the valve core 14 at great pressure, and the complete device is then checked for leaks.
Example 2
[0114] A second composition comprising delta-9-THC with HFC-134a suitable for use in a device as described above can be formulated from the following ingredients:
[0000]
Component
percent w/w
g/can
Delta-9-THC
0.164
0.010
Ethanol 96% BP
4.992
0.305
HFC-134a
94.844
5.795
Total
100
6.11
[0115] The delta-9-THC is dissolved in the ethanol in the proportions set out above and 0.315 g of the resulting solution is then placed in a canister 2 and a valve assembly, comprising a valve body moulding 4 , first sealing washer 11 , second sealing washer 13 , spring 22 , tube 23 , and annular seal 10 , is then sealed onto the canister 2 by crimping as shown in FIG. 1 by the cap 3 . The propellant (HFC-134a) is then added to the canister, by being forced through the valve core 14 at great pressure, and the complete device is then checked for leaks. After the propellant entered the canister it dissolves the remaining portions of the composition.
Example 3
[0116] A third composition comprising delta-9-THC and suitable for use in a device as described above can be formulated from the following ingredients:
[0000]
Component
percent w/w
g/can
Delta-9-THC
0.164
0.010
Ethanol 96% BP
7.5
0.458
HFC-134a
92.336
5.641
Total
100
6.11
[0117] The delta-9-THC is dissolved in the ethanol in the proportions set out above and 0.315 g of the resulting solution is then placed in a canister 2 . A valve assembly (as described in Example 2) is then sealed onto the canister 2 by crimping and the HFC-134a propellant is then added to the canister, by being forced through the valve core 14 at great pressure, and the complete device is then checked for leaks. After the propellant entered the canister it dissolves the remaining portions of the composition.
Example 4
[0118] Further compositions comprising delta-9-THC with HFC-134a, suitable for use in a device as described herein, can be formulated in accordance with the details set out in the following table, in which all figures are given on a percent by weight basis.
[0000]
Formulation
A
B
C
D
E
delta-9-THC
0.164
0.164
0.164
0.164
0.164
Transcutol
9.984
4.992
Oleyl alcohol
2.496
Propylene glycol
4.992
Ethanol
4.992
7.488
4.992
20.51
p134a
89.852
89.852
89.852
89.852
79.326
Total
100
100
100
100
100
[0119] Formulations A-E are prepared using a similar technique to that set out in Example 2 above. Briefly, the delta-9-THC is dissolved with the other excipient or excipients (excepting the HFC-134a) and the resulting solution is then placed in a canister 2 . A valve assembly is then sealed onto the canister 2 by crimping and the HFC-134a propellant is then added to the canister 2 , by being forced through the valve core 14 at great pressure. After the propellant enters the canister 2 , it dissolves the remaining portions of each composition.
[0120] Although only delta-9-tetrahydrocannabinol is referred to in the above mentioned examples, other cannabis active agents previously discussed in this application may be substituted therefor in quantities which would dissolve at least partially in the propellant/co-solvent mixture.
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The present invention relates to an improved mode of administration for cannabis and its natural and synthetic derivatives. A pharmaceutical composition suitable for sublingual aerosol or spray delivery of cannabis is provided. The formulation may be dispensed using a pump spray or the formulation may include a propellant, such as butane, 1,1,1,2-tetrafluoroethane (HFC-134a) or 1,1,1,2,3,3,3-heptafluoropropane (HFC-227). The term cannabis is used herein to refer to all physiologically active substances derived from the cannabis family of plants and synthetic cannabis analogues and derivatives, precursors, metabolites etc., or related substances having cannabis-like physiological effects.
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PRIORITY CLAIM
This application claims the benefit of provisional application Ser. No. 60/780,964 filed Mar. 8, 2006 and provisional application Ser. No. 60/791,671 filed Apr. 13, 2006, both of which are hereby relied upon and incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention generally relates to the control of the air/fuel mixture for small gasoline engines that utilize a carburetor, or some other means of providing fuel into the air stream using a venturi. More particularly, the invention relates to an apparatus and method for regulating the flow of fuel into the air stream using a fast acting solenoid. By controlling the flow of fuel into the air stream, the air-to-fuel (A/F) ratio can be controlled to ensure that the engine operates efficiently under varying loads.
It is well known that the A/F ratio for a typical low revolutions per minute (RPM) air cooled engine used on walk behind mowers, riding mowers and other equipment can be controlled by a carburetor. When the operator increases the RPM with a RPM-demand lever, the engine's throttle plate adjusts to meet the RPM demand and normally a RPM governing system continuously adjusts the throttle plate to meet the set RPM regardless of engine load.
Since engines of this type normally are air cooled, the A/F ratio is configured to get maximum power output without overheating the engine at maximum load. As such, the carburetor calibration normally is such that access to fuel is provided for assisting the cooling of the engine. Since carburetors typically used in these types of applications are of a fairly simple design, features that can enrich the fuel are not present. Due to this and other factors, the same A/F ratio that the engine requires operating at full load will often be supplied to the combustion chamber even when operating at lesser loads. When engines operate at lesser loads, the cooling effect from the fuel is not required; the result is an air-to-fuel mixture that is “rich”—or contains more fuel than needed—for partial load operations.
While using a rich mixture protects against overheating and assists the engine in reacting quickly to increased load demands, it also increases emissions and fuel consumption. With most engines of this type being operated predominantly at partial load, the A/F mixture does not need to be as rich. Thus the emissions and fuel consumption from engines operating at partial load are higher than if the A/F ratio could be adjusted leaner during partial load operation.
An additional problem can occur in small engines due to the lack of control over the flow of fuel into the combustion chamber of the engine. Many small engines are designed such that the exhaust valve remains open for a short time after the intake valve opens. Thus, for a brief period, unburned fuel can pass directly through the exhaust valve into the exhaust system. When fuel passes through the engine without contributing to combustion, the engine is not using fuel efficiently, and emissions will be increased.
It is well known that currently existing technology provides two main techniques for controlling the A/F ratio. One technique is through Electronic Fuel Injection (EFI) that can control A/F ratio cycle-to-cycle. EFI systems, however, are costly to implement due to the high complexity compared to a carburetor. The other common technique used to control the A/F ratio is by using an “air bleed system” that indirectly controls the fuel flow to the air stream. This system, however, usually cannot adjust on a cycle-to-cycle basis and also has longer delay times associated with the physics involved with the mixture adjustment.
SUMMARY OF THE INVENTION
The present invention recognizes and addresses the foregoing considerations, and others, of prior art construction and methods. Accordingly, it is an object of the present invention to provide an improved apparatus and method for the regulation and control of the A/F ratio in an engine.
In one aspect, the present invention provides an apparatus for use with a carburetor on a small engine to control the opening and closing of at least one carburetor fuel path (e.g. jet). The apparatus comprises at least one solenoid that acts to open and close the fuel path. The solenoid controls the operation of a pin—or “plunger”—that acts as a plug to the fuel path. The apparatus further comprises an electronic switching element which allows energy generated preferably by the turning of the flywheel to flow into the solenoid. The apparatus optionally comprises one power source, or in some embodiments several power sources, such as a battery, capacitor or equivalent, which stores energy sufficient to operate the solenoid(s). Finally, the apparatus comprises some control logic (CL) which operates the electronic switching element, thereby directing current to the solenoid at selected intervals.
In another aspect, the present invention provides a method of controlling the opening and closing of the fuel path on a carburetor as to accurately control the amount of fuel that flows into the engine's combustion chamber during a single combustion cycle. The CL can receive data regarding the quality of the combustion from sensors placed in the combustion chamber or in the exhaust system. Using this data, along with information about the speed of the engine a closed loop control of A/F ratio can be achieved. The CL activates and deactivates the solenoid which opens and closes the fuel path pin such that the amount of fuel flowing into the combustion chamber is varied according to the target value for A/F ratio. The control is not limited to be a close loop control. The invention can be controlled based on different sensors and is not limited to any given control strategy.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended drawings, in which:
FIG. 1 is a diagrammatic representation of a carburetor including an air-to-fuel ratio control system in accordance with the present invention;
FIG. 2 is a graphical presentation of the sequence of one complete 4-stroke engine cycle of 720 crank shaft degrees;
FIG. 3 is a circuit diagram of an exemplary power circuit constructed in accordance with an embodiment of the present invention;
FIG. 4 is a circuit diagram of an exemplary power circuit including a second power source constructed in accordance with another embodiment of the present invention;
FIG. 5 is a circuit diagram of an exemplary power circuit including a second power source and switching system in accordance with another embodiment of the present invention; and
FIG. 6 is a schematic diagram of another exemplary power circuit constructed in accordance with another embodiment of the present invention.
Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations.
Many engines have a fuel shut-off solenoid on the carburetor operated by a voltage supplied by a battery. The function of the solenoid is to open the fuel flow into the carburetor when voltage is applied. When the engine is stopped the voltage will be removed and the solenoid will close to prevent fuel from reaching the combustion chamber. The fuel shut-off solenoid performs this function by sealing the carburetor mixing tube so fuel is prevented from mixing with the air. The present invention recognizes that the fuel shut-off function of the solenoid can be controlled and synchronized to the crankshaft rotation so that it can be used for fuel control during engine operation. By controlling fuel flow, the A/F ratio can be regulated.
A 4-stroke engine running at 3000 RPM will have a 25 Hz firing frequency and also a 25 Hz fuel intake frequency. The fuel window if the valves are open the entire inlet stroke is approximately 10 ms at 3000 RPM. Therefore, shortening this fuel window will shorten the amount of fuel transferred into the cylinder. If the fuel flow is proportional to the time and a fuel reduction of 20% is needed, the fuel window should be reduced by 2 ms.
A normal fuel shut-off solenoid that operates with the battery as its power source will have a delay time of at least 5 ms from the stroke command until the stroke is finished. This delay time consists of two portions: (1) delay due to the necessary build up of electromechanical force overcoming friction and spring forces, and (2) the time for the actual movement of the armature. The magnitude of this tolerance will be in the order of 10% due to variation in armature mass, winding resistance, spring forces, friction, operating temperature supply voltage and others. As understood a solenoid with a long delay time cannot be used when accuracy of the fuel control is required.
The following formulas are valid for a solenoid:
F =( N·I ) 2 ·k Eq. 1
Where:
F=Force
N=Winding turns
I=Supply current
k=constant
The constant (k) will depend upon the design and for a given design it can be disregarded:
U
=
R
·
I
+
L
·
ⅆ
I
ⅆ
t
Eq
.
2
This is valid during initiation of the current when time T<<L/R when an approximation of ΔI/ΔT can be calculated as:
Δ I Δ T = U L Eq . 3
Where:
U=Voltage
L=Inductance
I=Supply Current
Δ
I
Δ
T
=
Current
rise
R=Solenoid winding resistance
L=N 2 ·k Eq. 4
Where:
L=Inductance
N=Winding turns
k=Mechanical constant
The mechanical constant (k) depends upon mechanical design and material but for the same mechanical design this value can be assumed constant.
Finally, as an approximation if time T much smaller than L/R:
U = N 2 · k · ( Δ I Δ T ) Eq . 5
Giving that
Δ I Δ T = U N 2 · 1 k Eq . 6
and if k is constant:
Δ I Δ T
only varies with
U N 2
Where:
U=Voltage
N=Winding turns
k=Mechanical constant
Δ
I
Δ
T
=
Current
rise
Note that initially the current rise will only depend upon voltage and inductance as U/L.
Based on these equations it should be apparent to those skilled in the art that by increasing supply voltage, delay time will be reduced. This fact allows for a design where a higher number of winding turns are used which serves to increase the winding resistance. When the stroke of the solenoid is completed all input energy will be in the form of heat that needs to be dissipated by the winding. Therefore the winding resistance needs to be kept at a high enough value such that the current is limited to a safe level. To achieve the same response time with a low supply voltage (e.g., 12V) the resistance needs to be low. Thus, without an active current control the heat build-up in the winding will be too high.
The present invention makes it possible to combine a short delay time through the use of a low energy, high voltage power source to energize the solenoid. Furthermore, the power dissipation in the present invention is self controlled due to the limited energy dissipated to the solenoid. When voltage is high the number of winding turns can be kept high. A high number of winding turns creates a high resistance making this solenoid also suited to be used with a lower voltage (i.e., 12V) without using active current control. Therefore, the high initial voltage causes the solenoid to be fast acting while the low sustaining voltage provides that the solenoid can be energized for a long time without overheating.
In order to regulate the A/F ratio in an open loop manner without using an oxygen sensor, a solenoid with a low delay time is needed in order to reach proper levels of accuracy. A low delay time is needed since there is a correlation between the time the solenoid takes to start and stop the fuel flow and the change in A/F ratio. Accordingly, on applications where the reduction of the A/F ratio is based on load, RPM, or some other factor, the accuracy of the opening and closing time of the solenoid will be a relatively large portion in the deviation in A/F ratio.
In order to reduce the solenoid's delay time previously described (1) a higher supply voltage should be used and (2) the mass of the armature should be kept as low as possible to reduce the actual stroke time. The present invention uses the principle that if the solenoid supply voltage increases then the current for the same resistance will also increase. Since the build-up of the magnetic force depends upon current rise time, ΔI/ΔT should be high. The actual force created by the solenoid depends upon the product of current in the winding and the number of winding turns. A high supply voltage makes it possible to achieve a high ΔI/ΔT with a higher number of winding turns such that a higher magnetic force is achieved.
In one preferred embodiment, the system uses energy stored in a high voltage capacitor to generate the initially needed high current rise to overcome the first delay factor and start the stroke of the armature. When energy stored in the capacitor is limited, the supply voltage will quickly drop down. Since the force needed to move the plunger decreases with a decrease in distance from the plunger seat, the voltage needed to maintain an adequate force also decreases. Thus, a low voltage power source can be engaged to either complete the stroke or to hold the plunger in its inner position. Furthermore, in some embodiments the system will utilize components of the vehicle's ignition system.
FIG. 1 shows a carburetor 204 including an air-to-fuel control system in accordance with certain aspects of the present invention. A jet 200 delivers fuel from fuel chamber 202 into carburetor 204 . Solenoid 206 , plunger 208 , and plunger seat 210 are associated with jet 200 . A valve is created with plunger 208 selectively engaging and disengaging plunger seat 210 . Valve control logic and circuitry 212 operates solenoid 206 . As throttle valve 214 rotates, air enters first opening 216 . If the valve is open, fuel will mix with the air. The air and fuel mixture will then exit carburetor 204 through second opening 218 . This mixture then enters a combustion chamber. An exemplary carburetor which may utilize principles of the present invention is described in PCT application no. PCT/EP2006/011839 to Bing Power Systems GmbH and R.E. Phelon Company, Inc., incorporated herein by reference.
FIG. 2 is a graphical presentation of the sequence of one complete 4-stroke engine cycle of 720 crank shaft degrees. Timing plot 114 demonstrates the electric spark timing (“EST”) in a 4-stroke engine cycle. “TDC” refers to the position of the piston at top dead center and “BDC” refers to the position of the piston at bottom dead center. As can be seen, the fuel window 102 is the period that begins with the opening of the intake (inlet) valve, creating a flow of air that draws fuel through the carburetor and into the combustion chamber. In some embodiments, this fuel window 102 may be longer than the inlet valve opening. For instance, if there is a large air plenum between carburetor outlet 218 and the combustion chamber, it will average the air pulsation so the fuel window may be longer than the inlet valve opening. The fuel window may also vary due to throttle plate opening.
The control of fuel flow can be accomplished by controlling the opening or closing of the solenoid within the fuel window. Accordingly, fuel flow can be controlled by adjusting the opening point or closing point of the solenoid (or both the opening and closing point) which controls fuel flow. By adjusting the fuel flow within the fuel window, the A/F ratio can be adjusted upon demand.
The fuel flow supplied by the carburetor is dependent upon the air speed over the venturi or the lower pressure present in front of the throttle plate. Some types of engines, in particular single cylinder engines, experience a large pulsation of the air flow when the air path to the combustion chamber is open only a part of the complete engine cycle. Back pressure can occur in the system that can alter the air flow and subsequently alter fuel flow. In accordance with the present invention, the opening and closing of the fuel path can be synchronized to the angular position of the engine. Thus, the fuel path can be closed during the period where back pressure can occur. In one relatively simple configuration, the fuel path in the present invention is timed to open during the time period that the inlet valve is opened. As discussed herein, the opening of the fuel path can also be controlled more precisely to control the air-to-fuel ratio.
Fuel can only flow from the fuel reservoir into the carburetor, and thus into the engine's combustion chamber, when the fuel flow path is open. Timing plot 104 illustrates the opening of the fuel path via the fuel shut-off solenoid according to the prior art. As plot 104 makes clear, in the prior art the fuel path through the main jet is open at all times while the engine is running. Because the main jet is the only path through which fuel flows from the fuel reservoir into the mixing tube and then the air steam in a typical small engine application, the main jet is tuned to deliver the amount of fuel that is needed by the engine when operating with full load air flow. A small engine, however, often runs at less than a full load. Accordingly, under the prior art operation that timing plot 104 exemplifies, the engine typically receives more fuel than is necessary when operating at less-than-full load, and as such, does not operate fuel or emission efficient at lesser loads.
Timing plots 108 and 106 , where timing plot 108 is with only one power source and timing plot 106 is with two power sources, demonstrate the timing of fuel flow from the main jet into the engine's combustion chamber according to the present invention. Specifically, timing plots 108 and 106 represent the current flow in the solenoid. The plots indicate that the present invention can open the main jet at some point after fuel window 102 opens, but before fuel window 102 closes. By controlling the opening and, if needed, the closing time of the main jet relative to fuel window 102 opening, the present invention precisely regulates the amount of fuel that flows through the carburetor and into the engine depending on the engine's need at a given time. It can also be seen in FIG. 2 that the solenoid operating windows 110 and 112 are bigger than the fuel window. Therefore, the invention is not limited to embodiments in which the solenoid is operating only within the fuel window.
With a fast acting solenoid, the delay time from the stroke command to fully open is generally in the order of 1 ms. Shortening of the delay time decreases the inaccuracy of A/F ratio caused by the tolerances of the time it takes for turning on and off the solenoid. Precise control over the opening and closing of the fuel path is one significant aspect of the present invention. By opening the fuel path for a controlled time during the fuel intake cycle, the present invention assumes precise control over the amount of fuel that enters the combustion chamber. The end result of this control is that when the engine is operating at less than full load, less fuel flows into the combustion chamber than under the prior art. By accurately controlling the solenoid, the present invention ensures that the engine receives a more precise amount of fuel necessary for efficient operation.
The present invention solves an additional problem over the prior art. Many small engines experience a period of “short circuiting” when the path for exhaust gases remains open for a short time during the inlet stroke. Under the prior art, during this “short circuiting” period some unburned fuel passes directly into the exhaust system without participating in the combustion cycle. According to the present invention, however, the main jet can be closed while the exhaust valve is open, thus preventing fuel from flowing into the combustion chamber until after the exhaust valve closes. By holding the fuel path closed during the early portion of the intake window, the present invention reduces the fuel flow during the sequence where short circuiting can occur.
Referring now to FIG. 3 , a charge coil 12 is positioned such that a magnet 54 on the flywheel 52 will pass by in close proximity. Coil 12 induces a voltage that is rectified by a rectifier diode 14 and stored by capacitor 16 . Control logic is used to recognize the engine position and determine the engine phase. For a combustion turn, capacitor 16 is discharged through a primary coil 18 and a first switching element 10 . Switching element 10 is controlled by the CL to allow conduction through primary coil 18 at the appropriate time. A spark is thus generated at a spark plug 26 by a secondary coil 27 . One skilled in the art will appreciate that the CL can be implemented using hardware, firmware, software or combinations thereof, depending on the requirements of a particular application.
The next engine revolution is a waste turn meaning that no spark is needed at spark plug 26 . Capacitor 16 is again charged when the magneto passes by charge coil 12 . During this waste turn the CL commands second switching element 28 to close. Switching element 28 can be any suitable electronic switching element, such as an insulated gate bipolar transistor (IGBT) or an SCR. When switching element 28 is closed, a solenoid 24 will be energized by capacitor 16 and the armature of solenoid 24 will move. In a preferred embodiment, solenoid 24 will also function as the fuel shut-off solenoid associated with the carburetor.
In many embodiments, the CL will also function to turn off solenoid 24 by opening switching element 28 . By turning off the solenoid, fuel flow will also be stopped. The timing of this step will depend upon the required change in fuel flow as determined by the performance demands of the engine. The operating window will be similar to operating window 110 as shown in FIG. 2 and a timing plot similar to timing plot 108 as shown in the same figure.
Referring now to FIG. 4 , if energy stored in capacitor 16 is not sufficient to keep solenoid 24 active throughout the time needed, then a second power source 30 could be used. Second power source 30 can be any suitable energy supplying means, such as a battery. As shown, second power source 30 is preferably connected to solenoid 24 via a diode 32 . With this configuration, the energy stored in capacitor 16 will energize solenoid 24 when switching element 28 closes and then second power source 30 will hold the solenoid armature in its energized position until switching element 28 opens. The operating window will be similar to operating window 110 as shown in FIG. 2 and a timing plot similar to timing plot 106 as shown in the same figure.
Solenoids have an internal spring that biases the armature in a first direction. Movement of the armature in the second direction is electrically controlled. Thus, fuel flow can be controlled by solenoid 24 using two different options. According to a first option, the solenoid armature spring force closes fuel flow. Utilizing the spring to close fuel flow is generally the preferable solution for the fuel shut-off function. As soon as solenoid 24 is not energized, fuel flow will be restricted. When this solution is used the time the solenoid needs to be open for maximum fuel flow is often too long for just using the energy stored in capacitor 16 . Therefore, use of second power source 30 is generally needed.
According to the second option, the solenoid spring force opens fuel flow. This solution makes it possible to just activate solenoid 24 when fuel flow needs to be restricted. The spring biasing force keeps the fuel flow at the maximum setting calibrated by the carburetor main jet. This solution is generally preferable for applications when the energy stored in capacitor 16 will be sufficient for the time the fuel flow needs to be restricted and a second power source 30 is not used.
A preferred strategy for reduced emissions is to run the engine on standard carburetion and restrict fuel flow at lower engine loads. Thus, if the spring force closes fuel flow the solenoid must be energized most of the time to not restrict the flow. Using the arrangement shown in FIGS. 3 and 4 switching element 28 would be closed all the time and the voltage induced in charge coil 12 would be a short circuit through solenoid winding 24 and switching element 28 . In these circumstances, the ignition system may not work properly.
Referring now to FIG. 5 , in order to alleviate the short circuit concern an additional switching element 34 , preferably an SCR, is utilized. Switching element 34 can be opened and closed so that the functionality of the ignition system 42 is maintained at all times. Thus, switching element 34 can be controlled so that short circuiting of the charge voltage is prevented even when the solenoid is active. Specifically, switching element 34 can be turned off after the energy in capacitor 16 is dissipated. This functionality also allows for a larger operating window 112 and associated timing plot 106 as shown in FIG. 2 . In some embodiments of the present invention, switching element 28 and switching element 34 are both controlled by one output pin from the control logic.
FIG. 6 illustrates another solenoid control circuit constructed in accordance with the present invention. This embodiment includes a solenoid with a plurality of windings 38 . In this embodiment, the CL enables switching element 34 which allows current to flow into one of the windings of solenoid 38 . This winding opens the fuel path plunger, allowing fuel to flow into the engine's combustion chamber. Once the plunger is open, the CL turns on switching element 28 , which allows current from second power source 30 to flow through a different winding of solenoid 38 , holding the plunger open. To close the plunger, the CL turns switching element 28 off (i.e, opens switching element 28 ). The CL turns switching element 34 open as soon as the energy in capacitor 16 is drained. The spring then pulls the main jet plunger closed, plugging the main jet and preventing fuel from flowing into the combustion chamber of the engine. The resulting operating window will be similar to operating window 112 as shown in FIG. 2 .
It would be appreciated by those skilled in the art that the circuit represented in FIGS. 3 , 4 , 5 , and 6 without the primary coil 18 , secondary winding 27 , switching element 10 , and an anti-parallel diode 22 could be used as a dedicated power source for solenoid 24 . This type of configuration would also increase the operating window to a period similar to the window shown by operating window 112 for the circuits represented in FIGS. 3 and 4 .
It can thus be seen that the present invention provides an apparatus and method for adjusting A/F ratio in a small internal combustion engine. While one or more preferred embodiments of the invention have been shown and described, modifications and variations may be made thereto without departing from the spirit and scope of the invention. For example, embodiments of the invention are contemplated utilizing a solenoid or stepper motor capable of achieving and maintaining a range of intermediate positions for the carburetor plunger (in addition to open or closed). It should be understood that any and all equivalent realizations of the present invention are included within the scope and spirit thereof. The embodiments depicted are presented by way of example only and are not intended as limitations upon the present invention. Thus, it should be understood by those of ordinary skill in this art that the present invention is not limited to these embodiments since modifications can be made.
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An apparatus and method for use with a carbureted internal combustion engine that accurately controls the amount of fuel that passes through the carburetor into the combustion chamber of the engine. A controlled triggering system controls the activation and deactivation of a solenoid. The solenoid, in turn, operates a plunger that varies the flow of fuel during the fuel intake cycle of the engine depending on the amount of fuel needed by the engine under any operating load. Thus, an engine can run leaner under partial load and run richer during periods of load and acceleration. By controlling the air-to-fuel ratio lower engine emissions and fuel consumption can be achieved.
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RELATED APPLICATIONS
The present invention is a continuation in part of the application Ser. No. 09/024,035, filed on Feb. 16, 1998 now U.S. Pat. No. 5,878,976.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to dispensing apparatus for rolled material, more particularly, to a spring actuated, paper towel holding and dispensing apparatus.
2. Description of the Related Art
As is well-known in the art, numerous devices exist which simplify the process of holding and dispensing of rolled materials, such as bathroom tissue and paper towels. It is also well known that when rolled materials are dispensed, certain problems are routinely encountered. These include the following.
The first problem with the previous art devices is the unintentional disconnection of the paper towel roll from the support and dispensing device. This is due to the structure of many paper towel holding and dispensing apparatus. Many designs include a pair of support arms which extend outward, perpendicular from a base support. These arms normally contain cylindrical shafts mounted horizontally to the arms, upon which the open ends of the paper towel roll are inserted. Others incorporate a spindle placed through the paper towel roll and which connects to both support arms. The paper towel roll is attached to the paper towel holder by pulling the support arms outward, away from the ends of the paper towel roll, such that the paper towel roll can be inserted over the protruding cylindrical shaft, or in the case of devices with spindles, the spindle can be connected to both cylindrical shafts. This outward movement of the support arms flexes the base support, placing significant pressure on it, and over time, deforming the base support. In fact, the pressure on the base support is intentional, as it creates a means of creating the lateral force required between the support arms and the paper towel roll to keep the paper towel roll in place. This deformation of the base support reduces the lateral force that the support arms can exert on the ends of the paper towel roll, or the spindle, thus allowing the paper towel roll to detach from the assembly, most likely during the dispensing of the paper towels.
Some rolled material holding and dispensing devices attempt to solve this deformation problem by utilizing a spring loaded spindle that connects to both support arms. Examples of this technology as applied to toilet paper dispensers, include U.S. Pat. No. 5,374,008, issued in the name of Halvorson et. al., U.S. Pat. No. 3,362,653, issued in the name of Carlisle, U.S. Pat. No. 2,801,809, issued in the name of Glaner, U.S. Design Pat. No. D347,534, issued in the name of Gottselig. Other devices, such as that disclosed in U.S. Pat. No. 5,292,083, issued in the name of Ridenour, utilize a spring, without a spindle, that slides into the paper towel roll cardboard core, to apply the lateral force upon the support arms.
There are, however, problems with applying this type of technology to paper towel holding and dispensing devices. First, these devices and others that utilize the spring loaded spindle are usually used in conjunction with metal dispensers. The base support of these devices can withstand the pressure that the spindle places on the support arms without deforming. Paper towel holders, however, are usually plastic in design, and as such, the pressure placed on the base support from the spring loaded spindle will cause the deformation of the base support and subsequent detachment of the paper towel roll, as discussed above in relation to typical rolled paper dispensers. Thus, plastic paper towel holders with spring loaded spindles are problematic. Second, the metal assemblies, necessary for the adequate function of the spring loaded spindle, are prohibitively heavy, as many paper towel holders are mounted on counter tops without wooden wall supports to be connected to. As such, the metal devices would detach from the drywall, and cause aesthetic damage to the wall. Furthermore, the use of metal in the fabrication of paper towel holders creates several other problems, including increased cost, and increased difficulty of manufacture.
Another problem with spindles is that the use of spindles as a means of attaching the rolled paper to the dispensing assembly is burdensome. The spindle must be removed and reinserted into a new paper towel roll each time one runs out of paper towels, and the spindle must then be connected to the support arms with the bulky paper towel roll obstructing one's view and limited hand space to connect the spindle and the support arms. Also, the spindles typically fall out of the paper towel roll cardboard core during attachment and detachment of the paper towel roll, creating frustration for the user. Second, the spindles fall to the ground and disassemble when the support arms fail to support the paper towel roll during dispensing. Also, upon detachment, the spindle is likely to get lost, even if temporarily, thus adding to frustration of the user. Fourth, the fact that many of the springs are not secured within the spindle housing means that these components will likely spill out even when the roll is purposefully being detached, as during roll changes.
U.S. Pat. No. 4,535,947, issued in the name of Hidle, attempts to deal with the disconnection problem another way. The '947 device discloses support cylinders which are inserted into the roll of paper towels, increasing the axial penetration of the cylindrical shafts, and which connect to the support arms, thus keeping the roll from disconnecting. There are problems with this design, however. First, removing the support cylinders from a used device is time consuming and burdensome. Second, the overall design is complicated. Third, the device does not address the other problems discussed below.
Another problem associated with the dispensing of rolled paper products is the inability to control the exact amount of paper to be dispensed in an easy manner. This problem is due to the fact that most paper towel holders offer too much or too little resistance to the rolling action of the paper towel roll.
Devices which attempt to deal with this problem have generally been of the type disclosed in U.S. Pat. No. 4,239,163, issued in the name of Christian. The '163 device discloses a tissue roll holder brake member insertable to fit snugly into an open end of a cardboard tube on which a roll of tissue paper is wound. The '163 device also employs a spring loaded spindle, which creates the deformation problems when applied to plastic paper towel dispensers, discussed above. As such, the '163 device cannot be adapted to work effectively on paper towel dispensing apparatus.
Some devices rely on the flexing of the support arms and rear main support to place pressure on the paper towel roll. These devices suffer from the deformation problems discussed above. Also, the devices do not place pressure primarily against the cardboard roll that holds the paper towels, but instead, place what little pressure they do create, on the entire paper towel roll. Typically, the entire ends of the paper towel roll rest against the support arms. This configuration gives much resistance when the paper towel roll is full, and the paper towel roll is in contact with a large surface area of the support arms, but offers little resistance when the paper towel roll is near empty. Thus, it is too difficult to turn the paper towel roll when it is full, and too much paper comes off the paper towel roll when it is nearly empty.
In addition, too much pressure on the paper towel roll will likely result in a detachment of the paper towel roll from the device, as the additional force required to tear a sheet of paper towel will likely disconnect the paper towel roll from its point of attachment.
Another problem with devices in the previous art relates to their inability to accommodate paper towel rolls whose widths differ. Different brands of paper towels utilize paper towel roll cardboard cores of differing lengths, and paper towels of differing widths. Because the support arms of these devices are at a fixed distance apart from each other, they cannot adapt to these variations. Paper towel rolls of decreased width cause the roll to detach, while rolls of increased width cause the base support deformation problems discussed above.
Support for the proposition that no one device has solved all these problems and been adopted by the majority of the public, is the fact that no such device exists in the homes of most people.
A search of the previous art did not disclose any patents that read directly on the claims of the instant invention.
Consequently, a need has been felt for providing a simple and economical paper towel holding and dispensing device which overcomes the problems associated with the previous art.
SUMMARY OF THE INVENTION
It is therefore a general object of the present invention to provide an improved, spring activated, paper towel holding and dispensing apparatus that is effective, simple and easy to use, and facilitates the controlled dispensing of paper towels.
In accordance with a preferred embodiment of the present invention, a spring actuated, paper towel holding and dispensing apparatus is disclosed, consisting of a base support, attachment holes, base support male projections, support arm receiving orifices, support arms, cylindrical shafts, spring members, spring member guides, spring member guide holes, spring member retaining orifices, spring member alignment protrusions, base support retention means, flanges, and tension adjustment assemblies.
The base support is longitudinally elongated, and is constructed of a durable, lightweight material, such as plastic. Positioned in lateral linear alignment on the base support are two attachment holes, which can be used in conjunction with an attachment means, such as screws, to attach the present invention to a wall, underneath a cabinet, etc. The base support extends outward and terminates on either end with a base support male projection. The base support male projections are tapered in design. Each of the two base support male projections passes into and terminates inside of a support arm receiving orifice. Attached to the end of each support arm receiving orifice is a support arm. Each support arm is elongated and extends outward, perpendicular to the centerline of the base support. Connected to the interior surface of each support arm, opposite the support arm receiving orifice, is a cylindrical shaft. Each cylindrical shaft is mounted such that its center line is perpendicular to the interior planar surface of each support arm and parallel to the centerline of the base support.
Spring members are positioned within the base support. The one or two spring members extend laterally, running parallel to the center line of the base support, which is hollow in design. Each spring member is positioned in the same plane relative to the centerline of the base support. In the case of two spring members, each spring member passes through the center of the base support, being kept equidistant from each other by means of a spring member guide.
The spring member guide consists of two spring guide member holes positioned in linear alignment. The spring member guide is positioned at the end of each base support male projection. Each spring member passes through the hollow base support male projection and through a spring member guide hole. Each spring member attaches to the support arm by means of a spring member retaining orifice, which is positioned on the exterior surface of a spring member alignment protrusion. The spring member alignment protrusions are cylindrical in shape, and are positioned on the interior surface of the support arm receiving orifice, extending laterally outward, toward the base support. Each spring member alignment protrusion is in linear alignment with the corresponding spring member.
When each base support male projection is inserted into the corresponding support arm receiving orifice, each of the two spring member alignment protrusions is inserted into the corresponding spring member guide hole. A base support retention means, such as a raised wedge, is positioned on the rear interior surface of the support arm receiving orifice. The base support retention means is positioned such that it increases in thickness as its depth into the support arm receiving orifice increases. Once the spring member guide slides over the base support retention means, its lateral movement is limited such that the base support male projection cannot exit from the support arm receiving orifice. Once the base support and the support arm receiving orifice are connected, the relative position of each support arm with respect to the base support can be varied such that the lateral distance between the support arms can be adjusted to fit a variety of paper towel rolls of differing widths.
Each cylindrical shaft contains a flange at the position where the paper towel roll cardboard core contacts the cylindrical shaft. The flange permits the cylindrical shafts to come in contact primarily with the paper towel roll cardboard core, and not the sheets of paper towels. This creates even tension regardless of the amount of paper towels on the paper towel roll.
Lateral force is also applied to the paper towel roll by an inner spring that rests within the cylindrical shaft. Retraction of the cylindrical shaft away from the paper towel roll is facilitated by a retraction means.
To use the device one separates the support arms by pulling them apart. The paper towel roll is then placed in between the support arms, and the paper towel roll cardboard core is place over the cylindrical shafts. The separation of the two support arms elongates the two spring members, which places sufficient, even, lateral forces on the paper towel roll cardboard core when the support arms are released. The paper towel roll will turn slowly and evenly, permitting the easy tearing of the desired number of towels, with one hand, without the paper towel roll becoming disconnected from the cylindrical shafts.
It is another object of the present invention to provide a spring actuated, paper towel holding and dispensing apparatus that successfully addresses the problem of the paper towel roll accidentally detaching from the present invention when the paper towel roll is being turned or when a paper towel is being torn off the paper towel roll.
It is another object of the present invention to provide a paper towel holding and dispensing apparatus that can be used with all brands of paper towels, regardless of minor variations in paper towel width.
It is another object of the present invention to provide a spring actuated, paper towel holding and dispensing apparatus that applies an even resistance to the rolling action of the paper towel roll. Thus, the present invention facilitates the release of precisely the number of sheets the user wishes, without excess paper towels coming off the paper towel roll or without excessive force being required to remove the paper towels from the paper towel roll. Thus, an advantage of the present invention is that it can be operated with one hand.
It is another object of the present invention to provide a spring actuated, paper towel holding and dispensing apparatus that applies pressure to the paper towel roll cardboard core without the paper towels rubbing against the support arms. This creates the advantage of controlled, sufficient pressure applied to the paper towel roll both when the paper towel roll is full and almost empty.
It is another object of the present invention to provide a device which does not require the use of a detachable spindle to hold the paper towel on the device. This creates several advantages. First, no spindle need be inserted into the paper towel core of the rolled paper towels, saving time and effort. Second, there is no spindle to lose, or springs inside the spindle to misplace.
It is another object of the present invention to provide a device that applies sufficient lateral force on the paper towel roll cardboard core without flexing the support arms outward from the paper towel roll and consequently, flexing and compromising the structural integrity of the main support over time.
It is another object of the present invention to provide a device that facilitates the quick and easy installation and removal of paper towel rolls.
It is another object of the present invention to provide a device that is simple in construction, inexpensive to manufacture, and ruggedly constructed.
Yet another object of the present invention is to provide a device that is made from a strong substance, such as plastic, and which parts can be attractively colored for consumer appeal.
It is another object of the present invention to provide a spring actuated, paper towel holding and dispensing apparatus that can be utilized in kitchens, laundry rooms, basements, garages, bathrooms, and any other place it is required.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a front view of the preferred embodiment of a spring actuated, paper towel holding and dispensing apparatus;
FIG. 2 is a top view of the preferred embodiment;
FIG. 3 is a rear perspective cross sectional view of the preferred embodiment cut along line I--I, showing a partial cutaway view of the base support;
FIG. 4 is an enlarged, exploded, perspective view of the support arm and base support showing how they are connected;
FIG. 5 is an enlarged, front, cross sectional view of the cylindrical shaft cut along line II--II;
FIG. 6 is a front perspective view of the preferred embodiment shown with a modified tension adjustment assembly;
FIGS. 7a-7l are a series of perspective views of alternate embodiments of the present invention, designed for aesthetic purposes, using the same spring mechanism as the preferred embodiment;
FIG. 8a is a rear view of an alternate design for the base support;
FIG. 8b is a side view of the spring member;
FIG. 8c is an end view of the base support of the alternate design of FIG. 8a;
FIG. 9 is a rear view of another alternate design for the base support; and
FIG. 10 is a perspective view of an alternate embodiment of the present invention.
______________________________________ 10 spring actuated, paper towel holding and dispensing apparatus 20 base support 30 attachment hole 35 attachment means 40 base support male projection 50 support arm receiving orifice 60 support arm 70 cylindrical shaft 80 spring member 90 spring member guide100 spring member guide hole110 spring member retaining orifice120 spring member alignment protrusion130 base support retention means140 paper towel roll150 flange160 paper towel roll cardboard core170 paper towel180 tension adjustment assembly190 retaining ring210 cylindrical shaft retaining ridge240 retaining notch260 tension adjustment means290 internal spring300 internal spring housing310 retention means hole320 retention means330 grasping means340 retention means body350 cross brace______________________________________
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to describe the complete relationship of the invention, it is essential that some description be given to the manner and practice of functional utility and description of a spring actuated, paper towel holding and dispensing apparatus 10.
The best mode for carrying out the invention is presented in terms of its preferred embodiments, herein depicted within the FIGS. 1 through 10.
1. Detailed Description of the Figures
Referring now to FIGS. 1, 2, and 3, a spring actuated, paper towel holding and dispensing apparatus 10 is shown, according to the present invention, and which consists of a base support 20. The base support 20 is longitudinally elongated, and is constructed of a durable, lightweight material, such as plastic. Positioned in lateral linear alignment on the base support 20 are two attachment holes 30, which can be used in conjunction with an attachment means 35, such as screws, to attach the present invention to a wall, underneath a cabinet, etc. The base support 20 extends outward and terminates on either end with a base support male projection 40. The base support male projections are tapered in design. Each of the two base support male projections passes into and terminates inside of a support arm receiving orifice 50. Attached to the end of each support arm receiving orifice 50 is a support arm 60. Each support arm 60 is elongated and extends outward, perpendicular to the centerline of the base support 20. Connected to the interior surface of each support arm 60, opposite the support arm receiving orifice 50, is a cylindrical shaft 70. Each cylindrical shaft 70 is mounted such that its center line is perpendicular to the interior planar surface of each support arm 60 and parallel to the centerline of the base support 20.
Referring to FIG. 3, two spring members 80 are positioned within the base support 20. The two spring members 80 extend laterally, running parallel to the center line of the base support 20, which is hollow in design. Each spring member 80 is positioned in the same plane relative to the centerline of the base support 20. Each spring member 80 passes through the center of the base support 20, being kept equidistant from each other by means of a spring member guide 90.
Referring now to FIG. 4, the spring member guide 90 consists of two spring member guide holes 100 positioned in vertical linear alignment. The spring member guide 90 is positioned at the end of each base support male projection 40. Each spring member 80 passes through the hollow base support male projection 40 and through a spring member guide hole 100. Each spring member 80 attaches to the support arm 60 by means of a spring member retaining orifice 110, which is positioned on the exterior surface of a spring member alignment protrusion 120. The spring member alignment protrusions 120 are cylindrical in shape, and are positioned on the interior surface of the support arm receiving orifice 50, extending laterally outward, toward the base support 20. Each spring member alignment protrusion 120 is in linear alignment with the corresponding spring member 80.
When each base support male projection 40 is inserted into the corresponding support arm receiving orifice 50, each of the two spring member alignment protrusions 120 is inserted into the corresponding spring member guide hole 100. A base support retention means 130, such as a raised wedge, is positioned on the rear interior surface of the support arm receiving orifice 50. The base support retention means 130 is positioned such that it increases in thickness as its depth into the support arm receiving orifice 50 increases. Once the spring member guide 90 slides over the base support retention means 130, its lateral movement is limited such that the base support male projection 40 cannot exit from the support arm receiving orifice 50. Once the base support 20 and the support arm receiving orifice 50 are connected, the relative lateral position of each support arm 60 with respect to the base support 20 can be varied such that the lateral distance between the support arms 60 can be adjusted to fit a variety of paper towel rolls 140 of differing widths.
FIG. 5 provides further detail as to the configuration of the cylindrical shaft 70. The cylindrical shaft 70 contains a flange 150 at the position where the paper towel roll cardboard core 160 contacts the cylindrical shaft 70. The flange 150 permits the cylindrical shaft 70 to come in contact primarily with the paper towel roll cardboard core 160, and not the paper towels 170 on the paper towel roll 140. This creates even tension regardless of the amount of paper towels 170 on the paper towel roll 140.
Referring now to FIG. 6, the preferred embodiment is shown with a tension adjustment assembly 180 located on each support arm 60 is used to adjust the lateral force placed upon a paper towel roll 140. The tension adjustment assembly 180 also provides better clearance for placing the paper towel roll 140 on the present invention.
Each cylindrical shaft 70 is held in place by means of a retaining ring 190. Located on the exterior surface of each cylindrical shaft 70 is a series of three cylindrical shaft retaining ridges 210, which are equidistantly located relative to the radial center of each cylindrical shaft 70.
An internal spring 290 is positioned inside of the cylindrical shaft 70. The internal spring 290 and cylindrical shaft 70 share the same axial center. The internal spring 290 provides the lateral force against the paper towel roll 140. An internal spring housing 300 is a cylindrical protrusion positioned on the outside surface of each support arm 60 and extending laterally outward. The end of the internal spring housing 300 opposite the support arm 60 terminates with an end surface consisting of a retention means hole 310 with the same axial center as the internal spring housing 300.
A retention means 320, consisting of a grasping means 330 and a retention means body 340, is used to facilitate retraction of the cylindrical shaft 70 away from the paper towel roll 140 and into the internal spring housing 300.
The retention means body is a long, cylindrical rod which extends through the retention means hole 310, the internal spring housing 300, the support arm 60, and the internal spring 290, snapping permanently into the end of the cylindrical shaft 70. The retention means hole 310 is of sufficient diameter to allow the retention means body 340 to pass through it.
The cylindrical shaft retaining ridges 210 that slide into retaining notches 240 on the internal spring housing 300 prevent rotational movement of the cylindrical shaft 70.
Referring now to FIGS. 7a through 7k, alternate embodiments of the present invention are disclosed. These alternate embodiments are for aesthetic purposes, and each uses the same spring mechanism complete with spring members 80, as the preferred embodiment of the present invention described above.
Referring now to FIG. 8a through 8c, in an alternate design of the base support 20, the posterior ends of the base support 20 are curved so as to create a decorative design that is aesthetically pleasing.
Referring now to FIG. 9, cross braces 350 are depicted inside the spring member guide 90. The cross braces 350 provides structural support for the base support 20, as force is applied to the spring member 80 during use.
Referring now to FIG. 10, it is envisioned that only one spring member 80 is utilized in this embodiment. The length, size and configuration of the spring member 80 is adapted to provide sufficient force for operation of the present invention. For purpose of disclosure, the spring member 80 has a length of 9.5 inches hook to hook, an outside diameter of 0.312 inches, and a wire diameter of 0.035 inches.
The alternate design removes the need for internal spring member guides 90. The one spring member guide 90 is configured as an external channel, located on and formed from the rear of the base support 20. Also, the spring member alignment protrusions 120 have been modified in size and configuration, and are now located on the inside lateral wall of the support arm receiving orifice 50.
2. Operation of the Preferred Embodiment
In accordance with a preferred embodiment of the present invention, to use the device, one separates the support arms 60 by pulling them apart. The paper towel roll 140 is then placed in between the support arms 60, and the paper towel roll cardboard core 160 is place over the cylindrical shafts 70. The separation of the two support arms 60 elongates the two spring members 80, which places sufficient, even, lateral force on the paper towel roll cardboard core 160 when the support arms 60 are released. The paper towel roll 140 will turn slowly and evenly, permitting the easy tearing of the desired number of paper towels 170, with one hand, without the paper towel roll 140 becoming disconnected from the cylindrical shafts 70.
The cylindrical shaft 70 can be retracted by pulling on the grasping means 330. This action pulls the cylindrical shaft 70 into the support arm 60 and into the internal spring housing 300. Lateral force on the paper towel roll 140 is restored by releasing the grasping means 330.
The foregoing description is included to illustrate the operation of the preferred embodiment and is not meant to limit the scope of the invention. The scope of the invention is to be limited only by the following claims.
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A spring actuated, paper towel holding and dispensing apparatus is provided, which functions to provide adjustable and constant pressure to paper towels by utilizing a main body which slidably engages two support arms, with lateral tension being provided by a set of spring members which runs inside the main body and connects the support arms. Such lateral force permits lateral adjustment of the device to fit a variety of paper towels of differing lateral widths. The paper towel roll is secured to the device by a tension adjustment assembly, which provides constant, even, adjustable lateral tension to the paper towel roll itself, and not the paper towels.
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RELATED APPLICATIONS
This application is a divisional application of our application Ser. No. 08/576,949 filed Dec. 22, 1995, now U.S. Pat. No. 5,766,735, which in turn is a continuation application of our application Ser. No. 08/160,492 filed Dec. 1, 1993 (now U.S. Pat. No. 5,494,628, issued Feb. 27, 1996), which prior applications are hereby incorporated by reference herein.
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a mat produced on basis of a nonwoven.
Such mats are known.
The object of the present invention is to provide a new mat produced on basis of a nonwoven.
SUMMARY OF THE INVENTION
As a result of the development of the invention, there is created a new mat produced on basis of a nonwoven which has a high flexibility produced by the entanglement of low-melting and high-melting parts. The mat of the invention comprises predominantly fibrous plastic parts which are in part thermoplastic and of low melting point and in part of higher melting point. By the superficial melting of the low melting thermoplastic fibers, the fibrous parts are held together. As high-melting fibers polyamide fibers which have a melting point of about 220° C. are preferred. This melting point is clearly above that of the thermoplastic low-melting fibers. Here, polyolefins such as polypropylene, polyethylene or the like are preferred. By the action of heat on the fibers which are strewn of applied loosely in the form of a mat, a superficial melting of the low-melting thermoplastic fibers such as, for instance, polyethylene or polypropylene is obtained, leading to adherence between the low-melting parts and the higher-melting parts. The temperature during the action of the heat corresponds in this connection approximately to the melting point of the low-melting fibers, i.e. about 120-170° C. In this connection, the stiffness and self-supporting character of the mat can be controlled. For instance, it is increased with an increasing percentage of low-melting thermoplastic fibers within the mat or else upon the lengthy action of heat, whereby the lower lying low-melting fibers are also melted. The mat can furthermore contain portions of polyester fiber material as well as portions of styrene/butadiene, styrene/acrylate or else ethylene vinyl acetate. It has been found particularly advantageous for the melted regions to be arranged in the manner of islands or interlaced as islands. In this way, a netlike support structure of the mat is established, the narrowness of the netting and thus the stiffness and self-supporting character of the mat being dependent on the quantitative ratio between low-melting and high-melting portions and the time of action of the heat. In this connection, it is preferred to arrange the melted regions so that they lie only on the surface. This means that the regions which are melted on the surface of the mat produce coherence together of the fiber portions and thus form a stabilizing "outer skin". The high-melting portions and those low-melting portions not melted by the action of the heat adhere to each other on the one hand due to their entangled condition and, on the other hand, by melting together at the melted regions, to the low-melting portions. In a preferred embodiment, the melted regions are arranged on the surface on one side. The mat thus has a stabilizing "outer skin" only on one side. It is also particularly advantageous for the mat produced as nonwoven to be made conductive, for instance by portions of carbon fibers or metallized conductive fibers (the latter, in their turn, preferably having a base of polyamide).
The object of the invention is, furthermore, a method of manufacturing a mat produced on basis of a nonwoven, for instance a mat of the type described above. In this connection, a carpet consisting predominantly of plastic fibers and which consists preferably of a pile material having a base of preferably polyamide 6,6, preferably of a support material of polypropylene nonwoven or polypropylene ribbon fabric, and furthermore preferably of a precoat of styrene butadiene, ethylene vinyl acetate, styrene acrylate or the like, furthermore preferably of a laminating adhesive having a base of polyolefins such as, for instance, polyolefin and polypropylene, and furthermore preferably of a back layer having a base of polyolefins, preferably polypropylene or the like, is torn into fibrous pieces, a nonwoven, which is possibly needled, is formed therefrom and is acted on, at least the surface of this nonwoven, by heat in such a manner that the low melting thermoplastic portions melt. For this there is required an action of heat which melts the polyolefin parts but not the fibrer portions having a base of in particular polyamide. For example, polyamide has a melting point of 220° C., while the polyolefins used soften and melt already at 120-170° C. In this way, the low-melting fibers arranged on the surface of the nonwoven are superficially melted, whereby a punctiform bonding of the parts arranged entangled on the surface of the nonwoven is obtained. As already described, the melted regions can be arranged in the form of islands or linked in the form of islands. In order to obtain better adherence of the pieces to each other, it is preferred that the mat be compacted after the melting. In this way, greater stability of the mat is also obtained. It is advantageous to compress the mat between pressing-cooling rolls after the melting. Finally, it is provided that the web be placed on a support web which travels along at least until the low-melting thermoplastic portions have melted. In this way handling is made possible despite coherence of the fibrous parts merely by the entangled position of the individual parts prior to the action of the heat.
In addition to this, the object of the invention is a carpet, in particular a carpet having a pile layer of pile threads, a support layer which consists of fiber or ribbon material of polyolefins or polyesters, and a rear coating, the pile threads being possibly firmly attached to the support layer by the rear coating, and of a plastic which is comparatively resistant to high temperatures, in particular polyamide 6 or 6,6. In this connection, it is intended that an intermediate layer consist of a mat, the mat having fibrous parts which consist predominantly of plastic which are in part thermoplastic and of low melting point and in part of higher melting point, coherence being obtained by the superficial melting of the low-melting thermoplastic fibers, preferably produced in a method in which a carpet consisting predominantly of plastic fibers is torn up into fibrous parts, a nonwoven, possibly a needled woven, is formed therefrom and at least the surface of this nonwoven is acted on by heat in such a manner that low-melting thermoplastic parts melt. The mat described in the previous embodiments can, on the one hand, be used as underlay for tacked carpets or else as intermediate layer within a carpet. In this connection, the mat may be covered on its bottom by a fabric layer. Finally, the mat can advantageously be laminated to an intermediate layer, in particular by the superficial melting of the low-melting thermoplastic parts. In this connection, one can proceed in the manner that the superficial melting of the low-melting thermoplastic parts of the nonwoven form both the coherence between the fibrous parts of the mat and the adherence to an intermediate layer. This can be done in one operation, provided that the parts of the carpet which is to be provided with the mat consist of thermoplastics which are resistant to high temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described below with reference to the accompanying drawings, which, however, show merely illustrative embodiments. In the drawing:
FIG. 1 is a diagrammatic showing of a mat produced on basis of a nonwoven, shown in a greatly enlarged view;
FIG. 2 is a section along the line II--II of FIG. 1;
FIG. 3 is a greatly enlarged showing of a portion of FIG. 1 in the region of melted regions of low-melting thermoplastic fibrous parts which are arranged in the form of islands;
FIG. 4 is a diagrammatic showing of an apparatus for the manufacture of a mat produced on basis of a nonwoven; and
FIG. 5 is a diagrammatic view of a carpet shown partially torn open, the carpet being provided with an intermediate layer consisting of a mat in accordance with FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is first of all shown and described a mat 2 made on basis of a nonwoven 1 and having fibrous parts 3 consisting predominantly of plastic. These fibrous parts 3 are a mixture of thermoplastic low-melting fibers 4 and higher-melting fibers 5. The low-melting fibers 4 consist, for instance of polyolefins, such as polyethylene, polypropylene, or the like. As fibers 5 which are resistant to high temperature fibers of polyamide 6 or polyamide 6,6 are preferably used. The fibers 4 and 5 are entangled in each other, whereby the fibers 4 and 5 are held together, this holding being increased by regions 7 of melted low-melting fibers arranged distributed on the one surface 2' of the mat 2. As can be noted in particular from FIG. 3, the higher-melting polyamide fibers 5 are connected together by the low-melting fibers 4 which bond the polyamide fibers, surrounding them, as shown, for instance, at the reference numeral 6. Larger accumulations, as indicated by the reference numeral 8, of the thermoplastic portions are also present. Fiber groups 8 which are connected by longer polyamide fibers 5 to other fiber groups 8' result. Furthermore, melted regions 9 in the form of adhesive points on the surface 2' of the mat 2 result. By these adhesive points, which are arranged in the form of islands, improved coherence of the fibers within the mat 2 is obtained. Depending on the frequency of the low-melting fibers 4, these adhesive points can also pass in netlike manner into each other. A support structure is thus established, the adhesive points 9 consisting of melted low-melting fibers 4 partially surrounding the fibers 5 of higher melting point. The latter, in turn, are held together by their entanglement. As can be noted from FIG. 2, only the low-melting fibers 4 which are arranged close to the surface 2' are melted to form adhesive points 9. The low-melting fibers 4 which are remote from the surface 2', i.e. arranged in the center or on the opposite side, are not melted and are included in the entanglement. As a result of the island-like bonding or island-like linked bonding of the fibers 4 and 5 and the entangled position of the fibers, flexibility of the mat 2 is obtained.
In addition to this, the mat 2 contains conductive substances. They may consist, for instance, of carbon fibers 26 or of metallized conductive fibers (the latter, in their turn, having preferably a base of polyamide).
In FIG. 4, an apparatus 10 for the manufacture of a mat 2 produced on basis of a nonwoven 1 is shown. For this purpose, fibrous parts 11 which are obtained from a torn carpet consisting predominantly of plastic fibers are shaped in a first apparatus 12 into a loose web held together merely by the entanglement of the individual fibers 4 and 5, for instance by means of a slide 13, and laid on a support web 14 in the form of a circulating endless belt. The nonwoven, which is formed merely by the entanglement of the fibrous parts 3, bears the reference numeral 15 in FIG. 4. The nonwoven lying on the support web 14 now passes below a melting device 16, whereby the low-melting fibers 4 arranged on the surface 2' of the mat 2 are melted and thus form a stabilizing "outer skin". During the further course of the transport after moving below the melting device 16 in the direction indicated by the arrow x, the mat is acted on by pressing-cooling rolls 18 and compacted.
FIG. 5 shows an example of the uses of a mat 2 produced in this way. In this case, the mat serves as intermediate layer 19 of a carpet 20. This carpet 20, which is shown diagrammatically in FIG. 5, has pile threads 21 which form a pile layer, consisting of polyamide 6 or polyamide 6,6. These pile threads 21 are needled into a support material 22. The support material 22 can be a nonwoven or ribbon fabric of polypropylene. A first attachment of the pile threads 21 to the support material 22 is obtained by a so-called precoat 23, which is shown here as a layer of exaggerated thickness. Actually, the precoat layer is very thin. The precoat consists of copolymers of, for instance, styrene/acrylate, styrene/butadiene, ethylene vinyl acetate, and the like. The support material 22 with the pile threads 21 needled and fastened therein--due, for instance, to the precoat 23--is attached by a lamination 24, shown here also for reasons of demonstration as a layer of exaggerated thickness, to the mat 2, developed as intermediate layer 19. This attachment can, however, also be effected by the melting of the low-melting thermoplastic fibers 4 of the mat 2. On its bottom, the mat is covered by a fabric layer 25. The latter can, for instance, be a fabric having a base of polypropylene.
The mat 2 shown and described can, however, also be used as independent product in the sense of an underlay for tacked carpets.
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A carpet having a pile layer, a support layer and a rear coating. The carpet has an intermediate layer formed from a mat comprising fibrous parts made predominantly of plastic which are in part thermoplastic and of low-melting point fibers and in part higher-melting point fibers, and melted regions providing coherence of both of the fibers, the melted regions being formed of partly melted regions of the low-melt-ing point thermoplastic fibers.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part of application Ser. No. 10/142,078, filed May 8, 2002, and of application Ser. No. 10/100,960, filed Mar. 18, 2002, and this application claims the benefit of U.S. Provisional Application No. 60/290,128, filed May 10, 2001.
TECHNICAL FIELD
[0002] This invention relates to storage device enclosures that reduce vibrations in a disk rotating in such a storage device.
BACKGROUND ART
[0003] Disk drives are an important data storage technology. Read-write heads directly communicate with a disk surface containing the data storage medium over a track on the disk surface.
[0004] [0004]FIG. 1A illustrates a typical prior art hard disk drive, which may be a high capacity disk drive 10 . Disk drive 10 includes an actuator arm 30 that further includes a voice coil 32 , actuator axis 40 , suspension or head arms 50 . A slider/head unit 60 is placed among data storage disks 12 .
[0005] [0005]FIG. 1B illustrates a typical prior art high capacity disk drive 10 . The actuator 20 includes actuator arm 30 with voice coil 32 , actuator axis 40 , head arms 50 , and slider/head units 60 . A spindle motor 80 is provided for rotating disk 12 .
[0006] Since the 1980's, high capacity disk drives 10 have used voice coil actuators 20 to position their read-write heads over specific tracks. The heads are mounted on head sliders 60 , which float a small distance off a surface 12 - 1 of a rotating disk 12 when the disk drive 10 is in operation. Often there is one head per head slider for a given disk surface 12 - 1 . There are usually multiple heads in a single disk drive, but for economic reasons, usually only one voice coil actuator 20 for positioning head arms 50 .
[0007] Voice coil actuators 20 are further composed of a fixed magnet actuator 20 interacting with a time varying electromagnetic field induced by voice coil 32 to provide a lever action via actuator axis 40 . The lever action acts to move head arms 50 to position head slider units 60 over specific tracks. Actuator arms 30 are often considered to include voice coil 32 , actuator axis 40 , head arms 50 , and swage mounts 70 . Swage mounts mechanically couple head sliders 60 to actuator arms 50 . Actuator arms 30 may have as few as a single head arm 50 . A single head arm 52 may connect with two head sliders 60 and 60 A (as shown in FIG. 1B).
[0008] [0008]FIG. 1C illustrates a cross sectional view of a single platter prior art disk drive 10 and FIG. 1D illustrates a cross sectional view of a double platter prior art disk drive 10 . Each disk drive 10 includes a disk base 100 and cover 110 that encloses disks 12 that are rotated by the spindle motor 80 .
[0009] Read-write head positioning errors are a significant point of failure and performance degradation. Positioning errors are caused in part by disk fluttering. Disk fluttering occurs when a disk flexes, or vibrates, as it rotates. Some fluttering problems for disks are due to instabilities in the motor turning the disk. Fluttering problems of this type are usually addressed by spindle motor manufacturers.
[0010] There have been attempts to address disk flutter problems in the prior art. U.S. Pat. No. 6,239,943 B1, entitled “Squeeze film dampening for a hard disc drive” is directed to an attempt to address disk flutter problems. This patent discloses “a spindle motor . . . cause[ing] rotation of . . . a single or multiple disc or stack of disks . . . mounted in such a way that the rotating bottom or top (or both) disc surface is closely adjacent to a disc drive casting surface. The squeeze film action in the remaining air gap provides a significant dampening of the disc vibration. . . . Typical implementations use air gaps of 0.004-0.006″[inch] for 2½ inch [disk] drives and 0.006-0.010″[inch] for 3½| 0 inch [disk] dirves” (lines 12-21, column 2). “According to the theory presented . . . , the damping provided by the squeeze film effect between the disc and base plate should not be a function of the spinning speed.” (lines 53-55, column 5). “Significant reduction in the vibration of the top disc, in a two disc system, can be achieved by supplying squeeze film damping to the bottom disc alone. This is important because in a practical design, damping discs other than the bottom disc may be difficult.” (line 65 column 5 to line 2 column 6).
[0011] While the inventors are respectful of U.S. Pat. No. 6,239,943, they find several shortcomings in its insights. It is well known that the combined relationship of read-write heads on actuators accessing disk surfaces of rotating disks brings operational success to a disk drive. There are significant aerodynamic forces acting upon a read-write head assembly and its actuator due to the rotational velocity of the disk(s) being accessed. These significant aerodynamic forces acting upon the actuator, the read-write head, or both, are unaccounted for in the cited patent. There are also significant gap distances that may relate to rotational velocity which are unaccounted for in the cited patent, as well as the inventors' experimental evidence indicating larger air gap providing reductions in track position error than this patent or any other prior art accounts for. There are significant insights to be gained from seeing the development of wave related phenomena in the physical system, both acoustically and mechanically, which are unaccounted for in the cited patent.
[0012] Increased recording density and increased spindle speeds are key factors to competitiveness in the disk drive industry. As recording densities and spindle speeds increase, both head positioning accuracy and head-flying stability must also increase. However, as spindle speeds increase, air flow-induced vibrations may also increase which may result in larger amplitude vibrations of the head-slider suspension causing read-write head positioning errors. Additionally, air flow-induced vibrations acting upon a rotating disk cause disk fluttering, which contributes to track positioning errors. Thus, reducing air flow-induced vibration is essential to reducing head-positioning and read-write errors.
SUMMARY OF THE INVENTION
[0013] The present invention comprises a dampening mechanism reducing aerodynamic forces acting upon a disk rotating in a single disk storage device. The present invention achieves a reduction of disk fluttering and at least some forms of air flow-induced vibration around actuator arms, reducing head-positioning and read-write errors.
[0014] The rotational velocity of a disk surface of the rotating disk may affect significant aerodynamic forces in an air cavity in which the disk rotates. These aerodynamic forces may act upon a read-write head assembly, its actuator, and the rotating disk causing disk fluttering, head-positioning errors and read-write errors.
[0015] A boundary layer is defined herein as an air region near a solid surface with essentially no relative velocity with regards to that surface. This region is caused by the effect of friction between the solid surface and the air. The depth of this region is roughly proportional to the square root of the viscosity divided by the velocity of the surface.
[0016] Aerodynamic theory indicates the following: A rotating disk surface creates a rotating boundary layer of air. This boundary layer tends to rotate in parallel to the motion of the disk surface. A stationary surface, such as a base or cover, of the disk drive cavity facing the rotating disk surface also tends to generate a boundary layer. When the distance between the stationary surface and the disk surface is more than the boundary layer thickness of the rotating disk surface, a back flow is created against the direction of flow from the rotating disk surface. This back flow of air may act upon the disk surface, causing the disk to flutter, and may act upon the read-write head assembly, causing the head assembly to vibrate. This back flow of air, as well as other aerodynamic forces, may induce disk fluttering, head-positioning and read-write errors.
[0017] It is useful to view the physical system of the rotating disks in a sealed disk enclosure as forming a resonant cavity for both acoustic and mechanical vibrations. Simulations and experiments by the inventors have found the resonant or natural frequencies for such cavities to be dampened based upon providing a dampening surface near a spinning disk at greater distances than either theory or the prior art report.
[0018] The invented enclosure acts as a dampening mechanism including a stationary dampening surface positioned adjacent to a rotating disk surface at a distance, or air gap, between the dampening surface and the disk surface. Improvements in disk fluttering are noted for air gaps at or less than the boundary layer thickness. However, the inventors have also observed significant dampening effects in experimental conditions matching the sealed interior of an operational disk drive at larger air gaps than either theory or the prior art indicate.
[0019] The reduced distance, or air gap, between the dampening surface of the dampening mechanism and rotating disk surface inhibits the creation of the back flow of air between the rotating disk surface and dampening surface. The air gap may also minimize the effects of the back flow of air and other aerodynamic forces acting upon the disk surface and the read-write head assembly, including its actuator. This reduces disk fluttering, improves head-positioning and aids the overall quality of disk drive performance.
[0020] The invention includes not only the mechanical enclosures housing disk surfaces within a disk drive, but also the manufacturing methods, and the resulting disk drives. The disk drives may further be at most 13 millimeters in height.
[0021] These and other advantages of the present invention will become apparent upon reading the following detailed descriptions and studying the various figures of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1A illustrates a typical prior art hard disk drive, which may be a high capacity disk drive 10 ;
[0023] [0023]FIG. 1B illustrates a typical prior art high capacity disk drive 10 ;
[0024] [0024]FIG. 1C illustrates a cross sectional view of a single platter prior art disk drive 10 ;
[0025] [0025]FIG. 1D illustrates a cross sectional view of a double platter prior art disk drive 10 ;
[0026] [0026]FIG. 2A illustrates a cross section view of spindle motor 80 and one disk 12 with air flow between the upper disk surface 12 and top disk cavity face, as well as air flow between the lower disk surface 12 and bottom disk cavity face;
[0027] [0027]FIG. 2B illustrates a view of strong dynamic force (or pressure) near the outer-diameter region generated by the rotating air flow, leading to excitation of disk vibration;
[0028] [0028]FIG. 2C illustrates the air flow situation between the upper disk surface 12 and top disk cavity face of FIG. 2A showing the formation of two separate boundary layers;
[0029] [0029]FIG. 2D illustrates the air flow situation between the lower disk surface 12 and bottom disk cavity face of FIG. 2A showing the formation of only one boundary layer;
[0030] [0030]FIG. 3 illustrates disk vibration harmonics of rotation speed of a 3.5 inch conventional two platter disk drive 10 operating at 7200 revolutions per minute rotational velocity;
[0031] [0031]FIG. 4 illustrates a head Position Error Signal (PES) spectrum experimentally determined as a Non-Repeatable Run Out (NRRO) PES spectrum in a conventional 57,000 Track-Per-Inch (TPI) disk drive system as disclosed in the prior art;
[0032] [0032]FIG. 5 illustrates an exploded schematic view of a thin disk drive 10 using a single head and supporting various aspects of the invention;
[0033] [0033]FIG. 6 illustrates a top schematic view of the thin disk drive 10 using the single head as illustrated in FIG. 5;
[0034] [0034]FIG. 7 illustrates a top schematic view of disk drive 10 employing a dampening mechanism 120 in accordance with certain aspects of the invention providing over 180 degrees of radial coverage where the dampening surface (not shown) is within a first gap of the first disk surface of disk 12 ;
[0035] [0035]FIG. 8 illustrates a perspective view of certain preferred embodiments of dampening mechanism 120 comprised of at least one plate providing at least a first surface 122 , which, when assembled in disk drive 10 , provides a first gap near a first disk surface of rotating disk 12 , as further seen in FIGS. 11 A- 12 A;
[0036] [0036]FIG. 9 illustrates a top schematic view of disk drive 10 employing an alternative embodiment dampening mechanism 120 of FIG. 7 providing less than 180 degrees of radial coverage where the dampening surface (not shown) is within a first gap of the first disk surface of disk 12 ;
[0037] [0037]FIGS. 10A and 10B illustrate experimental results regarding track position errors obtained from an offline servo track write setup using an airflow stabilizer similar to the dampening mechanism 120 illustrated in FIGS. 8 and 9;
[0038] [0038]FIGS. 11A and 11B illustrate cross section views of two alternative preferred embodiments of a single platter 12 disk drive 10 of the invention;
[0039] [0039]FIG. 11C illustrates a cross section view of a preferred embodiment of a double platter 12 and 14 disk drive 10 of the invention;
[0040] [0040]FIG. 12A illustrates a more detailed cross section view related with FIGS. 11A to 11 C;
[0041] [0041]FIG. 12B illustrates theoretical results of the elasto-acoustic coupling effect regarding the damping coefficient of a vibrating disk surface 12 with regards to a normalized gap height Gap 1 of FIG. 12A;
[0042] [0042]FIG. 12C illustrates theoretical results of the elasto-acoustic coupling effect regarding the damping coefficient of a vibrating disk surface 12 with regards to the normalized first dampening surface 122 of FIG. 12A;
[0043] [0043]FIGS. 13A, 13B, and 14 illustrate the experimentally determined actuator vibration spectrum from 0 to 1K Hz at the inside diameter, middle diameter and outside diameter, respectively;
[0044] [0044]FIGS. 15A and 15B illustrate experimental results of the elasto-acoustic coupling effect regarding the power spectrum of a vibrating disk surface 12 with regards to Gap 1 of FIG. 12A being 0.6 mm and 0.2 mm, respectively;
[0045] [0045]FIGS. 16A and 16B illustrate experimental results of the elasto-acoustic coupling effect regarding the power spectrum of a vibrating disk surface 12 with regards to various values Gap 1 of FIG. 12A for disk rotational speeds of 7200 and 5400 revolutions per minute, respectively;
[0046] [0046]FIG. 17 illustrates experimental results of the elasto-acoustic coupling effect regarding the displacement frequency spectrum of vibrating disk surface 12 , both with a dampening mechanism of 25 mm radial width 570 and without a dampening mechanism 560 ;
[0047] [0047]FIG. 18 illustrates head Position Error Signal (PES) spectrum experimentally determined as a Non-Repeatable Run Out (NRRO) PES spectrum in a conventional 57,000 Track-Per-Inch (TPI) disk drive system 580 and in a disk system employing a 25 mm dampening mechanism 590 providing a 30% reduction in PES;
[0048] [0048]FIG. 19 illustrates head Position Error Signal (PES) spectrum experimentally determined as a Non-Repeatable Run Out (NRRO) PES spectrum in a conventional 57,000 Track-Per-Inch (TPI) disk drive system 600 and in a disk system employing dampening mechanism with varying radial widths;
[0049] [0049]FIG. 20 illustrates head Position Error Signal (PES) levels experimentally determined in a conventional 57,000 Track-Per-Inch (TPI) disk drive system 600 and in a disk drive employing dampening mechanism with varying radial widths;
[0050] [0050]FIG. 21 illustrates head Position Error Signal (PES) levels experimentally determined in a conventional 57,000 Track-Per-Inch (TPI) disk drive system 600 and in a disk system employing dampening mechanism with varying coverage angles and radial width of one inch or 25 mms;
[0051] [0051]FIG. 22 illustrates an extension of the material and analyses of FIGS. 2A and 12A for further preferred embodiments of the invention; and
[0052] FIGS. 23 A- 23 E illustrate various shapes, edges, and materials for a plate used in dampening mechanism 120 of the previous Figures.
DETAILED DESCRIPTION OF THE INVENTION
[0053] The rotational velocity of a disk surface of the rotating disk may affect significant aerodynamic forces in an air cavity in which the disk rotates. These aerodynamic forces may act upon a read-write head assembly, its actuator, and the rotating disk causing head-positioning and read-write errors and disk fluttering.
[0054] As stated in the summary, a boundary layer is an air region near a solid surface with essentially no relative velocity with regards to that surface. This region is caused by the effect of friction between the solid surface and the air. The depth of this region is roughly proportional to the square root of the viscosity divided by the velocity of the surface.
[0055] [0055]FIG. 2A illustrates a cross section view of a spindal motor 80 and one disk 12 with air flow between the upper disk surface 12 - 1 and top disk cavity face, as well as air flow between the lower disk surface 12 - 2 and bottom disk cavity face. The disk surface is rotating at an essentially constant speed.
[0056] Theoretically, a rotating disk surface tends to create a boundary layer of air rotating in parallel to the motion of the disk surface. A stationary surface, such as a base or cover, of the disk drive cavity facing the rotating disk surface will also tend to generate a boundary layer. When the distance between the stationary surface and the disk surface is more than the boundary layer thickness of the rotating disk surface, a back flow is created against the direction of flow from the rotating disk surface. This back flow of air may act upon the disk surface, causing the disk to flutter, and may act upon the read-write head assembly, causing the head assembly to vibrate. The faster the disk rotates the greater the aerodynamic effect upon the read-write head assembly and attached actuator.
[0057] [0057]FIG. 2A may also provide insight into the tendency of such physical systems to display both acoustic and mechanical resonance. It is useful to view the physical system of the rotating disks, in the enclosure of operating hard disk drive, as forming a resonant cavity for both acoustic and mechanical vibrations. Simulations and experiments by the inventors have found the resonant or natural frequencies for such cavities to be dampened based upon providing a dampening surface near a spinning disk at greater distances than either theory or the prior art report.
[0058] [0058]FIG. 2B was adapted from a presentation by Professor Dae-Eun Kim entitled “Research and Development Issues in HDD Technology: Activities of CISD” at the International Symposium on HDD Dynamics and Vibration, Center for Information Storage Device (CISD), Yonsei University, Seoul, Korea on Nov. 9, 2001, and illustrates a view of strong dynamic force (or pressure) near the outer-diameter region generated by the rotating air flow, leading to excitation of disk vibration. The air flow near the outer diameter, between disks 12 and 14 experiences unsteady periodic vortices, causing resonant harmonic mechanical vibrations, fluttering the disks 12 and/or 14 . Additionally, near the enclosure region formed by the disk base 100 and/or cover 110 (best seen in FIGS. 1C and 1D), a region of strong, turbulent air forms. FIGS. 2C and 2D discuss this phenomena further.
[0059] [0059]FIG. 2C illustrates the typical air flow between a disk surface and a non rotating surface showing the formation of two separate boundary layers.
[0060] In a conventional hard disk drive, the flow pattern has secondary flows, radially outward near the disk and inward at the housing, which dominate the air flow. The air flows are connected by axial flows near the periphery and near the axle. When the gap between disk and a stationary surface is larger than that of the boundary layer thickness, a significant quantity of air in the interior region is essentially isolated from the main flow. The isolated air rotates approximately as a rigid body at one-half the angular velocity of the disk. These flow characteristics make a large vortex and accelerate the disk-tilting effect, which results in a severe Position Error Signal (PES) problem.
[0061] In situations involving radial surface motion, the boundary layer is often formulated as proportional to the square root of the viscosity divided by radial velocity in radians per sec. Table 1 shows boundary layer thickness to Revolutions Per Minute (RPM).
TABLE 1 RPM Boundary Layer Thickness (mm) 5400 0.7 7200 0.55 10,000 0.45
[0062] [0062]FIG. 2C tends to indicate the existence of a large vortex over the area of the top disk of a disk stack, which may have just one disk. This vortex provides a mechanical force acting to excite disk fluttering . Near the rotating disk surface, toward its rim, air flow velocities nearing 10 meters (m) per second (sec) have been found in simulations. At the edge of the boundary layer, about one boundary layer thickness from the disk surface, air velocity is about 0. Further from the disk surface, a back flow forms due to the friction with the stationary surface.
[0063] Removing the vortex adjacent the disk surface has been found to improve mechanical stability. By making the gap too narrow for secondary flows to exist, as illustrated in FIG. 2D, the air adopts a Couette flow pattern with a nearly straight-line, tangential velocity profile between the housing and the disk.
[0064] Accordingly, in one embodiment of the invention, a dampening mechanism is positioned adjacent to the surface of a rotating disk to significantly reduce the distance between a stationary surface and the rotating disk surface. This reduced distance, or air gap, between the dampening mechanism and the disk surface may be approximately the boundary layer thickness of the rotating disk. Alternatively, the air gap may be less than the approximate boundary layer thickness.
[0065] The reduced distance, or air gap, between the dampening mechanism and rotating disk surface may inhibit the creation of the back flow of air between the rotating disk surface and stationary surface. The air gap may also minimize the effects of the back flow of air and other aerodynamic forces acting upon the disk surface and the read-write head assembly, including its actuator. This may reduce disk fluttering and may improve head-positioning. When the air gap is a smaller fraction of the boundary layer thickness, there may be further improved in head positioning and reduced disk fluttering.
[0066] [0066]FIG. 3 graph showing disk vibration as harmonics of a rotation speed of a 3.5 inch conventional two platter disk drive (configured as seen in FIGS. 1D and 2B) operating at 7200 revolution per minute rotational velocity, wherein the disks 12 and 14 are 1.27 mm thick aluminum disks driven by a fluid-dynamic bearing motor 80 . The measurements are of axial disk vibration at the outside diameter of the top disk as measured by a laser Doppler velocity meter. The vertical axis indicates displacement of the outside diameter as measured in meters on a logarithmic scale from 100 pico-meters to 100 nano-meters. The peaks circled on the left represent Harmonics of a rotation speed, while the peaks circled on the right represent disk vibration modes.
[0067] [0067]FIG. 4 is a graph showing a head Position Error Signal (PES) spectrum experimentally determined as a Non-Repeatable Run Out (NRRO) PES spectrum in a conventional 57,000 Track-Per-Inch (TPI) disk drive system as disclosed in the prior art. The left axis indicates NRRO PES in nano-meters, and the right axis equivalently indicates NRRO PES in percentage of track pitch. The trace indicates the readings within three standard deviations for PES, which is roughly 35.7 nano-meter or seven percent of the track pitch. The PES peak 400 is caused by flow-vortex induced effects. The PES peaks within region 410 are induced by disk vibration.
[0068] Both FIGS. 3 and 4 indicate resonant or standing wave phenomena. The resonant frequencies of the disk vibration modes of FIG. 3 have a high correlation to the PES peaks within region 402 of FIG. 4.
[0069] [0069]FIG. 5 illustrates an exploded schematic view of a typical thin disk drive 10 using a single head and supporting various aspects of the invention. A thin disk drive may be preferred in applications such as multi-media entertainment centers and set-top boxes. The thin disk drive may preferably use only a single head, allowing further reduction in the gap between surfaces if base 100 and a surface of disk 12 . Using a single head in the disk drive may reduce manufacturing costs and increases manufacturing reliability.
[0070] In the typical configuration shown in FIG. 5, drive 10 includes a printed circuit board assembly 102 , a disk drive base 100 , a spindle motor 80 , a disk 12 , a voice coil actuator 30 , a disk clamp 82 and a disk drive cover 110 . Voice coil actuator 30 may further include a single read-write head on a head/slider 60 , and Disk drive cover 110 may further include at least one region 112 providing a top stationary surface close to an upper surface of disk 12 .
[0071] [0071]FIG. 6 illustrates a top schematic view of the thin disk drive 10 of FIG. 5.
[0072] Note that region 112 may be essentially outside the region traveled by the actuator arm(s) 50 and head sliders 60 of voice coil actuator 30 when assembled and in normal operation. Region 112 may provide a connected surface, without breaks. Region 112 may further provide a simply connected surface, lacking any perforations or holes.
[0073] [0073]FIG. 7 illustrates a top schematic view of disk drive 10 employing a dampening mechanism 120 in accordance with certain aspects of the invention providing over 180 degrees of radial coverage where the dampening surface (not shown) is within a first gap of the first disk surface of disk 12 .
[0074] [0074]FIG. 8 illustrates a perspective view of certain preferred embodiments of dampening mechanism 120 comprised of at least one plate providing at least a first surface 122 , which, when assembled in disk drive 10 , provides a first gap near a first disk surface of rotating disk 12 , as further seen in FIGS. 11 A- 12 A. Note that various embodiments of the invention may provide more than one dampening surface to other disk surfaces, which may or may not belong to other disks.
[0075] [0075]FIG. 9 illustrates a top schematic view of disk drive 10 employing an alternative embodiment dampening mechanism 120 providing less than 180 degrees of radial coverage where the dampening surface (note shown) is within a first gap of a surface of disk 12 .
[0076] In some embodiments the dampening surfaces may form one or more plates. The dampening surfaces indicated in FIGS. 7 and 9 may each preferably form essentially a truncated annulus or “C” shape, comprising an inner boundary 140 and an output boundary 142 facing toward and away from the spindle motor, respectively. Dampening surfaces may further include first 144 and second 146 non-radial boundaries. Various preferred plates are illustrated in FIGS. 23 A- 23 E.
[0077] Dampening mechanism 120 is also referred to herein as a disk damper, a disk damping device, a dampening means, and an airflow stabilizer. Dampening mechanism 120 may further include a shroud or wall arranged away from the axis of rotation, in certain preferred cases to be further discussed in FIG. 22, rigidly attached to at least one of the plates shown in FIG. 8.
[0078] [0078]FIGS. 10A and 10B show experimental results regarding track position errors obtained from an offline servo track write setup using an airflow stabilizer similar to the dampening mechanism 120 illustrated in FIGS. 8 and 9.
[0079] The vertical axis of FIG. 10A indicates track position root mean square errors in micro-inches. Box 520 indicates the experimental track position error results without dampening mechanism 120 , indicating 0.056 micro-inches root mean square errors. Box 522 indicates the experimental track position error results using dampening mechanism 120 , indicating 0.036 micro-inches root mean square errors.
[0080] The vertical axis of FIG. 10B indicates the probability density per micro-inch. The horizontal axis indicates track position errors in micro-inches. Trace 524 indicates the probability density at various positional errors without the use of dampening mechanism 120 . Trace 526 indicates the probability density at various positional errors with the use of dampening mechanism 120 .
[0081] [0081]FIGS. 11A and 11B illustrate cross section views of two alternative embodiments of a single platter 12 disk drive 10 of the invention.
[0082] [0082]FIG. 11C illustrates a cross section view of an embodiment of a double platter 12 and 14 disk drive 10 of the invention.
[0083] FIGS. 11 A- 11 C illustrate dampening mechanism 120 may include a plate providing at least one dampening surface 122 close to a first disk 12 at essentially a first gap. FIG. 11C illustrates dampening mechanism 120 further providing a second dampening surface 124 close to a second disk 14 at essentially a second gap.
[0084] [0084]FIG. 12A illustrates a more detailed cross section view related to FIGS. 11A to 11 C, and more specifically to FIG. 11B, of the dampening mechanism 120 and adjacent disks 12 and 14 . Dampening mechanism 120 includes first dampening surface 122 separated from first disk surface 12 - 1 of disk 12 by essentially air layer Gap 1 as shown in FIGS. 11A to 11 C.
[0085] Note that in FIG. 11A, the first disk surface 12 - 1 is the bottom disk surface of disk 12 . In FIGS. 11B and 11C, the first disk surface 12 - 2 is the bottom disk surface of disk 12 .
[0086] Dampening mechanism 120 may further include a second dampening surface 124 separated from a second disk surface 14 - 1 , in this case, of a second disk 14 by essentially air layer Gap 2 , as shown in FIGS. 11C and 12A.
[0087] Each of these gaps is at most a first distance, which is preferably less than 1 mm. Each of these gaps is preferably greater than 0.3 mm. It is further preferred that each of these gaps be between 0.35 and 0.6 mm.
[0088] One or more of these gaps may preferably be less than the boundary layer thickness. In certain embodiments, one or more of these gaps may preferably be less than a fraction of the boundary layer thickness.
[0089] Some inventors describe the dampening of disk 12 vibrations by an elasto-acoustic coupling effect between an elastic-vibration wave field of disk 12 and an acoustic pressure wave field of the adjacent air medium in the gap separating the first disk surface 12 - 1 and first dampening surface 122 . These inventors define the elasto-acoustic coupling effect as a coupling generated between the elastic-vibration wave field of disk 12 and the acoustic pressure wave field in the gap between first disk surface 12 - 1 and first dampening surface 122 .
[0090] Experimental results by these inventors point to the acoustic-pressure wave of the air layer gap providing a strong damping force to the elastic-vibration wave of disk 12 . These inventors additionally describe the dampening of disk 14 vibrations by a similar elasto-acoustic coupling effect between an elastic-vibration wave field of disk 14 and an acoustic pressure wave field of the adjacent air medium in the gap separating the second disk surface 14 - 1 and second dampening surface 124 .
Rotation Disk Size Rate in Radial Disk (Number RPM Width(s) Coverage Figure Material of Tracks Per Gap(s) Inches angle(s) in Number (Thickness) Platters) Inch (TPI) Mms (mm) degrees 3 Al 3.5 in 7200 RPM Not Not Not (prior (1.27 mm) 2 Not relevant relevant relevant relevant art) 4 Al 3.5 in 7200 RPM Not Not Not (prior (1.27 mm) 2 (57,000 relevant relevant relevant art) TPI) 10A Al 3.5 in 7200 RPM 0.6 mm 1 in 180 (1.27 mm) 3 Not (25 mm) relevant 10B Al 3.5 in 7200 RPM 0.6 mm 1 in 180 (1.27 mm) 3 Not (25 mm) relevant 12B Theoretical Arbitrary Any RPM See Figure Arbitrary Arbitrary Lumped Arbitrary Not relevant Mass Model 12C Theoretical Arbitrary Any RPM See Figure Arbitrary Arbitrary Lumped Arbitrary Not relevant Mass Model 13A Al 3.5 in 7200 0.5 mm 2/3 in 180 (1.27 mm) 2 (17 mm) 13B Al 3.5 in 7200 0.5 mm 2/3 in 180 (1.27 mm) 2 (17 mm) 14 Al 3.5 in 7200 0.5 mm 2/3 in 180 (1.27 mm) 2 (17 mm) 15A Al 3.5 in 7200 RPM 0.6 mm 1 in 200 (1.27 mm) 2 Not relevant (25 mm) 15B Al 3.5 in 7200 RPM 0.6 mm 1 in 200 (1.27 mm) 2 Not relevant (25 mm) 16A Al 3.5 in 7200 and 0.2-1.8 mm 1 in 200 (1.27 mm) 2 5400 RPM (25 mm) Not relevant 16B Al 3.5 in 7200 and 0.2-1.8 mm 1 in 200 (1.27 mm) 2 5400 RPM (25 mm) Not relevant 17 Al 3.5 in 7200 RPM 0.5 mm 0 and 1 in 200 (1.27 mm) 2 (57,000 (25 mm) TPI) 18 Al 3.5 in 7200 RPM 0.5 mm 0 and 1 in 200 (1.27 mm) 2 (57,000 (25 mm) TPI) 19 Al 3.5 in 7200 RPM 0.5 mm 0 to 1 in 200 (1.27 mm) 2 (57,000 (25 mm) TPI) 20 Al 3.5 in 7200 RPM 0.5 mm 0 to 1 in 200 (1.27 mm) 2 (57,000 (25 mm) TPI) 21 Al 3.5 in 7200 RPM 0.5 mm 1 in 0-200 (1.27 mm) 2 (57,000 (25 mm) TPI)
[0091] [0091]FIG. 12B illustrates theoretical results of the elasto-acoustic coupling effect regarding the damping coefficient of a vibrating disk surface 12 with regards to a normalized gap height Gap 1 of FIG. 12A.
[0092] The normalized gap height is in dimensionless units corresponding to a range roughly from 0 to 10. The damping coefficient is defined as used in theoretical vibration theory. In viscous damping, the damping force is proportional to the velocity of the vibrating body. The viscous damping coefficient c is expressed by c=−F/v where F is damping force and v is the velocity of the vibrating body. The negative sign indicates that the damping force is opposite to the direction of velocity of vibrating body.
[0093] [0093]FIG. 12C illustrates theoretical results of the elasto-acoustic coupling effect regarding the damping coefficient of a vibrating disk surface 12 with regards to the normalized first dampening surface 122 of FIG. 12A. The horizontal axis shows the ratio of dampening surface 122 area to disk surface 12 area multiplied by a factor of ten, which is best seen in the top views of FIGS. 7 and 9.
[0094] [0094]FIGS. 13A, 13B, and 14 illustrate the experimentally determined actuator vibration spectrum from 0 to 1K Hz at the inside diameter, middle diameter and outside diameter, respectively obtained using laser Doppler vibrometer readings taken of an actuator operating in a 3.5 inch disk drive rotating two platters at 7200 RPM. The actuator was a fully assembled actuator including suspension mechanism, head-gimbal assembly and four channel read-write heads.
[0095] Traces 530 and 532 illustrate actuator vibration through the frequency range respectively without and with dampening mechanism 120 . Dampening mechanism 120 is a plate as illustrated in FIGS. 7, 8 and 11 C, positioned within a gap of 0.5 mm from the respective disk surfaces of the two disks 12 and 14 . The plate has a radial width of two thirds of an inch, or about 17 mm.
[0096] Peak 534 is a vortex-sound induced actuator resonance at approximately 258 Hz in trace 530 , which is almost completely eliminated in trace 532 . Peak 536 is a vortex-sound induced actuator resonance at approximately 346 Hz in trace 530 , which is almost completely eliminated in trace 532 . The removal of these resonance peaks is advantageous to the overall track positioning capability of the actuator with regards to the disk surfaces.
[0097] [0097]FIGS. 15A and 15B illustrate experimental results of the elasto-acoustic coupling effect regarding the power spectrum of a vibrating disk surface 12 with regards to Gap 1 of FIG. 12A being 0.6 mm and 0.2 mm, respectively. The vertical axis indicates displacement of the outside diameter as measured in meters on a logarithmic scale from 100 pico-meters to 100 nano-meters.
[0098] Peaks in regions 540 and 550 are considered by the inventors to be attributable to disk vibration. Peak 542 at a gap of 0.6 mm reduces to peak 552 when the gap decreases to 0.2 mm.
[0099] [0099]FIGS. 16A and 16B illustrate experimental results of the elasto-acoustic coupling effect regarding the power spectrum of a vibrating disk surface 12 with regards to various values Gap 1 of FIG. 12A for disk rotational speeds of 7200 and 5400 revolutions per minute, respectively. The reported vibration data are the measured axial disk vibration made at the outside diameter of the top disk as measured by a laser Doppler velocity meter.
[0100] [0100]FIG. 17 illustrates experimental results of the elasto-acoustic coupling effect regarding the displacement frequency spectrum of vibrating disk surface 12 , both with a dampening mechanism of 25 mm radial width 570 and without a dampening mechanism 560 .
[0101] [0101]FIG. 18 illustrates head Position Error Signal (PES) spectrum experimentally determined as a Non-Repeatable Run Out (NRRO) PES spectrum in a conventional 57,000 Track-Per-Inch (TPI) disk drive system 580 and in a disk system employing a 25 mm dampening mechanism 590 providing a 30% reduction in PES.
[0102] The left axis indicates NRRO PES in nano-meters. The right axis equivalently indicates NRRO PES percentage of track pitch. Trace 580 indicates readings within three standard deviations for PES of roughly 36 nano-meters or equivalently, 7 percent track pitch. Trace 590 indicates readings within three standard deviations for PES of roughly 24 nano-meter or equivalently, 4.7 percent of track pitch.
[0103] [0103]FIG. 19 illustrates head Position Error Signal (PES) spectrum experimentally determined as a Non-Repeatable Run Out (NRRO) PES spectrum in a conventional 57,000 Track-Per-Inch (TPI) disk drive system 600 and in a disk system employing dampening mechanism with varying radial widths.
[0104] Results from dampening mechanisms 120 of 25, 17 and 12.5 mm radial width are indicated by traces 602 , 604 , and 606 , respectively.
[0105] [0105]FIG. 20 illustrates head Position Error Signal (PES) levels experimentally determined in a conventional 57,000 Track-Per-Inch (TPI) disk drive system 600 and in a disk drive employing dampening mechanism with varying radial widths.
[0106] In the experiments illustrated by FIGS. 19 and 20, the pitch of one data track is 0.44 micrometers. The vertical axis indicates the PES level at three standard deviations. Box 600 indicates the experimental results when no dampening mechanism is used. Boxes 602 , 604 , and 606 indicate the experimental results when dampening mechanisms of one inch, two-thirds inch and one half inch in radial width, respectively, are used. Dampening mechanism 120 was a plate as illustrated in FIG. 23E.
[0107] The experimental results indicate that the 25 mm radial width dampening mechanism has the lowest PES level, supporting the hypothesis that the wide-width dampening mechanism reduces the PES more than the narrow-width dampening mechanism.
[0108] [0108]FIG. 21 illustrates head Position Error Signal (PES) levels experimentally determined in a conventional 57,000 Track-Per-Inch (TPI) disk drive system 600 and in a disk system employing dampening mechanism with varying coverage angles and radial width of one inch or 25 mms.
[0109] In these experiments, the pitch of one data track is 0.44 micrometers. The vertical axis indicates the PES level at three standard deviations. Box 600 indicates the experimental results when no dampening mechanism is used. Boxes 612 , 614 , and 616 , indicate experimental results when a dampening mechanism with a coverage angle of 200, 130, and 80 degrees, respectively are used.
[0110] The experimental results illustrated in FIG. 21 support the hypothesis that wide-angle dampening mechanisms reduce PES more than narrow-angle dampening mechanisms.
[0111] [0111]FIG. 22 illustrates an extension of the material and analyses of FIGS. 2A and 12A for further preferred embodiments of the invention.
[0112] As in FIGS. 11A and 12A, dampening mechanism 120 includes first dampening surface 122 separated from first disk surface 12 - 1 of disk 12 by essentially air layer Gap 1 as shown in FIGS. 11A to 11 C. Dampening mechanism 120 further includes a second dampening surface 124 separated from a second disk surface 12 - 2 , in this case, of first disk 12 by essentially air layer Gap 2 .
[0113] Dampening mechanism 120 includes a “vertical-plane” disk damper containing a first vertical surface 130 separated from an outer edge 12 - 3 of disk 12 by essentially HGap 1 . The horizontal gap between first vertical surface 130 and the outer edge of disk 12 creates an enclosing disk-edge wave field in the air medium, further contributing to stabilizing the disk 12 .
[0114] As in FIG. 12A, each of these Gaps 1 - 4 is at most a first distance, which is preferably less than 1 mm. Each of the gaps is further preferably greater than 0.3 mm. Each of the gaps is further preferred between 0.35 mm and 0.6 mm.
[0115] One or more of these gaps may preferably be less than the boundary layer thickness. In certain embodiments, one or more of these gaps may preferably be less than a fraction of the boundary layer thickness.
[0116] The invention contemplates using the disk cover 110 to provide at least first dampening surface 122 as part of the dampening mechanism 120 and also using disk cover 110 to further provide first vertical surface 130 .
[0117] [0117]FIG. 22 further illustrates dampening mechanism 120 including a third dampening surface 126 separated from a third disk surface 14 - 1 belonging to a second disk 14 by essentially a third gap, Gap 3 .
[0118] Dampening mechanism 120 may also include the “vertical-plane” disk damper containing a second vertical surface 132 separated from the outer edge 14 - 3 of disk 14 by essentially HGap 2 . The horizontal gap between second vertical surface 132 and outer edge 14 - 3 of disk 14 create an enclosing disk-edge wave field in the air medium, further contributing to stabilizing the disk 14 .
[0119] Dampening mechanism 120 may also include a fourth dampening surface 128 separated from a fourth disk surface 14 - 2 by a fourth gap, Gap 4 .
[0120] Each of the horizontal gaps is at most a second distance, which is preferably less than 1 mm. Each of the gaps is further preferably greater than 0.3 mm. Each of the gaps is further preferred between 0.35 mm and 0.6 mm. One or more of these horizontal gaps may preferably be less than the boundary layer thickness. In certain embodiments, one or more of these horizontal gaps may preferably be less than a fraction of the boundary layer thickness.
[0121] The invention also contemplates using the disk base 100 to provide at least fourth dampening surface 128 as part of the dampening mechanism 120 and also using disk base 100 to further provide second vertical surface 132 .
[0122] FIGS. 23 A- 23 E illustrate various shapes, edges, and materials for a plate used in dampening mechanism 120 of the previous Figures.
[0123] Note that boundaries 140 - 146 are only indicated in FIG. 23E to simplify the other Figures and is not meant to limit the scope of the claims.
[0124] [0124]FIG. 23A illustrates an aluminum plate 120 including a sharp step edge on boundaries 140 , 144 and 146 with perforations. The perforations are preferably about 5 mm is diameter to optimally reduce actuator vibration. FIG. 23B illustrates a hard plastic, preferably a polycorbonate material such as LEXAN®, plate 120 including a wedge type edge on boundaries 140 , 144 and 146 . FIG. 23C illustrates a hard plastic plate 120 including a sharp step edge on boundaries 140 , 144 and 146 . FIG. 23D illustrates an aluminum plate 120 including a round chamfer edge on boundaries 140 , 144 and 146 . FIG. 23E illustrates an aluminum plate 120 including a sharp step edge on boundaries 140 , 144 and 146 . In embodiments using an aluminum plate, the plates may preferably include a coating of Aluminum Plus on one or more surfaces.
[0125] The invention further contemplates plates such as illustrated in FIGS. 23 A- 23 E further including fingers formed to disrupt formation of vortices in the neighborhood of the actuator and its components.
[0126] The disk drive system employing dampening mechanisms 120 as illustrated in the previous Figures also benefits from reduced noise levels. Table 3 below illustrates experiments conducted upon several disk drives employing two disks rotating at 7200 revolutions per minute. The experiments used a preferred dampening mechanism 120 illustrated in FIG. 23D with a Gap of 0.5 mm, radial width of ⅔ in, or 17 mm, and a coverage angle of 200 deg.
TABLE 3 Acoustic Noise with no Acoustic noise with dampening mechanism dampening mechanism Drive No. (Sound power level: dB) (Sound Power Level: dB) 1 27.8 25.6 2 28.3 26.1 3 28.6 26.1 4 28.4 26.1 5 26.9 24.9 Average value 28.0 25.8 Average Reduction 2.2
[0127] The preceding embodiments have been provided by way of example and are not meant to constrain the scope of the following claims.
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Aerodynamic forces contribute to disk and actuator vibration leading to track positioning errors in storage devices such as hard disk drives. The invention provides a variety of dampening mechanisms and a method of dampening to alleviate these problems in single disk storage devices. This includes disk drives of at most 13 millimeters in height.
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[0001] This invention relates to an apparatus and method for cutting a trench in the ground and more especially (but not exclusively) for cutting a trench in the bed of a body of water such as the bed of a lake or the sea bed. The invention relates in particular to apparatus and a method which avoids or reduces undercutting of the trench when executing a turn of the trench.
BACKGROUND
[0002] The formation of trenches in the ground is a well known requirement and is typically needed for burying utility supply means such as gas and water pipes and electricity and telecommunications cables. In underwater environments, the cutting of a trench is typically required for burial of pipes and cables and requires specially constructed or adapted equipment configured for underwater conditions, such as the nature of the seabed. Herein “seabed” is used to refer to the bed of the sea or of a lake or even a river, unless the context requires otherwise.
[0003] Various apparatus for constructing a trench are known in the art. These can include soil cutting devices in the form of ploughs, jetting apparatus (for underwater use) and chain cutters which form the desired trench. Typically the soil cutting device is mounted on a vehicle which moves over the ground (e.g. the seabed) either under its own power of by external means. For example, the trench cutting vehicle might be towed by a tractor vehicle or by a ship at the surface. Generally it is preferred that the trench cutting vehicle is self-powered. Typically the trench cutting vehicle is mounted on endless articulated tracks.
[0004] An issue encountered by trench forming vehicles of this type is when the course of the trench executes a turn, in particular a turn of small turning radius. In this situation, it is possible for the soil cutting device (more especially where the soil cutting device is a chain cutter or jetting device) to undercut the trench wall on the outer side of the curved portion of the trench. This has the effect of de-stabilising the trench wall. Also, it is possible for the soil cutting device such as a chain cutter to become wedged or jammed with respect to the trench wall
BRIEF SUMMARY OF THE DISCLOSURE
[0005] The present invention seeks to ameliorate or overcome the above problem. In particular, the present invention seeks to provide trench cutting apparatus and a method of trench cutting which reduces, minimises or avoids the undercutting of the trench wall as a turn in the trench is executed. The wall of the trench is formed at a desired angle, most preferably substantially vertical.
[0006] In accordance with the a first aspect of the present invention there is provided a trench cutting apparatus comprising a main body portion, ground contacting conveying means on which the body portion is mounted and by which the apparatus can traverse the ground and at least one soil cutting device operable to cut a trench wherein the attitude of the soil cutting device is adjustable between a first use configuration configured for cutting a linear trench portion and a second use position configured for cutting a curved trench portion, said second use position being selected to minimise undercutting of a trench wall as said curved trench portion is formed.
[0007] In preferred embodiments the soil cutting device is a chain cutter or a jetting cutter.
[0008] In preferred embodiments the apparatus further comprises a control device wherein the attitude of the soil cutting device is adjustable under the control of the control device.
[0009] In some preferred embodiments the attitude of the soil cutting device is automatically adjusted by the control device in dependence on the radius of curvature required for the trench being formed.
[0010] In some preferred embodiments the soil cutting device is a chain cutter comprising a plurality of soil cutting teeth mounted for movement in an endless loop, the chain cutter having, in an operational position, a lower end at which the soil cutting teeth cut the soil to form the trench and a upper end at which the teeth are spaced apart from the soil, said lower end having an outer edge and an inner edge which respectively define opposed boundaries of the trench being cut, and wherein the adjustment in the attitude of the chain cutter is such that at least a portion of said outer edge is displaced towards the direction of curvature of the trench.
[0011] Preferably in these embodiments the attitude of the chain cutter is adjusted by rotating the chain cutter about a nominally horizontal axis. Said horizontal axis is preferably at least approximately parallel to the direction of motion of the trench cutting axis at any given time.
[0012] In other preferred embodiments the soil cutting device is a jetting cutter having, in an operational position, a first portion from which cutting fluid is expelled along a line of action to cut the soil to form the trench and a second portion which is in fluid communication with a supply of cutting fluid and wherein the adjustment in the attitude of the jetting cutter is such that said line of action of the cutting fluid is displaced towards the direction of curvature of the trench.
[0013] Preferably in these other preferred embodiments the attitude of the jetting cutter is adjusted by rotating the jetting cutter about a nominally horizontal axis. Said horizontal axis is preferably at least approximately parallel to the direction of motion of the trench cutting axis at any given time.
[0014] In preferred embodiments the apparatus further comprises actuators coupled to the soil cutting device and configured to adjust the attitude of the soil cutting device by rotating the soil cutting device about said horizontal axis.
[0015] Preferably the change in attitude of the soil cutting device is effected by a change in attitude of the body portion, the attitude of the soil cutting device being maintained in fixed relation to the body portion.
[0016] Preferably the attitude of the body portion is adjustable by adjustment of the spacing of one or both of the ground contacting conveying means with respect to the body portion.
[0017] According to a second aspect of the present invention there is provided a method of cutting a trench comprising providing a trench cutting apparatus having an soil cutting device which is adjustable between first and second attitudes and prior to cutting a curved portion of the trench, adjusting the attitude of the soil cutting device to an attitude in which undercutting of the trench wall of said curved portion is minimised.
[0018] In preferred embodiments of the second aspect of the invention the attitude of the soil cutting device is adjusted in dependence on the radius of curvature of the trench being formed
[0019] Preferably the adjustment in the attitude of the soil cutting device comprises rotating the soil cutting device about a nominally horizontal axis. Said horizontal axis is preferably at least approximately parallel to the direction of motion of the trench cutting axis at any given time.
[0020] Preferably the trench cutting apparatus comprises a main body portion to which the soil cutting device is attached and the adjustment in the attitude of the soil cutting device comprises adjusting the attitude of the main body portion.
[0021] In particularly preferred embodiments the trench cutting apparatus is an apparatus as defined in the first aspect of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Embodiments of the invention are further described hereinafter, by way of example only, with reference to the accompanying drawings, in which:
[0023] FIG. 1 is a representation of a typical trench cutting apparatus;
[0024] FIG. 2 a shows schematically a plan view of a trench and a cutting part of a trench cutting apparatus according to the prior art indicating the potential for undercutting of the trench wall;
[0025] FIG. 2 b is similar to FIG. 2 a and illustrates the reduction in the undercutting of the trench wall achieved by the apparatus and method of the invention;
[0026] FIG. 3 a is a view of the outline of a trench cutting device viewed from the front and illustrating the degree of undercutting of the trench wall which can occur with trench cutting arrangements of the prior art;
[0027] FIG. 3 b is similar to FIG. 3 a and shows the outline of a trench cutting device when the attitude thereof is adjusted according to the present invention and illustrating the reduction in the degree of undercutting which is achieved;
[0028] FIG. 4 a is a plan view of a typical trench cutting device according to the present invention;
[0029] FIG. 4 b is a side view of the trench cutting device of FIG. 4 a ; and
[0030] FIG. 4 c is a perspective view of the trench cutting device of FIGS. 4 a and 4 b.
DETAILED DESCRIPTION
[0031] Referring now to the drawings, the present invention addresses the problem of the formation of undercuts in a trench side wall in curved portions of a trench when the trench is formed using apparatus of the prior art. Undercuts are formed with prior art apparatus in the outer trench wall, that is, the wall in a curved section of trench having a greater radius of curvature than an opposed inner trench wall.
[0032] FIG. 1 shows on example of a prior art trenching apparatus 100 , in this particular case configured for forming a trench 102 in the seabed 104 and simultaneously burying a pipeline 106 in the trench 102 . For the avoidance of doubt, the apparatus according to the present invention may usefully be equipped with means both for trench forming and for simultaneous burying of a pipeline, but pipe burying means are not per se an essential feature of the apparatus of the invention. The prior art apparatus 100 includes a main body 108 and ground contacting conveying means 110 in the form of endless articulated tracks on which the main body 108 is mounted and by means of which the apparatus 100 moves over the seabed 104 in the direction of arrow A. The prior art trenching apparatus 100 as illustrated in FIG. 1 includes primary and secondary soil cutting devices 112 , 114 , it being noted for the avoidance of doubt that there is no requirement for the apparatus according to the present invention to include both primary and secondary soil cutting devices, although useful embodiments may do so. In FIG. 1 , the primary soil cutting device 112 is a chain cutter and the secondary soil cutting device 114 is a jetting cutter. The chain cutter 112 comprises an endless belt 116 carrying a plurality of soil cutting teeth 118 . The belt 116 is driven by suitable drive means so that the soil cutting teeth move in an endless loop during the course of which the teeth 118 contact, and displace, soil so to form the trench 102 . The chain cutter 112 is mounted to pivot about horizontal axis 120 in order to adjust the depth of cut of the trench. Horizontal axis 120 passes transversely with respect to the body 108 , that is, perpendicular with respect to the direction of travel A of the apparatus 100 . Jetting cutter 114 comprises a plurality of outlets or nozzles from which fluid (typically water) is expelled under high pressure to displace soil.
[0033] FIGS. 2 a and 3 a and FIGS. 2 b and 3 b respectively illustrate the formation of an undercut using prior art apparatus and the avoidance of undercut formation using the apparatus of the invention. In FIGS. 2 a and 2 b the trench is illustrated schematically at 202 A and 202 B respectively. The centre lines of the trenches are shown at 240 A and 240 B. In the right hand portions of FIGS. 2A and 2B , the trenches 202 A and 202 B are substantially linear and the problem of undercutting of the trench walls does not arise. Thus, the orientation of the trench walls is about vertical, generally in alignment with the side edges of the soil cutting devices 200 A and 200 B. If in any particular case the soil cutting device is set an angle to the vertical (e.g. when cutting a V-shaped trench) then the trench walls follow the orientation of the soil cutting device.
[0034] At about points 230 A and 230 B respectively the trenches 202 A and 202 B begin to curve or turn, in the illustrated case to the left. In FIG. 2 a the illustrated positions of soil cutting devices 200 A and 200 AA in the left portion of the Figure indicate the degree of undercutting of the trench wall which can occur, it being noted that portions of the soil cutting devices 200 A 200 AA extend beyond the indicated boundaries of the trench. In FIG. 2 a (and in FIG. 3 a ) according to the prior art method, the soil cutting device 200 a , 200 AA is maintained in a vertical orientation. In contrast, in FIG. 2B which illustrates an adjustment of the attitude of the trench cutting device 200 B, 200 BB according to the invention, the undercuts are avoided, as can be noted at 232 B and 234 B, and substantially vertical trench walls are achieved.
[0035] The same effect is illustrated in FIGS. 3 a and 3 b . In FIG. 3 a , the soil cutting device 200 A (shown schematically) produces an undercut 232 A when executing a turn (because of the essentially vertical orientation of the soil cutting device 200 A) whereas in FIG. 3 b , the soil cutting device 200 B according to the invention produces no such undercut, as can be noted at 232 B.
[0036] FIGS. 4 a to 4 c show a typical arrangement of a trench cutting apparatus 400 according to the invention, the apparatus 400 including a main body portion 408 (shown schematically) on which is mounted a soil cutting device 412 . The main body portion 408 is mounted on ground contacting conveying means (not illustrated) of any suitable type such as endless tracks of the kind illustrated at 110 in FIG. 1 .
[0037] The soil cutting device as illustrated in FIGS. 4 a to 4 c is a chain cutter device which includes a plurality of teeth (not specifically illustrated) mounted to process around an endless path in the same manner as discussed in relation to chain cutter 112 in FIG. 1 . The chain cutter 412 is mounted to the main body 408 at a pivot 420 . The inclination of the chain cutter 412 is controlled by means of an actuator 452 , such as a hydraulic actuator, mounted on an arm 450 by means of which the orientation of the chain cutter 412 about the pivot 420 can be adjusted in order to determine the depth of the trench being cut.
[0038] As noted above, in accordance with the present invention, the attitude of the soil cutting device is adjustable in order to minimise or prevent the formation of undercuts in the walls of the trench being formed in cases where the trench is other than linear. The problem of forming undercuts in the trench walls is particularly acute with prior art apparatus when it is necessary to form curves or turns in the trench of small radius. In its broadest sense, the attitude of the soil cutting device 412 is changed by adjusting the lower end 412 a of the soil cutting device by displacement of at least a part or portion thereof in the direction of curvature of the trench. That is, if the trench curves to the left (with respect to the direction of trench cutting), then the lower end portion 412 a of the soil cutting device 412 is also adjusted to the left and, likewise if the trench curves to the right (with respect to the direction of trench cutting), then the lower end portion 412 a of the soil cutting device 412 is also adjusted to the right.
[0039] In preferred embodiments, for the adjustment of the attitude of the soil cutting device 412 , the soil cutting device 412 is rotated about a horizontal axis such as axis 454 illustrated in FIGS. 4 b and 4 c , such that a lower part 412 a of the trench cutting device 412 is moved away from the outer trench wall. Axis 454 preferably is substantially parallel to the direction of travel of the apparatus 400 and will generally pass through the soil cutting device 412 . Rotation of the soil cutting device 412 about axis 454 is indicated by arrows 454 t (no particular significance being given to the direction of the arrows in the Figures). In preferred operational orientations of the soil cutting device 412 , where a turn is to be made to the right, the soil cutting device 412 is rotated about axis 454 in an anti-clockwise (counter-clockwise) sense and, similarly where a turn is to be made to the left, the soil cutting device 412 is rotated about axis 454 in a clockwise sense.
[0040] The apparatus 400 according to the invention is provided with suitable actuating means for adjusting the attitude of the soil cutting device 412 , these actuating means being shown generally at 456 in FIG. 4 a . Suitable actuating means include hydraulic actuators.
[0041] The apparatus 400 according to the invention most preferably further includes a control device, such as an electronic controller, which controls the adjustment of the attitude of the soil cutting device 412 (via actuators 456 ). Such control device may rely on the manual inputs of an operator, but in more preferred arrangements the control device determines the required attitude of the soil cutting devices 412 at least partially automatically. For example, the control device may determine the attitude of the soil cutting device 412 on the basis of positional data relating to the steering system of the apparatus 400 and/or reference data relating to the required curvature of the trench.
[0042] In a further alternative construction, the attitude of the soil cutting device 412 may be adjusted by adjusting the attitude of the main body 408 of the apparatus on which the soil cutting device 412 is mounted. This may be achieved by providing adjustment of the height of the ground contacting conveying means (e.g. endless articulated tracks) with respect to the body portion. In other words, the distance of the respective conveying means, primarily in the vertical plane, is adjusted so that the conveying means at one side of the main body 408 is at a greater displacement from the main body 408 than the conveying means at the opposite side of the body. The body 408 must thus adopt an inclined attitude with respect to the horizontal and the soil cutting device 412 is correspondingly inclined. In practical terms, for cutting of a trench which curves to the left, the right hand side of the main body is made relatively higher and the left hand side is made relatively lower, and vice versa for cutting a trench which curves to the right.
[0043] The details of the present invention have been described primarily herein in relation to the use of a chain cutter as the soil cutting device. It is noted that the principles of the invention are applicable also to the use of jetting tools (jetting cutters) as the soil cutting device. Jetting cutters expel one or more jets of high pressure cutting fluid—normally water)—in order to displace soil and form the trench. The line of action of the jets of cutting fluid (i.e. the direction in which the cutting fluid is expelled) is determined by the orientation of the one or more nozzles from which the cutting fluid is expelled. Typically the (or each) nozzle is mounted at an end of an arm. The present invention contemplates the adjustment of the attitude of such an arm in order to adjust the line of action of the (or each) jet of cutting fluid, the line of action being adjusted at least generally in the direction in which the trench is to turn or curve.
[0044] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps.
[0045] Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
[0046] Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
[0047] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
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A trench cutting apparatus comprises a main body portion, ground contacting conveying means on which the body portion is mounted and by which the apparatus can traverse the ground and at least one soil cutting device operable to cut a trench wherein the attitude of the soil cutting device is adjustable between a first use configuration configured for cutting a linear trench portion and a second use position configured for cutting a curved trench portion, said second use position being selected to minimise undercutting of a trench wall as said curved trench portion is formed.
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BACKGROUND OF THE INVENTION
This invention relates to a water cooling system for an engine, employable in connection with a marine propulsion unit; and more specifically, to a valve arrangement for controlling coolant flow through the cooling system.
It has been known to employ an engine as a powering means in connection with marine propulsion units. Cooling systems in such engines have included means for introducing a coolant, such as water from the body of water within which the marine craft is operated, into the engine. Valving arrangements have commonly been employed to control the flow of coolant through the engine, in order to maintain desired engine temperatures during operation.
Concerning such valve control arrangements, it has specifically been known to include both a thermostatically controlled valve and a pressure actuated valve for controlling coolant flow. Such a system employing both a thermo-sensitive control valve and a pressure-sensitive control valve has been disclosed in Japanese Unexamined Patent Publication Sho61-48687. The thermo-sensitive valve primarily controls the coolant flow under low RPM operating conditions. The maximum amount of coolant which will flow through the engine as a result of the opening of the thermo-sensitive control valve, however, may not be sufficient to allow proper cooling of the engine under higher loads. To increase the flow of coolant in the high RPM range, where the thermal load of the engine is higher, a pressure-sensitive control valve is provided.
However, certain problems have been encountered when utilizing known pressure-sensitive valves for the above-discussed purpose. For example, sufficient water flow cannot be achieved in the high RPM operation range when a pressure-sensitive control valve 1 of the type shown in FIG. 1 is used. Although the valve body 2 will become unseated, thereby opening the valve device 1, when the pressure rises on the water jacket side (indicated by the arrow accompanying the notation "in"), the valve body 2 will immediately return to its seated, closed position, under the force of the spring member 3, due to a resulting subsequent drop in pressure on the water jacket side. Accordingly, repeated opening and closing of the valve device will occur, thereby rendering adequate water flow impossible to achieve.
The valve device 4 of FIG. 2 overcomes some of the problems of the device of FIG. 1 by retarding such closing of the valve body 5 immediately after opening via a diaphragm 6 exposed to atmospheric pressure. However, the valve device 4 requires the use of a throttling area 7 along the discharge passage 8 in order to achieve such results. The throttling area 7 impairs the achievement of a sufficient water flow.
It is, therefore, a primary purpose of this invention to provide an improved water flow control arrangement for use in a water cooling system for the engine of a marine propulsion unit.
It is yet a further object of this invention to provide an improved pressure-sensitive valve device for such a water cooling system which allows the achievement of a sufficient coolant flow rate in the high RPM operation range of an engine.
SUMMARY OF THE INVENTION
This invention is adapted to be embodied in a water cooling system for a marine propulsion unit. The invention comprises a coolant jacket having an input port and a discharge port. A pressure sensitive valve device is provided which is responsive to a pressure differential in the coolant jacket. The pressure sensitive valve device opens to coolant flow therethrough when the pressure differential exceeds a predetermined limit. A temperature sensitive valve device is also provided. The temperature sensitive valve device and the pressure sensitive valve device are positioned within the cooling system in parallel flow paths. Also, the pressure sensitive valve device and the temperature sensitive valve device are located just beyond the discharge port of the coolant jacket.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially schematic view of one prior valve device for use in controlling coolant flow in an engine cooling system.
FIG. 2 is a partially schematic view of another prior valve device for use in controlling coolant flow in an engine cooling system.
FIG. 3 is a side elevational view of an outboard motor suitable for use in connection with the cooling system of the present invention.
FIG. 4 is a partially schematic view of a pressure-sensitive valve device constructed in accordance with this invention.
FIG. 5 is a graph of the water coolant flow rate as a function of engine RPM, showing the delivery flow rate Q of a water pump to the engine cooling jacket, as well as the controlled water flow rate through the cooling system employing a thermo-sensitive valve (W b1 ) and, additionally, the pressure-sensitive valve (W b2 ) of this invention.
FIG. 6 is a graph of the coolant system water pressure as a function of engine RPM, showing how the pressure difference -- P (where P1 and P2 are water pressures along different regions of the engine coolant jacket) increases with an increase in RPM.
FIG. 7 is a graph of the coolant system water flow rate as a function of engine RPM, showing the required water flow rate (Wa) achievable in accordance with the invention.
FIG. 8 is a graph of the coolant system water temperature as a function of engine RPM, showing the desired cooling jacket water temperature (Ta) achievable in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first primarily to FIG. 3, an outboard motor constructed in accordance with this invention is identified generally by the reference numeral 12. The motor 12, includes a power head, indicated generally by the reference numeral 14, which includes a water cooled internal combustion engine 15 and a surrounding protective cowling. A drive shaft housing 16 depends from the power head 14 and rotatably supports a drive shaft, shown in part in phantom and indicated by the reference numeral 18,that is driven in a known manner by the engine 15. A lower unit 20 is positioned beneath the drive shaft housing 16 and includes a forward, neutral, reverse transmission system (not shown) for driving a propeller 22.
The outboard motor 12 is adapted to be affixed to the transom of an associated watercraft (not shown) for steering about a generally vertically extending axis and for tilting about a generally horizontally extending axis by means of a mounting assembly, which is described next.
A steering shaft (not shown) is affixed to the drive shaft housing 16 and is rotatably journalled in a swivel bracket 24. This rotational movement accommodates steering of the outboard motor 12 about a vertically extending axis defined by the axis of rotation of the steering shaft within the swivel bracket 24.
The swivel bracket 24 is, in turn, pivotally connected to a clamping bracket 26 by means of a pivot pin 28. This pivotal connection permits tilting of the outboard motor 12 about the horizontally disposed axis defined by the pivot pin 28 for trim adjustment and so that the outboard motor 12 may be tilted up to an out of the water condition during trailering and when not in use. The clamping bracket 26 carries a clampingdevice (not shown) so as to permit attachment of the outboard motor 12 to the transom of an associated watercraft.
The engine of the invention is also provided with a cooling system 29. In the illustrated embodiment, the engine is water cooled and draws cooling water from the body of water in which the watercraft is operating. This isaccomplished, in part, by means of a water pump 30 which is located within the drive shaft housing 16 and which is driven by the drive shaft 18, in aknown manner. Water is drawn from the body in which the watercraft is operating through an inlet 32 and upwardly towards the coolant pump 30 through a conduit 34. The water is then discharged from the pump 30 through a supply conduit 36 which extends upwardly through the drive shafthousing 16 and which terminates at an engine cooling jacket, indicated generally by the reference numeral 40.
A valve arrangement is located along a discharge region of the engine cooling jacket 40. This arrangement includes a pair of control valves 42 and 44 positioned in parallel with one another. Each control valve, 42 and44, communicates at its outlet portion with a discharge passage 46. Water coolant, having passed through one of the control valves, is returned to the body of water within which the watercraft is operating via the discharge passage 46, in an appropriate manner.
The control valve 42 is a thermo-sensitive control valve. The thermo-sensitive valve 42 employed with this invention may be of any appropriate known type. Generally, operation of such a valve involves a thermostat which opens and closes the valve to the passage of coolant water according to a desired water temperature.
The control valve 44 is a pressure-sensitive control valve. The structure of the pressure-sensitive control valve 44, according to this invention, is shown in FIG. 4. A T-shaped valve body 50 is disposed within an encasement assembly 52. The valve body 50 includes a stem portion 50A and a cross-bar portion 50B. The inside of the encasement assembly 52 is divided into three distinct sections by a partition 54 and a diaphragm 56.The partition 54 is formed integrally with the encasement assembly 52. Further, the partition 54 is provided with a hole in its central region, through which the stem portion 50A of the valve body 50 passes. The diaphragm 56 is movable within the encasement assembly in a back and forthdirection. The end of the stem portion 50A of the valve body 50 contacts a central area of the diaphragm 56 so that such back and forth movement may be imparted to the valve body 50.
The cross-bar portion 50B of the valve body 50 lies on a side of the partition 54 opposite the side adjacent the diaphragm 56. The cross-bar portion 50B is urged against the partition by way of a spring member 58. Arubber sealing washer 60 is attached to the cross-bar portion 50B, around the stem portion 50A, to seal the valve member 44 closed to water flow under certain conditions, to be described below. It should be noted that the diameter of the hole is greater than the diameter of the valve stem 50A so that water may pass through the hole when the cross-bar portion 50Band sealing washer 60 are not engaging the partition 54.
As shown in FIG. 4, the encasement assembly 52 is provided with two inlet passages and one outlet passage. A first inlet passage allows water to enter a first chamber 55 within the encasement assembly 52, bounded by theinner wall of the encasement 52 and the diaphragm 56. Flow into this chamber is indicated in the drawing by the arrow accompanying the notationP1. A second inlet passage allows water to enter a middle chamber 57 withinthe encasement assembly 52, bounded by the encasement inner wall, the diaphragm 56 and the partition 54. Flow into this chamber is indicated by the arrow accompanying the notation P2. The outlet passage is denoted by the reference numeral 64, and allows water to exit from a third chamber 59within the encasement assembly 52, bounded by the inner wall of the encasement 52 and the partition 54.
The operation of the pressure-sensitive control valve 44 within the contextof the overall cooling system 29 will now be described. A coolant conduit 66 (FIG. 3) communicates water flowing through the engine coolant jacket 40 with the first chamber 55 of the valve 44. Water flow within this conduit 66 supplies a water pressure P1 to the chamber 55, and consequently, against the side of the diaphragm 56 facing the chamber 55. The pressure P1 is representative of the line pressure within the water jacket 40 at a location proximate to the point where water is introduced into the water jacket 40 from the supply conduit 36. The water jacket 40 itself leads directly to the valve 44 and supplies a water pressure P2 to the chamber 57, and consequently against the side of the diaphragm 56 facing the chamber 57. The pressure P2 is representative of the line pressure within the water jacket at the end of the water jacket 40 line.
As a consequence of an increase in the engine speed, the temperatures of the engine and coolant liquid rise, as is well known in the art. As shown in FIGS. 5 and 6, additionally the coolant delivery rate and coolant jacket water pressure increase as the engine speed is increased. As will be discussed below, the thermo-sensitive valve is operational to open during relatively low engine speed operation, in response to the temperature of the coolant in the water jacket. However, when the thermo-sensitive valve is fully opened, and thus the coolant temperature is elevated, the pressure sensitive valve is employed to help accommodate the increased flow of coolant supplied by the coolant pump during high engine speed operation.
The pressure-sensitive control valve 44 is operable in response to the difference between the water pressures P1 and P2, denoted herein as -- P (i.e., -- P=P1-P2). The valve 44 is set to open during highRPM operation of the engine 15, when the pressure difference -- P exceeds a predetermined value. This predetermined value is controlled by the force applied by the spring member 58 against the valve body 50 tending to seat the valve body 50 in its closed position. The pressure differential -- P must exceed the spring's force in order to open thevalve 44. That is, the predetermined value which -- P must exceed in order to open the valve 44 is equal to the force applied against the valvebody 50 by the spring member 58.
The thermo-sensitive control valve 42 opens in response to the coolant temperature. If the temperature of the coolant increases to the opening temperature, the thermostat of the valve 42 will open slightly. As the temperature of the coolant further increases, the thermostat opens more, allowing more coolant to reduce the engine temperature. When the engine 15is under high loads, the thermostat will be opened fully.
The maximum amount of coolant which will flow through the engine 15 as a result of the opening of the thermo-sensitive control valve 42, however, may not be sufficient to allow proper cooling of the engine under higher loads. Therefore, this invention provides, in parallel with the thermo-sensitive control valve 42, the pressure-sensitive control valve 44, as set out above, which opens at an engine RPM exceeding a predetermined limit so that the required water flow may be achieved.
As shown in FIG. 5, the delivery flow rate Q of the water pump 30 increaseslinearly as the engine RPM increases. Wb 1 is a controlled water flow rate through the thermo-sensitive control valve 42, and Wb 2 is a controlled water flow rate through the pressure-sensitive control valve 44. With further reference to FIG. 6, the pressure-sensitive control valve44 is set to open at an engine RPM exceeding N 0 at which the pressure differential -- P exceeds this predetermined limit, utilizing the phenomenon, as is shown in the Figure, that the pressure differential -- P increases as the engine RPM rises, which is due to flow resistance within the water jacket 40.
Certain water flow rate and cooling jacket temperature characteristics and requirements are shown graphically in FIGS. 7 and 8. FIG. 7 is a graph of the water flow rate as a function of engine RPM. The line Wa shows the water flow rate which the engine requires. When utilizing only a thermo-sensitive control valve, however, only the curve Wb may normally beobtained. The rate Wa may be achieved by employing the pressure-sensitive valve device of this invention, opening at the predetermined limit, in combination with a thermo-sensitive valve device.
FIG. 8 is a graph of the water temperature as a function of engine RPM. Therequired water flow rate curve Wa of FIG. 7 can be achieved by utilizing a thermo-sensitive valve having opening characteristics in accordance with the water temperature as shown by the curve Ta. However, most thermostats have a constant character as depicted by the line Tb. Using the pressure-sensitive valve device of this invention, under high engine RPM conditions, the higher flow rate thus achievable allows the attainment within the cooling jacket of a water temperature corresponding to the curve Ta.
Although an effective coolant flow control arrangement for the water cooling system of an engine has been illustrated and described above, various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims.
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A pressure sensitive valve device is provided for use in a cooling system for the engine of a marine propulsion unit. The pressure sensitive valve device of the invention communicates with the coolant line pressure of an engine cooling jacket at both a coolant input port region of the cooling jacket and a coolant output port region of the cooling jacket. When the difference in pressure between these two regions exceeds a predetermined limit the pressure sensitive valve device opens, thereby permitting coolant to pass therethrough. The cooling system also employs a temperature sensitive valve device positioned in parallel with the pressure sensitive valve device. The temperature sensitive valve device is operative to control coolant flow within the engine in the low RPM operation range, while the pressure sensitive valve device becomes operative to control coolant flow in the high RPM operation range, where the thermal load of the engine is great. Thus, sufficient coolant flow may be achieved throughout the entire engine operating range.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a division of parent application Ser. No. 742,672, filed Nov. 17, 1976, and now U.S. Pat. No. 4,095,443.
BACKGROUND OF THE INVENTION
In recent years, hard back entrance rugs or mats have become popular items for use at office locations of commercial and industrial enterprises, and these rugs are normally rented to such enterprises with the rental company being obligated to clean the rugs periodically. Such rugs are generally relatively small (e.g. 3 feet by 5 feet), and they include a backing of cotton-latex or nylon-vinyl to which are secured a variety of pilings, such as polyester, nylon, acrylic, and polypropylene.
The owner of such rugs is faced with the problem of cleaning large quantities of the rugs on a regular basis, and, as explained in greater detail in an article appearing at page 46 of the May, 1975, issue of Industrial Launderer magazine, two general types of cleaning equipment have been available heretofore for cleaning these rugs.
The first type are so-called "dry" machines which provide only mechanical means for vigorously beating the rugs, and which have been found to be unacceptable.
Additionally, "wet" machines are available which include, in various combinations, water and detergent sprays to soak the rug, and a plurality of brushes or mechanical fingers which are pressed against the rug piling to agitate the piling mechanically and loosen the dirt therefrom. While this type of cleaning equipment generally provides satisfactory cleaning results, the severe mechanical agitation of the piling by the brushes has a deleterious effect on the piling fibers, particularly in rugs having flocking secured to the rug backing by an adhesive in a predetermined design as disclosed, for example, in U.S. Pat. No. 3,793,050, issued Feb. 19, 1974, to Mumpower. Moreover, the adverse effects of mechanical agitation also serve to limit substantially the speed at which the rugs can be moved past the brushes, thereby limiting the cleaning cycle time for such rug cleaning equipment.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method is provided for cleaning rugs or mats and the like in a continuous manner by conveying a rug upwardly along an inclined path with the nap or piling of the rug facing upwardly, compressing the rug nap at a location extending transversely to the inclined path of the rug, and directing a jet of water and detergent toward the nap of the rug as it is conveyed past the compressing location. The inclined path of the rug and the damming effect of the compression cause the water and detergent from the jet to form a pool adjacent the compressing member, and the jet is directed toward this pool to agitate continuously the nap of the rug and thereby loosen any dirt which may be present in such nap, whereupon the loosened dirt is carried away with the drainage of the water and detergent. Thus, the dirt loosening agitation required to clean the rug properly is supplied by the directed jet acting against the pooled water and detergent, rather than by the mechanical agitation of brushes and the like which can be harmful to the rug nap.
Preferably, the rug nap is preliminarily soaked with water and detergent, as by spraying, prior to the rug being conveyed to the compressing location whereby the detergent will begin to loosen the dirt to some extent before the rug is subjected to the agitation of the jet.
Additionally, an adjustable rotating brush may be provided along the inclined path of the rug to lightly engage the extending ends of the rug nap ascensionally of the jet agitation thereof whereby more thorough cleaning will be obtained in some instances. However, it is to be emphasized that the primary source of dirt loosening agitation is supplied by the jet directed at the pool of water and detergent, and the cleaning action of the brush is entirely secondary. Thus, only one brush is required, and it may be arranged so as to engage the rug nap lightly and thereby avoid the aforementioned drawbacks of prior art rug washing equipment that relies almost entirely on the mechanical agitation of brushes to clean the rug.
In accordance with a further feature of the present invention, an additional compressing roller may be employed ascensionally of the first compressing roller and the rotating brush to thereby cause the rug to be held between two rollers as it is being agitated by the jet and brushed, and a jet of rinse water may be directed against the rug nap as it is conveyed past the second compressing roller to form a pool of rinse water that is continuously agitated by the jet of rinse water in the same manner as that described above in conjunction with the jet of water and detergent.
Finally, the present invention provides a water saving feature that includes a collecting arrangement having separate compartments located beneath the rug at locations for collecting the rinse water, and the water and detergent mixture, respectively. The rinse water compartment may be sub-divided by weirs of constantly decreasing heights to distribute the dirt contained in the rinse water and to carry off floating debris in the rinse water, whereby the relatively clean rinse water can be recirculated through the washing system and reduce the overall quantity of fresh water used by the cleaning equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a left side elevation view of a rug washing machine embodying the present invention;
FIG. 2 is a front end view of the rug working machine illustrated in FIG. 1;
FIG. 3 is a perspective view illustrating the conveyor and washing components of the rug washing machine shown in FIG. 1;
FIG. 4 is a detail view showing a particular washing portion of the rug washing machine illustrated in FIG. 1; and
FIG. 5 is a side elevation view of the water collecting portion of the rug washing machine illustrated in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Looking now in greater detail at the accompanying drawings, FIGS. 1-3 illustrate a rug washing machine 10, embodying the present invention, which includes a frame 12 on which an endless conveyor 14 is mounted about a turn roller 16 mounted in a bearing 18, a take-up roller 20 mounted in a bearing 22, and a drive roller 24 mounted in a bearing 26, the drive roller 24 being driven at a selectively variable speed through a conventional chain-and-sprocket arrangement (not shown) from a suitable electric motor (not shown). The conveyor 14 includes an inclined reach 14' extending upwardly from the turn roller 16 to the drive roller 24, and includes a plurality of spaced, open mesh chain belts 28 (see FIG. 3) with a first hold-down roller being mounted above the turn roller 16 at the inlet or front end of the rug washing machine 10. Also mounted to the frame 12 is a loading shelf 34 on which rugs are placed for feeding onto the conveyor 14, and a pair of squeezing rollers 36, 38 located at the discharge end of the conveyor 14 for squeezing the rugs after they have been cleaned and for directing the rugs to a stripper plate 40 that removes the cleaned rugs from the machine, the stripper plate 40 being disposed adjacent a rotating nap brush 42 which assist in raising the wet nap of the rug after it has been cleaned.
The frame 12 includes upstanding side walls 44 at opposite sides of the conveyor 14, and retainer blocks 46 are fixed to the side walls 44 for retaining three compression rollers 48, 50 and 52 spaced along the inclined reach 14' of the conveyor 14. The compression rollers 48, 50 and 52 are not driven, but they are free to rotate within the retainer blocks 46 and to slide vertically therein so that the weight of the compression rollers 48, 50 and 52 cause them to be biased against a rug carried by the conveyor reach 14'. Three support rollers 54, 56 and 58 are mounted in bearings 54', 56', and 58' for rotation beneath the conveyor reach 14' to support the same, and these support rollers are also located directly beneath the weighted compression rollers 48, 50 and 52 to act therewith in compressing a rug passing therebetween as will be explained in further detail presently.
The superstructure of the frame 12 supports a water inlet pipe 60 extending upwardly from a holding tank 62 (see FIG. 2), across the top of the machine 10, and into the inlet of a suitable motor operated pump 64. The inlet pipe 60 has connected thereto a detergent tube 66 leading upwardly from a source of detergent, such as a drum (not shown), with an adjustable regulating valve 68 being located adjacent such connection to control the amount of detergent that is drawn into the inlet pipe 60 by the suction of the pump 64. A discharge pipe 70 extends from the outlet of the pump 64 to a connection with hoses 72, 74, 76 connected, respectively, to two spray bars 78, 80 located above the conveyor reach 14' and one spray bar 82 located beneath the conveyor reach 14' as best seen in FIGS. 1 and 3. Each of the spray bars 78, 80 and 82 include a plurality of apertures spaced along the length thereof and designed to direct a concentrated jet of water and detergent toward the rug as it passes up the inclined conveyor reach 14', it being noted particularly that the jets from the spray bar 80 are directed toward the nap of the rug as it is conveyed past the compression roller 48 for a purpose to be explained in greater detail presently.
Similarly, the frame 12 supports a rinse water inlet manifold 84 having an end 84' that is connectable to any convenient source of fresh water (not shown), and this inlet manifold 84 is connected to three inlet pipes 86, 88 and 90, each leading to the intake side of a motor driven pump 92, 94 and 96, respectively. The discharge side of the pumps 92, 94 and 96 are connected to discharge conduits 98, 100, 102 and 103 leading to three rinse water spray bars 104, 106, 108 located above the inclined conveyor reach 14', and one rinse water spray bar 109 located beneath the inclined conveyor reach 14', it being noted that each of the spray bars 104, 106 and 108 include apertures, as described above, for directing a jet of rinse water toward the nap of the rug as it is conveyed upwardly along the inclined conveyor reach 14', and spray bar 109 similarly directs the jet of rinse water against the back of the rug.
In the preferred embodiment of the present invention, a cleaning brush 110 having helically arranged bristles is rotatably carried in a bracket 112 (see FIG. 1) that is mounted to the frame 12 by an adjustable bolt 114 which permits the brush to be selectively raised and lowered with respect to the inclined conveyor reach 14' and the rug carried thereby, the cleaning brush 110 being driven by any convenient source such as an electric motor (not shown) to rotate in a clockwise direction as seen in FIG. 1. A further support roller 116 may be mounted in bearings 118 for disposition beneath the inclined conveyor reach 14' and opposite to the cleaning brush 110.
The turn roller 16 is formed with a plurality of annular shoulders 117 located in the spacing between each chain belt 28 (see FIG. 3), and similar shoulders are formed on support rollers 54, 56, 58 and 116 to maintain the chain belts 28 in spaced relation and to guide them as they moved up the inclined conveyor reach 14'. Their shoulders have a height or thickness that is about the same as the thickness of the chain belts 28 so that the rugs being conveyed up the inclined conveyor reach 14 are supported on an uninterrupted flat surface at locations where the rugs are compressed by compression rollers 30, 48, 50, 58.
The bottom of the frame 12 has mounted thereto a drain pan 120 that extends across the entire machine 10 beneath the conveyor 14. The drain pan 120 includes an inclined wall 122 located beneath the front or inlet end of the rug washing machine 10 and a second inclined wall 124 located beneath the back or outlet end of the machine 10, and a compartmentalized chamber 126 is located intermediate the inclined walls 122 and 124, as best seen in FIG. 5. The chamber 126 has a first baffle or weir 128 extending across the entire width of the drain pan 120, and located substantially directly beneath the intermediate compression roller 50. This baffle separates the chamber 126 into a waste water compartment 130 having a drain connection 132 leading therefrom at the left side of the machine 10 (see FIGS. 2 and 5), and a rinse water compartment 134. The rinse water compartment 134 is divided into three subcompartments 136, 138 and 140 by two additional upstanding baffles or weirs 142, 144 which extend across the entire width of the machine 10. It will be noted that the intermediate weir 142 has a greater height than the weir 128 and a lesser height than the weir 144, whereby the height of the weirs 142, 144 increase as their spacing from weir 128 increases. The subcompartment 136 includes an outlet pipe 146 extending therefrom at the right side of the machine 10 to a connection with the holding tank 62 (see FIG. 2), and the subcompartments 138 and 140 include outlet pipes 148 and 150, respectively, both of which are connected to an outlet manifold pipe 152 which is, in turn, connected to the waste water drain connection 132 (see FIG. 1) at the left side of the machine 10, the outlet manifold pipe 152 having two valves 154 disposed therein for selectively opening either or both of the outlet pipes 148, 150 to the water drain connection 132.
The operation of the above-described rug washing machine 10 is as follows. Water is supplied to the rinse water inlet manifold 84, and the holding tank 62 is initially charged with a supply of water. Appropriate switches on the control panel 156 are operated to energize the motor drives for the conveyor 14, the nap brush 42, cleaning brush 110, squeeze rollers 36, 38, and the pumps 64, 92, 94 and 96. Two rugs of normal size (e.g. 3 feet by 5 feet) are placed side-by-side on the loading shelf 34 and fed to the conveyor 14 which supports the rugs with the nap thereof facing upwardly, and conveys them upwardly along the inclined path defined by the conveyor reach 14'. As the rugs are conveyed upwardly along this inclined path, they will first pass between the spray bars 78 and 82 which spray a mixture of water and detergent against the nap and the bottom surface of the rugs whereby the backing of the rugs is cleaned and the nap is saturated with water and detergent so that the detergent begins to loosen the dirt in the nap.
The rugs then continue up the inclined path of conveyor reach 14' until they reach the first compression roller 48 which, as described above, compresses the nap of the rugs as they pass beneath the compression rollers 48, as best seen in FIG. 4. The spray bar 80 directs a concentrated jet of water and detergent toward the nap of the rugs as they are conveyed past the compression roller 48. Since the compression roller 48 extends transversely across the rugs and bears downwardly thereagainst, and since the rugs are moving upwardly along an inclined path, the compression roller 48 forms a dam for the water and detergent being discharged to collect as a pool at the upstream or ascensional side of the compression roller 80. This pool of water and detergent is continuously agitated by the jet of water and detergent directed thereagainst, and this agitation combined with the cleaning action of the detergent results in a vigorous working of the rugs naps that loosens the dirt in such naps and causes the dirt to become entrained in the water and detergent mixture.
The aforementioned jet agitation and working of the rug nap provides excellent cleaning results. These results are improved still further by selectively adjusting the position of the cleaning brush 110, which is mounted ascentionally of the compression roller 48 and the spray bar 80, so that it makes only slight contact with the extending ends of the naps of the conveyed rugs so as to provide a light mechanical agitation for assisting the jet agitation. However, because of the generally thorough cleaning results which are obtained from the jet agitation alone, the mechanical agitation of the cleaning brush 110, is substantially less severe than the mechanical agitation required when brushing is used as the sole means of agitation, and, as a consequence, the nap of the rugs cleaned by the machine of the present invention is not burdened with the aforementioned drawbacks found in prior art mechanical brush cleaning machines.
As the rugs are conveyed upwardly beyond the cleaning brush 110, they will be compressed again by the second compression roller 50 which acts to compress or squeeze the nap of the rugs in the same manner as compression roller 48, described above. Thus, the rugs are generally held at two spaced transverse locations by the compression rollers 48 and 50, with the spray bar 80 and the cleaning brush 110 located therebetween, whereby the rugs and held in a somewhat taut disposition which renders the cleaning action of the spray bar 80 and the cleaning brush 110 more effective.
Additionally, the rinse water spray bar 104 is located ascentionally of the compression roller 50 for directing rinse water toward the rug naps as they are conveyed past the compression rollers 50, whereby the rinse water will collect at the dam formed by the compression roller 50 and be agitated continuously by the jet of rinse water in the same manner as that described above. This jet agitation acts to assist in rinsing the rugs naps so that the remaining dirt and detergent are carried away with the rinse water.
The rugs are then conveyed past another compression roller 52 which tends to squeeze out the rinse water and the dirt and detergent entrained therein, and the rugs are then subjected to additional rinsing by the jet sprays from spray bar 106 and 108. The rugs are then squeezed again by the heavier squeeze rollers 36, 38 to remove most of the water therefrom, and the rugs then move past the nap brush 42 which acts to raise the nap of the rugs and thereby permit better circulation of air around the rug piling during drying, while also removing any lint particles which remain on the surface of the rugs.
Thus, the rug washing machine 10 provides a thorough cleaning operation which utilizes a plurality of sequential cleaning steps, including a pre-soaking by spray bar 78, first light extraction by the squeezing of compression roller 48, jet agitation washing by spray bar 80, second light extraction by the compression roller 50, jet agitation rinsing by spray bar 104, third light extraction by the compression roller 52, second and third spray rinsing by spray bars 106 and 108, final extraction by the squeeze rollers 36, 38, and pile lifting and cleaning by the nap brush 42.
The present invention also provides a novel manner of collecting the rinse water separately from the mixture of water and detergent, and then recirculating this collected rinse water through the cleaning operation to reduce the quantity of fresh water needed to operate the machine 10. As best seen in FIGS. 3 and 5, the drain pan 120 is located directly beneath the conveyor 14 and extends beyond the conveyor 14 at all sides thereof so that all of the rinse water, and the water and detergent mixture, sprayed from spray bars 78, 80, 104, 106 and 108 eventually flow downwardly into the drain pan 120, either through the open mesh of the conveyor 14 or over the sides thereof. Since the dividing baffle or weir 128 is positioned substantially directly beneath the intermediate compression roller 50, as described above, it will be apparent that substantially all of the dirty mixture of water and detergent discharged from the spray bars 78 and 80 will tend to fall into the drain pan 120 at locations to the right of baffle 128 for collection in the waste water compartment 130. On the other hand, all of the rinse water discharged from the rinse water spray bars 104, 106 and 108 will tend to fall into the drain pan at locations to the left of baffle 128 for collection in the rinse water compartment 134. Because of the high concentration of dirt and used detergent which is included with the water in the waste water compartment 130, this water cannot be efficiently reused and it is therefore permitted to be discharged to a sewer connection or the like through the drain connection 132. However, the rinse water collected in the rinse water comparment 134 is mixed with only a relatively small amount of detergent, and it can be reused effectively if most of the dirt is removed therefrom.
The rinse water compartment 134 is preferably subdivided in a plurality of subcompartments by the baffles or weirs 142 and 144. Most of the rinse water falling into the drain pan 120 will hit the inclined wall 124 and flow toward the subcompartment 140, and the hearvier dirt and foreign matter entrained in such rinse water will settle to the bottom of the subcompartment 140. When the level of the rinse water in subcompartment 140 exceeds the height of the weir 144, the rinse water will flow over the weir 144 and into subcompartment 138 where additionally dirt is permitted to settle to the bottom. Similarly, when the rinse water level in the subcompartment 138 exceeds the height of weir 142, it will flow into subcompartment 136 where still more dirt settles. Finally, if the water level in subcompartment 136 exceeds the height of weir 128, it will flow to the waste water compartment 130 and out through the drain connection 132.
The water which is finally collected in the subcompartment 136 is permitted to flow through the outlet 146 to the holding tank 62 (see FIG. 2) which has one or more filters 158 disposed therein between the outlet 146 connection and the water inlet pipe 60 leading to the water and detergent pump 64 so that the rinse water must pass through the filters 158 before it reaches the water inlet pipe 60. Thus, the rinse water is collected by the drain pan 120 and kept generally separate from the water and detergent mixture, then is caused to flow through a plurality of subcompartments in which dirt settles to the bottom, and finally passed through filters 158 before it is recirculated through the water and detergent spray bars 78, 80 and 82. As a result, the recirculated water is relatively clean and is entirely suitable for use in mixing with detergent for subsequent cleaning action.
By dividing the rinse water compartment 134 into a plurality of subcompartments, most of the large volume of dirt entrained in the rinse water is collected in the first two subcompartments 138 and 140 so that very little dirt is present in the last subcompartment 136 or in the rinse water discharged through outlet 146. Additionally, because of the weir action of the baffles 128, 142 and 144, all of the lighter foreign matter, such as lint and some residual detergent, will float on top of the water in the subcompartments and eventually flow over the smallest baffle 128 into the waste water compartment rather than being discharged through outlet 146 for recirculation. Accordingly, the rinse water which is ultimately recirculated through the water and detergent spray bars is relatively clean. The outlets 148 and 150 from the subcompartments 138 and 140, respectively, and the manifold 152 permit the subcompartments 138 and 140 to be easily cleaned at periodic intervals by simply flushing a stream of water through such subcompartments to carry the dirt through the manifold 152 and the open valves 154 to the waste water drain connection 132.
In a typical rug washing operation of the machine 10, the conveyor 14 is operated at a speed of about 17-20 feet per minute so that the machine 10 can wash approximately 350 rugs of a 3' × 5' size per hour. This conveyor speed, and the resulting rug washing capacity, is substantially greater than the speed of existing rug washing machines which rely solely upon mechanical agitation of the rug, and which therefore have a limited maximum linear speed of about twelve feet per minute.
Additionally, the unique rinse water recirculation feature of the present invention results in a considerable reduction in water consumption. Without this feature, this rug washing machine 10 would use approximately one hundred gallons of water per minute, but this consumption is reduced to about sixty gallons per minute by the rinse water recirculation feature. When the rug washing machine 10 is operated for many hours during each day, as would be typical in a normal commercial use, it will be appreciated that this feature will result in substantial savings in water costs to the user.
The present invention has been described in detail above for purposes of illustration only and is not intended to be limited by this description or otherwise to exclude any variation or equivalent arrangement that would be apparent from, or reasonably suggested by, the foregoing disclosure to the skill of the art.
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Method and apparatus for washing rugs and the like which includes conveying a rug upwardly along an inclined path, with the nap of the rug facing upwardly, then compressing the rug, preferably by a roller, at a location extending transversely to the inclined path of the rug. A jet of water and detergent is then directed toward the rug as it is conveyed past the compressing roller to thereby form a pool of water and detergent that is dammed by the roller, such pool of water and detergent being continuously agitated by the directed jet to clean the rug. A cleaning brush may also be added ascensionally to the directed jet, and compartmentalized collection means may be provided for collecting the water and detergent mixture separately from the cleaner rinse water, with the rinse water being recirculated through the washing system to reduce the water requirements of the washing operation.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to machines for filling and sealing containers containing a liquid or semi-liquid product, and more specifically relates to a machine that has a first work station for positioning empty containers for subsequent filling, a second work station for filling the containers, and a third work station for delivering closure members to the filled containers and for sealing said containers with said closure members, and a fourth work station for ejecting the filled and sealed containers from the machine.
2. Description of the Prior Art
Earlier fill and seal machines generally incorporate perforated or apertured turntables, or carrier discs, for transporting the container or cup sought to be filled from work station to work station.
The use of such apertured turntables mandates that a relatively complex cup-ejecting mechanism be used, since the filled and sealed cups must be taken out of registration with the apertures that immobilizes the containers during the fill and seal operation, as a part of the ejection procedure.
Earlier machines in the field of this invention also provide separate work stations for delivering a closure means to an individual cup means on a successive basis and for accomplishing a sealing engagement between said cup and said closure member.
Moreover, earlier machines require a negative pressure source as a part of the lid delivery system, and a heat seal means as a part of the lid sealing system.
The machines of the prior art also incorporate complex drive mechanisms due to the number of work stations and due to the complex active tasks that must be performed at each station.
More specifically, the drive assemblies of the prior art generally include sprocket chains, power take off shafts, and numerous other parts such as cams, cam followers, levers, reciprocating rods and the like.
A need is therefore seen to exist in the packaging industry generally and in the fill and seal machine industry particularly for a machine that has a reduced number of work stations and, accordingly, a reduced number of active components.
SUMMARY OF THE INVENTION
The longstanding but heretofore unfulfilled need for an improved fill and seal machine is now fulfilled by a machine that reduces the number of work stations heretofore found in such machines by combining the lid delivery and lid sealing functions in such a way that such functions are performed substantially simultaneously at a single work station. Further, passive components are employed advantageously to reduce the probabilities of machine malfunction.
The complex cup-ejection systems of the earlier devices is essentially eliminated by the inventive machine, in that the cups are carried from station to station along a predetermined flow path as established by a rotatable turntable that has a plurality of circumferentially spaced pockets formed about the periphery thereof. The pockets are in open communication with the peripheral boundary, so that removal of the cups from the pockets is accomplished when the cups impinge upon a sweep arm member disposed in path-interruptive relation thereto with the attendant rotation of the turntable, the sweep arm guiding the cups to a pick-up area.
The pockets are closed throughout a major portion of each machine cycle by a ring-like element that at least partially surrounds the turntable, in co-planar relation thereto. The ring element imparts stability to the cups during the fill and seal procedure. The ring element is discontinuous adjacent the cup-discharge region of the machine, so that the sweep arm member can discharge the filled and sealed cups.
The lid delivery/lid sealing work station includes a lid or closure magazine having a frame structure for transiently retaining a supply of lids in stacked relation. The frame structure is disposed generally in aligned relation to the various cup-carrying pockets formed in the periphery of the turntable. The longitudinal axis of the generally upstanding frame structure is angularly offset from the vertical by about 7°. As the bottommost lid in the stack of lids held by the frame structure exits therefrom under the influence of gravity, a specifically disposed finger element interrupts the fall of the lid and supportingly engages the peripheral boundary of the lid. The finger element is orthogonally disposed relative to the longitudinal axis of the frame structure so that a lid resting partially thereon is tilted an 83° angle relative to the horizontal. The lip, or rim, portion of the cup requiring closure rotates into registration with the lowermost portion of the tilted lid, and a partial snap-fit engagement therebetween is effected. Continued rotation of the turntable and hence continued angular rotation of the cup completes the closure procedure in that such rotation causes the yieldable lid means to impinge upon a non-yieldable roller means that acts to snap-fittingly engage the remainder of the cup and lid in a generally wiping-type motion.
The turntable and the operable components of the respective work stations are driven by a drive assembly that includes a power source in the form of an electric motor, a gear reduction means disposed in driven relation to the motor means, and a novel gear train that is characterized at least in part by having the individual gears that collectively form the gear train disposed in substantially unidirectional alignment with one another. Only three gears are needed to operate the geneva mechanism that rotates the turntable as required and the operable components of the work stations.
It is therefore seen to be an important object of this invention to provide an improved fill and seal machine having a reduced number of work stations.
More specifically, it is an object of this invention to provide a fill and seal machine having only two work stations with active components, and two work stations with passive components.
A closely related object is to provide such a machine having a simplified drive assembly.
A very important object is to provide such a machine wherein the lid delivery and lid seal function is performed at a single work station.
Still another object is to provide a lid sealing means that harnesses the kinetic energy of a rotating turntable to apply a yieldable lid means to a cup in snap-fit engagement therewith.
Yet another object is to harness such turntable motion to effectuate ejection of filled and sealed cups from the machine.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings in which:
FIG. 1 is a top plan view of the preferred embodiment of the invention.
FIG. 2 is a side elevational view of the cup delivery, or cup drop work station.
FIG. 3 is a side elevational view of the liquid reservoir which forms a part of the cup filling work station.
FIG. 4 is a side elevational view of the lid delivery and lid sealing work station.
FIG. 5 is a diagrammatic plan view of the inventive gear train that forms a part of the drive assembly for the preferred embodiment.
FIG. 6 is a perspective view of the preferred embodiment of the invention.
Similar reference numerals refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A major portion of the inventive assembly is shown in top plan view in FIG. 1 and is designated 10 as a whole. A top plate 12 of the machine housing is preferably rectangular, flat, and disposed substantially in a horizontal plane. A discharge chute 14 is parallel to but vertically offset from the plate 12, as best shown in FIG. 6.
A drive assembly, hereinafter described, for the inventive machine 10 is disposed below the plane of the top plate 12 and is housed within the remainder of a box-like machine housing, not shown.
A carrier means or turntable 16 is spaced upwardly of the plane of the top plate 12, in substantially parallel relation thereto. The turntable 16 has a circular peripheral boundary and a plurality of equi-distant, circumferentially spaced, radially disposed cut-out apertures, or pockets 18. The pockets 18 are in open communication with the peripheral boundary of the turntable, and are specifically configured and dimensioned to correspond in size and shape to the cups that are filled and sealed by the inventive machine, so that said cups are supportingly engaged about their respective rims at least in part by the interior edges 19 of the pockets 18.
A stationary, dis-continuous ring element 20 partially surrounds the turntable 16, as shown in FIG. 1, and is co-planar therewith.
The turntable 16 is removably mounted to the machine housing, and is rotatable about an axis 22. A geneva mechanism, not shown, effects timed rotation of the turntable 16 in 45° increments, there being eight (8) cup-carrying pockets 18 formed in the turntable 16 in the preferred embodiment of the invention.
A plurality of work stations, collectively designated 24, are disposed in circumferential relation to one another about the periphery of the turntable 16, so that the operable components of each of the work stations are in communicating relation to different ones of the pockets 18, as depicted in FIG. 1. More specifically, at the completion of each incremental advance of the turntable 16, different ones of the pockets 18 are in vertically-spaced axial alignment with the operable components of different ones of the work stations 24.
The first work station, designated 26, conventionally supplies a container or cup to an aligned pocket 18 attendant each incremental advance of turntable 16. As shown in FIG. 2, the cup delivery work station 26 includes an upstanding support member 28 that is fixedly secured to the top plate 12 of the machine housing. An arm 30 is disposed in overhanging relation to the turntable 16 by a cantilever-type attachment to the support member 28. A plurality, preferably four (4), of upstanding arms 32 are provided to retain a supply of cups or containers in stacked, internesting relation in the area bordered by said arms 32. The mechanism 34 for successively depositing the cups into the respective pockets 18 is known to those skilled in the pertinent art.
In the embodiment of the invention that is depicted in FIG. 1, the turntable 16 is driven so that it undergoes dextrorotation. Accordingly, a cup deposited in a pocket 18 by the cup drop work station 26 is transported by the turntable 16 to a point in communication with the second work station, wherein a liquid or semi-liquid product is charged into the cup. The means for filling the cup at this work station is an essentially conventional pumping means, designated 36 as a whole. A liquid reservoir 38, shown in FIG. 3, is mounted in upstanding disposition with an outlet 40, as best shown in FIG. 1, being in fluid communication with a reciprocating piston-type pump means, generally indicated as 42, and a head, or discharge spout 44. A pair of one-way valves, not shown, prevent reverse flow of the product. The amount of liquid pumped into each cup is a function of the length of the stroke of the pump's piston (not shown), and a micro-adjustment means, generally indicated as 46, is provided so that the length of the piston stroke can be finetuned to meet specific dosage requirements.
The filled cup is next carried by the turntable 16 to the third work station which is designated 48 as a whole. At this work station, the lids or closures are supplied to each cup, on a successive basis, and are releasably attached thereto. The third work station 48 includes an upstanding support member 50, an arm 52 attached thereto in cantilever fashion to overhang the periphery of the turntable 16. A plurality of upstanding lid retainer members 54 extend from cantilever arm 52 and are collectively arrayed to provide a gravity fed, closure magazine to supply closure members or lids 56 for the containers 58. A block 60 of adequate predetermined mass rests atop the generally vertical stack of lids 56 to enhance the gravity-influenced discharge of successive lids 56 from the magazine 54.
As shown clearly in FIG. 4, the cantilever arm 52 is obliquely disposed relative to the turntable 16 so that the lid retaining assembly 54 disposed in orthogonal relation to the arm 52 are tilted from the vertical. Empirical studies have shown that the optimal amount of angular rotation of the lid retaining assembly 54 from the vertical is seven (7) degrees, although the amount of tilt can range from 5°-10° from the vertical.
As shown in FIG. 4, the turntable 16 is rotating from left to right, as indicated by the directional arrow 62. A cup 58 is shown just prior to the moment when a lid 56 is dropped thereon. The cup 58 is supportedly engaged about a container rim 59 by the interior edges 19 of the pocket 18 and by an adjacent portion of the ring element 20.
A tilt-maintaining finger element 64 is attached to the cantilever arm 52 and lies in a plane parallel to the obliquely-disposed plane of the arm 52. The finger element 64 projects into the path of free fall of the individual lids 56 and supportingly engages, on a transient basis, a portion of each lid 56 sufficient to retain such lid 56 in an inclined position, even after such lid 56 has separated from the lid stack. When one portion of a lid 56 is supportingly engaged by the finger element 64, a diametrically opposed portion thereof will engage the rim 59 of the cup 58. When the turntable 16 again advances, the inclined lid 56 travels into impinging relationship with a roller means 66 that is rotatably and non-translatably mounted on the cantilever arm 52 at edge 67. The roller means 66 has a length at least equal to the diameter of the cup lids 56 and is disposed in transverse relation to the direction of turntable 16 rotation. The lid 56 is made of substantially flexible materials, and accordingly yields to the roller means 66 attendant continued rotation of the turntable 16. Such yielding action on the part of the lid 56 causes the lid to conform to and snap-fittingly engage the cup 58 about the uppermost periphery of rim 59, thereby effectively sealing the cup 58 against spillage of the liquid (not shown) retained therein.
The above-described coining operation can also be accomplished, although less advantageously, by providing a stationary, non-rotatable wiper blade (not shown) in lieu of the preferred roller means.
Returning now to FIG. 1, it will be noted that a filled and sealed cup 58 exiting the capping work station 48 encounters the dis-continuous portion 21 of the ring element 20 and is thereby at least partially dis-engaged from pocket 18. A fixed-position sweep arm 68 is disposed downwardly of the turntable 16 and upwardly of the top plate and discharge chute 12 and 14, respectively, for guiding successive cups 58 out of the respective pockets 18 and onto the discharge chute 14 to be collected by the machine operator.
The novel gear train for the inventive machine is shown, diagrammatically, in FIG. 5. Four (4) of the seven (7) gears are idlers, and are collectively designated 70. The outermost gears, 72 and 74, are connected in driving relation to the pump 42 and the first work station 26, respectively. The centrally-disposed gear 76 is the main drive gear and is is connected in driven relation to a power supply means in the form of an electric motor (not shown).
The eight (8) position geneva mechanism (not shown) and the turntable 16 are connected in driven relation to the main gear 76.
The only active components of the entire assembly are thus seen to be the first work station 26, second work station 42, and the turntable 16. The lid delivery and lid sealing means 48, as well as the filled and sealed cup ejection means 68 are essentially passive components. The complex drive assemblies of earlier fill and seal machines have accordingly been eliminated and the probabilities of machine malfunction have been sharply and inventively curtailed.
It will thus be seen that the objects set forth above, and those made apparent by the foregoing description, are efficiently attained, and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description, or shown in the accompanying drawings, shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
Now that the invention has been described,
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A fill and seal machine designed to charge liquid products into open-topped containers of predetermined configurations and dimensions and to apply closure members to such containers after the charging operation. An incrementally rotatable carrier disc disposed in communicating relation to a plurality of work stations has a plurality of circumferentially spaced dished portions that communicate with the periphery of the carrier disc, said dished portions successively receiving and transiently retaining individual ones of the containers. A lid delivery assembly for supplying the closure members to conventionally filled containers also provides the lid-sealing function. The novel capping operation is performed by the lid delivery assembly that is angularly disposed at a critical angle relative to the vertical. The filled and sealed containers are removed from the container carrying disc by a passive sweeping arm disposed in path-interruptive relation to such containers.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of international application number PCT/EP2011/053778, filed on Mar. 14, 2011, which claims priority to German Appl. No. 10 2010 003 079.1, filed on Mar. 19, 2010, both of which are incorporated herein by reference in their entirety and for all purposes.
BACKGROUND OF THE INVENTION
The invention relates to a surface cleaning head for cleaning a surface, comprising a housing that has a cleaning chamber which is surrounded by a peripheral wall and open at the bottom, and in which at least one cleaning nozzle is mounted on a spray arm so as to be freely rotatable about an axis of rotation for applying cleaning fluid to the surface to be cleaned, and comprising a jet pump for suctioning off cleaning fluid that is applied to the surface, the jet pump having a pump inlet channel that is in flow connection with the cleaning chamber and is connected to a combining channel via a mixing chamber, a motive nozzle for forming a suction flow being situated upstream from the combining channel.
The invention further relates to a surface cleaning arrangement having a surface cleaning head and an outlet line.
This type of surface cleaning head is known from U.S. Pat. No. 4,895,179. A spray lance of a high-pressure cleaning appliance may be connected to the surface cleaning head so that the cleaning nozzle situated on the spray arm may be supplied with pressurized cleaning fluid by the high-pressure cleaning appliance. The cleaning fluid may be sprayed onto the surface to be cleaned by means of the cleaning nozzle. The nozzle thus experiences a recoil, thereby setting the spray arm in rotation about the axis of rotation. At least two diametrically opposite spray arms, each carrying a cleaning nozzle, are usually used, whereby the nozzles may be simultaneously acted on by pressurized cleaning fluid.
In addition to the cleaning nozzles, the known surface cleaning head has a jet pump which operates according to the principle of a Venturi pump. The jet pump is situated above the housing, and is in flow connection with the cleaning chamber via a connecting line leading alongside the cleaning chamber. The jet pump includes a pump inlet channel which is connected to a mixing chamber, and a combining channel downstream from the mixing chamber. Upstream from the combining channel, a motive nozzle is in alignment with the combining channel, and may be acted on by pressurized cleaning fluid so that a suction flow forms in the mixing chamber and the combining channel. A diffuser is connected to the combining channel. An outlet line may be connected to the diffuser. The suction flow generated by the motive nozzle allows the fluid that is applied to the surface to be cleaned, together with removed dirt, to be suctioned off and discharged via the outlet line.
For operating the surface cleaning head known from U.S. Pat. No. 4,895,179, the surface cleaning head is supplied with cleaning fluid under a pressure of at least 207 bar at a delivery rate of at least 1,620 liters per hour. Due to the high pressure of the cleaning fluid and the high delivery rate, a suction flow may be formed by means of the jet pump which is strong enough to effectively suction off the cleaning fluid that is applied to the surface to be cleaned.
Surface cleaning heads having at least one rotating cleaning nozzle which may be supplied with pressurized cleaning fluid and which have a jet pump for suctioning off the cleaning fluid that is applied to the surface are also known from DE 100 66 009 B4 and DE 103 13 396 B4. In these surface cleaning heads as well, the cleaning fluid is supplied to the motive nozzle under high pressure and at a high delivery rate.
It is an object of the present invention to improve a surface cleaning head of the generic kind in such a way that the pressure and the delivery rate of the cleaning fluid may be reduced without significant losses of suction force of the suction pump.
SUMMARY OF THE INVENTION
For a surface cleaning head of the type stated at the outset, this object is achieved according to the invention in that the longitudinal axis of the pump inlet channel is oriented radially with respect to the axis of rotation of the at least one spray arm, and the pump inlet channel is connected to the peripheral wall of the cleaning chamber, the diameter of the combining channel being 14 mm to 18 mm, and the distance between the motive nozzle and the combining channel being at least 10 mm.
In the surface cleaning head according to the invention, the pump inlet channel is connected to the cleaning chamber along a longitudinal axis that is aligned in the radial direction. The pump inlet channel is connected to the combining channel via the mixing chamber, and the motive nozzle is situated upstream from the combining channel. Thus, the mixing chamber as well as the motive nozzle are situated at a short distance from the cleaning chamber, and thus also at a short distance from the surface to be cleaned. As a result, an effective suction flow is formed in the cleaning chamber, with the aid of which the surface to be cleaned may be suctioned, and the pressure of the cleaning fluid supplied to the motive nozzle may be selected to be lower than for the surface cleaning head known from U.S. Pat. No. 4,895,179. For example, the pressure of the cleaning fluid supplied to the motive nozzle may be less than 150 bar, and the delivery rate may be less than 800 liters per hour, in particular less than 600 liters per hour.
A further increase in the effectiveness of the surface cleaning head is achieved according to the invention in that the diameter of the combining channel is 14 mm to 18 mm. For smaller combining channel diameters, although a considerable delivery pressure is formed at the outlet of the combining channel, the transmission of air through the combining channel is relatively low. For large diameters, a high air transmission rate is obtained, but only a relatively low delivery pressure then results at the outlet of the combining channel, so that there is a risk that the cleaning fluid may no longer be reliably transported up to the free end of an outlet line via which the fluid conveyed by the jet pump is discharged. In combination with a distance of at least 10 mm, in particular a distance of at least 15 mm, between the motive nozzle and the combining channel, for a combining channel diameter of 14 mm to 18 mm, a considerable suction flow may be generated not only in the region of the pump inlet channel, but also in the region of an outlet line, in particular a discharge hose, situated downstream from the combining channel. This has the advantage that the cleaning fluid suctioned off from the surface to be cleaned may be discharged via the outlet line even in case the outlet line has a certain upward oblique inclination with respect to the horizontal. This provides the user with the option, for example, of cleaning a terrace, the outlet line extending along an ascending floor area or surmounting a small garden wall, for example. The surface to be cleaned may thus be effectively suctioned, and the sucked away cleaning fluid may be placed under a considerable delivery pressure by the jet pump so that it may be discharged in a reliable manner.
In an advantageous embodiment of the invention, the distance between the motive nozzle and the combining channel is at most 60 mm.
In particular a distance of 40 mm between the motive nozzle and the combining channel has proven to be particularly advantageous in order to generate a particularly effective suction flow for suctioning the surface to be cleaned and to place the sucked-up fluid under a considerable delivery pressure at the lowest possible pressure of the cleaning fluid that is supplied to the motive nozzle, and at the lowest possible delivery rate of the cleaning fluid, so that the sucked-up fluid may be discharged in a reliable manner.
The distance between the motive nozzle and the combining channel is preferably 1.3 to 4.3 times the diameter of the combining channel For providing an effective suction flow, it is advantageous for the distance between the motive nozzle and the combining channel to be at least 1.3 times the diameter of the combining channel. Thus, the motive nozzle should not be situated directly at the inlet of the combining channel. On the other hand, the distance between the motive nozzle and the inlet of the combining channel should also preferably not be greater than 4.3 times the diameter of the combining channel, since otherwise the suction flow is impaired.
The length of the combining channel is preferably at least 10 mm. In particular, a length of 20 mm has proven to be advantageous for increasing the effectiveness of the jet pump.
It is advantageous if a diffuser is connected to the combining channel and has an opening angle of 4° to 12°, in particular an opening angle of 8°. The diffuser forms a line portion which is connected to the combining channel and continuously widens. The achievable suction flow may be improved in this way.
The combining channel and the diffuser advantageously have a combined length of at least 30 mm.
The ratio of the diameter of the combining channel to the combined length of the combining channel and the diffuser is advantageously 0.13 to 0.25.
In a preferred embodiment of the invention, the motive nozzle is formed as a cone jet nozzle, the opening angle of the cone jet being 15° to 40°. The opening angle of the cone jet is advantageously 20° to 25°.
In a particularly preferred embodiment of the invention, the housing has an outer wall which surrounds the peripheral wall of the cleaning chamber, the pump inlet channel being mounted on the peripheral wall and on the outer wall. In particular, it may be provided that the pump inlet channel protrudes through the outer wall to the outside. Thus, the pump inlet channel extends, at least partially, inside the housing, namely, in the region between the peripheral wall of the cleaning chamber and the outer wall of the housing. The installation space of the surface cleaning head may thus be kept relatively low. The pump inlet channel may protrude beyond the housing to the outside at its end region that faces away from the cleaning chamber. This increases the stability not only of the pump inlet channel, but also of the portions of the outer wall and of the peripheral wall connected to the pump inlet channel. Thus, the pump inlet channel not only has the function of establishing a flow connection between the cleaning chamber and the mixing chamber of the jet pump, but also forms a mechanical reinforcing element which increases the mechanical stability of the surface cleaning head.
At least three support elements are advantageously situated in the region between the peripheral wall of the cleaning chamber and the outer wall of the housing for supporting the surface cleaning head on the surface to be cleaned. The support elements may be provided, for example, in the form of rollers or casters, with the aid of which the surface cleaning head may be moved along the surface to be cleaned.
The peripheral wall of the cleaning chamber preferably has a circular cylindrical shape, and in top view, the outer wall of the housing preferably has a triangular shape with rounded corner regions, one support element being situated in each corner region. The support elements are thus overlapped by the housing, and the surface cleaning head has a very compact design overall.
It is advantageous if a pump outlet channel which defines the mixing chamber and the combining channel, and optionally also the diffuser, is mounted at the end of the pump inlet channel that faces away from the peripheral wall of the cleaning chamber. The pump outlet channel is preferably aligned coaxially with the pump inlet channel.
It is advantageous for the housing of the surface cleaning head, the pump inlet channel, and the pump outlet channel to be integrally joined to one another. The housing, pump inlet channel, and pump outlet channel are preferably formed as an integral molded plastics part. The manufacturing and assembly costs of the surface cleaning head may thus be kept low.
In an advantageous embodiment, the assembly of the surface cleaning head is simplified in that the motive nozzle is mounted on a nozzle mounting which is insertable into the pump inlet channel and mechanically connectable to the pump inlet channel. The nozzle mounting is preferably latchable to the pump inlet channel. In a first assembly step, the motive nozzle may be fixed to the nozzle mounting, and the nozzle mounting together with the motive nozzle fixed thereto may be subsequently inserted into the pump inlet channel and mechanically connected thereto.
In an advantageous embodiment of the invention, the nozzle mounting is connected, via a second line portion extending above the at least one spray arm within the cleaning chamber, to a first line portion which passes through a top wall of the cleaning chamber. The motive nozzle which is fixed to the nozzle mounting may be supplied with pressurized cleaning fluid via the line portions. In such a configuration, the surface cleaning head is characterized by a particularly compact design.
It is advantageous if the surface cleaning head has a distributor unit which is connected to the at least one cleaning nozzle via a first branch line, and to the motive nozzle via a second branch line, a supply line being pivotably mounted on the distributor unit. The spray lance of a high-pressure cleaning appliance, for example, may be connected to the supply line. The distributor unit may be supplied with pressurized cleaning fluid via the spray lance and the supply line. The distributor unit is connected to the at least one cleaning nozzle via the first branch line so that the surface to be cleaned may be sprayed with cleaning fluid, and is connected to the motive nozzle via the second branch line so that the motive nozzle may be acted on by pressurized cleaning fluid to form a suction flow. As mentioned above, the second branch line may have a first line portion which passes through the top wall of the cleaning chamber, and a second line portion which is connected to the first line portion and extends within the housing to the nozzle mounting of the motive nozzle.
The motive nozzle advantageously extends into the mixing chamber.
It is advantageous if the mixing chamber tapers conically in the direction of the combining channel. The mixing chamber preferably has the shape of a truncated cone, and extends from the pump inlet channel to the combining channel. The cone angle of the mixing chamber is preferably 20° to 50°, in particular 25° to 35°. A cone angle of 30° is particularly advantageous.
The combining channel is advantageously cylindrical.
The pump inlet channel likewise preferably has a conical taper; i.e., the flow cross-section of the pump inlet channel is reduced in the direction of the mixing chamber.
The pump inlet channel preferably has a wedge-shaped design.
In an advantageous embodiment, the pump inlet channel has two side walls oriented at an angle to one another. The side walls are preferably oriented at an angle of 90° to one another.
A connecting device for connecting to the outlet line is advantageously situated downstream from the combining channel. In particular, it may be provided that the pump outlet channel is releasably connectable to the outlet line via the connecting device.
It is advantageous if a coupling device having a connection diameter of 28 mm to 40 mm and which is connected to the outlet line is connectable to the connecting device. Pressure losses during discharge of the sucked-up fluid may thus be kept low, while a considerable flow velocity may still be formed. The outlet line and the coupling device may preferably engage with one another. For example, the outlet line may engage with or be fitted onto a tubular coupling element of the coupling device.
The invention further relates to a surface cleaning arrangement for cleaning a surface, comprising a surface cleaning head which is preferably formed as described above, and comprising an outlet line which is connected to the surface cleaning head, the surface cleaning head including a housing having a cleaning chamber which is surrounded by a peripheral wall and open at the bottom, in the cleaning chamber at least one cleaning nozzle being mounted on a spray arm so as to be freely rotatable about an axis of rotation for applying cleaning fluid to the surface to be cleaned, and the surface cleaning head for suctioning off cleaning fluid that is applied to the surface including a jet pump having a pump inlet channel that is in flow connection with the cleaning chamber and is connected to a combining channel via a mixing chamber, a motive nozzle for forming a suction flow being situated upstream from the combining channel, and the outlet line being connected to the surface cleaning head downstream from the combining channel. To be able to reduce the pressure and the delivery rate of the cleaning fluid that is supplied to the surface cleaning arrangement without impairing the suction force of the jet pump, the longitudinal axis of the pump inlet channel is oriented radially with respect to the axis of rotation of the at least one spray arm, and the pump inlet channel is connected to the peripheral wall of the cleaning chamber, and the diameter of the combining channel is one-third to two-thirds the internal diameter of the outlet line.
As a result of the radial orientation of the pump inlet channel which is directly connected the peripheral wall of the cleaning chamber, and due to the selection of the diameters of the combining channel and the outlet line in a ratio of one-third to two-thirds, effective suctioning of the surface that is sprayed with cleaning fluid and effective discharge of the sucked-up fluid and the removed dirt may be achieved at a reduced pressure and decreased delivery rate of the cleaning fluid that is supplied to the surface cleaning head. In particular, an internal diameter of the outlet line of 28 mm to 40 mm is advantageous.
The following description of a preferred embodiment of the invention serves for explanation in greater detail in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic top view of a surface cleaning arrangement, having a surface cleaning head to which an outlet line is connected;
FIG. 2 shows a sectional view of the surface cleaning head along the line 2 - 2 in FIG. 1 ;
FIG. 3 shows a sectional view of the surface cleaning head along the line 3 - 3 in FIG. 1 ; and
FIG. 4 shows a sectional view of the surface cleaning head along the line 4 - 4 in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
The drawing schematically illustrates a surface cleaning arrangement 5 according to the invention having a surface cleaning head 10 according to the invention. The surface cleaning head 10 has a hood-like housing 12 , which in the top view has a substantially triangular shape with rounded corners. The housing 12 includes a top wall 14 , the outer edge of which is connected to an outer wall 16 . A circular cylindrical peripheral wall 18 which surrounds a cleaning chamber 20 projects downwardly from the top wall 14 at a distance from the outer wall 16 . In the region between the outer wall 16 and the peripheral wall 18 , support elements in the form of support wheels 22 , 23 , and 24 are respectively associated with each corner region of the housing 12 , by means of which the surface cleaning head 10 can be supported on a surface to be cleaned, and the surface cleaning head 10 can be moved along the surface to be cleaned.
A circumferential splash guard and sealing element in the form of a bristle strip 26 is situated at the free edge of the peripheral wall 18 , by means of which the cleaning chamber 20 can be sealed off with respect to the surface to be cleaned, and the escape of spray water from the cleaning chamber 20 may be prevented.
Situated above the top wall 14 is a distributor unit 28 that has a distributor line 29 , the longitudinal axis 30 of which is oriented perpendicularly with respect to the cylinder axis 31 that is defined by the cylindrical peripheral wall 18 .
The distributor unit 28 forms a bearing element on which a supply line 33 is mounted so as to be pivotable about the longitudinal axis 30 of the distributor line 29 . At its free end that faces away from the housing 12 , the supply line 33 carries a connecting element 34 to which, for example, a spray lance of a high-pressure cleaning appliance, which is known per se and therefore not illustrated in the drawing, may be connected.
The supply line 33 opens into the distributor line 29 , which is connected to a first branch line 36 that is aligned coaxially with the cylinder axis 31 and extends into the cleaning chamber 20 , and at its free end, carries two diametrically opposite spray arms 37 , 38 . The two spray arms 37 and 38 each carry a cleaning nozzle 39 and 40 , respectively, at their free end. A surface to be cleaned in the region enclosed by the bristle strip 26 may be sprayed with cleaning fluid by means of the cleaning nozzles 39 and 40 . The cleaning nozzles 39 and 40 generate an obliquely downwardly directed liquid jet of a cleaning fluid, which, upon exiting from the cleaning nozzles 39 , 40 , exerts a torque on the spray arms 37 , 38 , thus setting them in rotation about the cylinder axis 31 .
The distributor line 29 is in flow connection with a jet pump 45 via a second branch line 43 . The jet pump includes a motive nozzle 46 which is fixed to a nozzle mounting 48 . The nozzle mounting 48 is inserted into a pump inlet channel 50 and is mechanically connected thereto. In the illustrated embodiment, the nozzle mounting 48 is latched to the pump inlet channel 50 . The pump inlet channel 50 extends from a lateral opening 52 in the peripheral wall 18 and through the outer wall 16 , along a longitudinal axis 53 oriented radially with respect to the cylinder axis 31 ; i.e., the pump inlet channel 50 protrudes outwardly beyond the housing 12 . This is apparent in particular from FIG. 4 . A pump outlet channel 55 , which is aligned coaxially with the pump inlet channel 50 and carries a connecting device at its free end, is integrally connected to the pump inlet channel 50 . The connecting device includes an annular space 61 which encloses the pump outlet channel 55 at its free end region and is externally delimited by a sleeve 62 . The sleeve 62 is integrally joined to the pump outlet channel via a radially outwardly protruding shoulder 63 . A coupling device 57 is connected to the connecting device. The coupling device 57 includes a coupling flange 58 having a central connection opening 59 . A first socket piece 60 extends into the annular space 61 and is releasably connected to the sleeve 62 , for example via a bayonet connection. On the side facing away from the first socket piece 60 , a second socket piece 64 is molded onto the coupling flange 58 , coaxially with the longitudinal axis 53 . The second socket piece 64 forms a tubular coupling element into which an outlet line in the form of a flexible discharge hose 76 is inserted. The discharge hose 76 is non-detachably joined to the coupling device 57 by means of an adhesive, and together with the coupling device 57 may be separated from the pump outlet channel 55 , and as necessary, connected to same. The internal diameter of the discharge hose 76 is advantageously identical to the diameter of the connection opening 59 , and is preferably 28 mm to 40 mm.
The flow cross-section of the pump inlet channel 50 decreases in the region between the lateral opening 52 and the pump outlet channel 55 . For this purpose, the pump inlet channel has two side walls 78 , 79 which are oriented obliquely, namely, at an angle of 90°, relative to one another, as is apparent from FIG. 4 .
Within the pump outlet channel 55 , the pump inlet channel 50 is connected to a mixing chamber 65 , which has a frustoconical configuration and tapers conically in the direction facing away from the pump inlet channel 50 at a cone angle of 30°. In the pump outlet channel 55 , the mixing chamber 65 is connected to a cylindrical combining channel 67 having a diameter of 14 mm to 18 mm and a length of 40 mm. The distance between the motive nozzle 46 and the combining channel 67 is at least 10 mm, in particular at least 15 mm, and at most 60 mm. In the illustrated exemplary embodiment, the distance is 40 mm. Within the pump outlet channel 55 , in the direction facing away from the pump inlet channel 50 , the combining channel 67 is connected to a diffuser 69 , which expands conically in the direction facing away from the pump inlet channel 50 ; in the illustrated embodiment, the cone angle of the diffuser 69 is 8°. In its end region, the diffuser 69 is enclosed by the annular space 61 , into which the first socket piece 60 of the coupling device 57 extends. The connection opening 59 adjoins at the end of the diffuser.
As previously mentioned, the motive nozzle 46 is mounted on the nozzle mounting 48 . The motive nozzle 46 is in alignment with the combining channel 67 , and at its free end extends into the mixing chamber 65 . The flow connection between the motive nozzle 46 and the distributor line 29 is established via the second branch line 43 . The second branch line has a first line portion 71 which starts at the distributor line 29 and passes through the top wall 14 of the housing 12 at a distance from the first branch line 36 . Within the cleaning chamber 20 , above the spray arms 37 , 38 , the first line portion 71 is connected to a second line portion 72 of the second branch line 43 , on the free end of which the nozzle mounting 48 together with the motive nozzle 46 is mounted. The motive nozzle 46 is configured as a cone jet nozzle; i.e., it emits a liquid jet, shaped as a cone jet, which is directed toward the combining channel 67 . In the illustrated embodiment, the opening angle of the cone jet is approximately 22°.
As mentioned above, the connection diameter of the coupling device 57 , i.e., the diameter of the connection opening 59 , as well as the internal diameter of the discharge hose 76 , is 28 mm to 40 mm. The ratio of the diameter of the combining channel 67 to the connection diameter of the coupling device 57 , and thus to the internal diameter of the discharge hose 76 , is one-third to two-thirds.
The liquid jet emitted by the motive nozzle 46 strikes the combining channel 67 , and according to the known Venturi principle, generates a suction flow which is directed into the pump inlet channel 50 and the pump outlet channel 55 connected thereto. By means of the suction flow, cleaning fluid which has been applied to the surface to be cleaned together with removed dirt may be picked up from the surface and discharged via the discharge hose 76 . The discharge hose 76 is releasably connected to the pump outlet channel 55 . Within the discharge hose 76 , a liquid flow which is directed in the direction facing away from the surface cleaning head 10 forms under the action of the motive nozzle 46 . Sucked-up cleaning fluid flows through the discharge hose 76 , even when the hose has a certain upward inclination. Due to the radial orientation of the pump inlet channel 50 which is connected to the peripheral wall 18 and of the pump outlet channel 55 that is connected to the inlet channel, and due to the diameter of the combining channel 67 and the connection diameter of the coupling device 57 , as well as the selected distances between the motive nozzle 46 and the combining channel 67 , there is little risk of fluid in the discharge hose 76 flowing back to the surface cleaning head 10 .
The surface cleaning head 10 is also characterized by high mechanical stability. The cleaning nozzles 39 , 40 , the same as the motive nozzle 46 , are situated within the housing 12 , and the second line portion 72 of the second branch line 43 also extends inside the housing 12 and is thus protected from mechanical damage. The pump inlet channel 50 is fixed both to the peripheral wall 18 and to the outer wall 16 , forming a stable anchor for the pump outlet channel 55 . The housing 12 together with the peripheral wall 18 and the outer wall 16 , in combination with the pump inlet channel 50 and the pump outlet channel 55 , forms an integral molded plastics part which has high mechanical stability and is manufacturable at low cost. The nozzle mounting 48 may be inserted into the pump inlet channel 50 through the lateral opening 52 in the peripheral wall 18 and latched thereto after the motive nozzle 46 has been fixed to the nozzle mounting 48 beforehand
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A surface cleaning head for cleaning a surface is provided that includes a housing that has a cleaning chamber surrounded by a peripheral wall and open at the bottom, and in which a cleaning nozzle is mounted on a spray arm and is freely rotatable about a rotational axis, and a jet pump for suctioning off cleaning fluid applied to a surface, the jet pump having a pump inlet channel connected to a combining channel via a mixing chamber, and a motive nozzle upstream from the combining channel. To improve the surface cleaning head, the pump inlet channel is oriented radially with respect to the spray arm and connected to the peripheral wall of the cleaning chamber, the diameter of the combining channel is 14 to 18 mm, and the distance between the motive nozzle and the combining channel is at least 10 mm.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the present invention generally relate to an artificial lift system for well production.
2. Description of the Related Art
One type of adverse well production is steam assisted gravity drainage (SAGD). SAGD wells are quite challenging to produce. They are known to produce at temperatures above two hundred degrees Celsius. They are typically horizontally inclined in the producing zone. The produced fluids can contain highly viscous bitumen, abrasive sand particles, high temperature water, sour or corrosive gases and steam vapor. Providing oil companies with a high volume, highly reliable form of artificial lift is greatly sought after, as these wells are quite costly to produce due to the steam injection needed to reduce the in-situ bitumen's viscosity to a pumpable level.
For the last decade, the artificial lift systems deployed in SAGD wells have typically been Electrical Submersible Pumping (ESP) systems. Although run lives of ESP systems in these applications are improving they are still well below “normal” run times, and the costs of SAGD ESPs are three to four times that of conventional ESP costs.
SUMMARY OF THE INVENTION
Embodiments of the present invention generally relate to an artificial lift system for well production. In one embodiment, a method of pumping production fluid from a wellbore includes deploying a centrifugal pump into a production wellbore; and pumping hydrocarbons from the production wellbore by rotating an impeller of the centrifugal pump in the production wellbore from surface using a drive string, wherein the impeller is rotated at a speed less than or equal to seventeen hundred fifty revolutions per minute.
In another embodiment, a downhole assembly of an artificial lift system includes: a receptacle for receiving a coupling of a drive string, the receptacle including a housing having a coupling for connection to a production tubing string and a shaft; a centrifugal pump including a housing connected to the receptacle housing and a shaft connected to the receptacle shaft; a thrust chamber including: a housing connected to the pump housing, a shaft torsionally and longitudinally connected to the pump shaft, a thrust bearing having a thrust driver longitudinally and torsionally connected to the pump shaft and a thrust carrier longitudinally and torsionally connected to the chamber housing, wherein: the thrust bearing is operable to receive thrust from the pump shaft, and the thrust bearing is in fluid communication with a pumped fluid path.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 illustrates an artificial lift system (ALS) pumping production fluid from a steam assisted gravity drainage (SAGD) well, according to one embodiment of the present invention.
FIGS. 2A-C illustrate a downhole assembly of the ALS.
FIG. 3A illustrates a rod receptacle of the downhole assembly. FIG. 3B illustrates a pump of the downhole assembly.
FIG. 4A illustrates a thrust chamber of the downhole assembly. FIG. 4B illustrates an intake of the downhole assembly.
FIGS. 5A-5D illustrate a stabilizer of the ALS.
DETAILED DESCRIPTION
FIG. 1 illustrates an artificial lift system (ALS) 50 h, r, d pumping production fluid, such as bitumen 8 p (aka tar sand or oil sand), from a steam assisted gravity drainage (SAGD) well 1 , according to one embodiment of the present invention. Alternatively, the production fluid may be heavy crude oil or oil shale. The ALS 50 h, r, d may include a drive head 50 h , a drive string 50 r , and a downhole assembly 50 d . The SAGD well 1 may include an injection well 1 i and a production well 1 p . Each well 1 i, p may include a wellhead 2 i, p located adjacent to a surface 4 of the earth and a wellbore 3 i, p extending from the respective wellhead. Each wellbore 3 i, p may extend from the surface 4 vertically through a non-productive formation 6 d and horizontally through a hydrocarbon-bearing formation 6 h (aka reservoir). Alternatively the horizontal portions of either or both wellbores may be other deviations besides horizontal. Alternatively, the injection well may be omitted and the ALS may be used to pump production fluid from other types of adverse production wells, such as high temperature wells.
Surface casings 9 i, p may extend from respective wellheads 2 i, p into respective wellbores 3 i, p and each casing may be sealed therein with cement 11 . The production well 1 p may further include an intermediate casing 10 extending from the production wellhead 2 p and into the production wellbore 3 p and sealed therein with cement 11 . The injection well 1 i may further include an injection string 15 having an injection tubing string 15 t extending from the injection wellhead 2 i and into the injection wellbore 3 i and having a packer 15 p for sealing an annulus thereof.
A steam generator 7 may be connected to the injection wellhead 2 i and may inject steam 8 s into the injection wellbore 3 i via the injection tubing string 15 t . The injection wellbore 3 i may deliver the steam 8 s into the reservoir 6 h to heat the bitumen 8 p into a flowing condition as the added heat added reduces viscosity thereof. The horizontal portion of the production wellbore 3 p may be located below the horizontal portion of the injection wellbore 3 i to receive the bitumen drainage 8 p from the reservoir 6 h.
A production string 12 may extend from the production wellhead 2 p and into the production wellbore 3 p . The production string 12 may include a string of production tubing 12 t and the downhole assembly 50 d connected to a bottom of the production tubing. A slotted liner 13 may be hung from a bottom of the intermediate casing 10 and extend into an open hole portion of the production wellbore 3 p . The downhole assembly 50 d may be located adjacent a bottom of the intermediate casing 10 . Alternatively, the downhole assembly 50 d may be located within the slotted liner 13 . An instrument string 14 may extend from the production wellhead 2 p and into the production wellbore 3 p . The instrument string 14 may include a cable 14 c and one or more sensors 14 i, o in data communication with the cable. The sensors 14 i, o may include a first 14 i pressure and/or temperature sensor in fluid communication with the bitumen 8 p entering the downhole assembly 50 d and a second 14 o pressure and/or temperature sensor in fluid communication with the bitumen discharged from the downhole assembly.
The drive head 50 h may include a motor 51 , a transmission 52 , an output shaft 53 , a clamp 54 , a stuffing box 55 , a frame 56 , a thrust bearing 57 , and a drive shaft, such as a polished rod 58 . The motor 51 may be electric, such as a two-pole, three-phase, squirrel-cage induction type and may operate at a nominal rotational speed 59 m of thirty-five hundred revolutions per minute (RPM) at sixty Hertz (Hz). Alternatively, the motor may be hydraulic or pneumatic. A housing of the motor 51 may be connected to the frame 56 . The frame 56 may be connected to the wellhead 2 p . A shaft of the motor 51 may be connected to the transmission 52 . The transmission 52 may be a belt and sheave, roller chain and sprockets, or a gearbox. Alternatively, the drive head may be direct drive (no transmission). The output shaft 53 may be connected to the transmission 52 . The transmission 52 may rotate the output shaft 53 at a rotational speed 59 o less than the motor rotational speed 59 m . The speed ratio (output speed 590 o divided by motor speed 59 m ) of the transmission 52 may be less than or equal to one-half, nine-twentieths, three-eighths, or one-third such that the output speed 59 o may be less than or equal to (about) seventeen hundred fifty, sixteen hundred, thirteen hundred, or twelve hundred RPM, respectively.
The polished rod 58 may be connected to the output shaft 53 by the clamp 54 . The clamp 54 may torsionally and longitudinally connect the output shaft 53 and the polished rod 58 such that the polished rod is driven at the output speed 59 o and the output shaft may transfer weight of the drive string 50 r to the thrust bearing 57 . The polished rod 58 may be longitudinally and torsionally connected to the drive string 50 r , such as by a threaded connection (not shown), such that the drive string is also driven at the output speed 59 o . The drive string 50 r may extend from the production wellhead 2 p and into the production wellbore 3 p . The drive string 50 r may include a continuous sucker rod 60 , stabilizers 61 spaced therealong at regular intervals, and a rod coupling 62 ( FIGS. 2A and 3A ). Alternatively, the drive string may include a jointed sucker rod string (sucker rods and couplings), coiled tubing, or a drill pipe string instead of the continuous sucker rod.
FIGS. 2A-C illustrate the downhole assembly 50 d . The downhole assembly 50 d may include a rod receptacle 100 , a pump 200 , a thrust chamber 300 , and an intake 400 .
FIG. 3A illustrates the rod receptacle 100 . The rod receptacle 100 may include a housing 101 and a shaft 105 disposed in the housing and rotatable relative thereto.
The rod coupling 62 may be longitudinally and torsionally connected to a bottom of the continuous sucker rod 60 , such as by a threaded connection. The rod coupling 62 may include a tubular body 62 b . Ribs 62 r may be formed along an outer surface of the body 62 b and spaced therearound. Flow passages may be formed between the ribs 62 r to minimize flow obstruction by the ribs. The ribs 62 r may facilitate alignment of the rod coupling 62 with the receptacle shaft 105 when landing the rod coupling into the rod receptacle 100 . An upper portion of the coupling body 62 b may have a threaded inner surface 62 t for connection to the continuous sucker rod 60 . Splines 62 s may be formed along and spaced around an inner surface of a mid and lower portion of the body 62 b . A shoulder may be formed at an upper end of the body 62 b for receiving the continuous sucker rod 60 .
A conical landing guide 62 c may be formed at a lower end of the body 62 b to also facilitate alignment of the rod coupling 62 with the receptacle shaft 105 when landing the rod coupling into the rod receptacle 100 . A clearance formed between the ribs 62 r and an inner surface of the receptacle housing 101 may be less than or equal to a clearance formed between the receptacle shaft 105 and a maximum diameter of the landing guide 62 c to ensure that the receptacle shaft is received by the landing guide 62 c . Engagement of the landing guide 62 c with the receptacle shaft 105 may even lift the rod coupling 62 from a bottom of the production tubing 12 t . The rod coupling 62 may further have one or more relief ports (not shown) formed through a wall thereof for exhausting debris during landing of the rod coupling into the receptacle 100 .
The receptacle housing 101 may include an upper connector portion 102 , a tubular mid portion 103 , and a lower connector portion 104 . The upper connector portion 102 may flare outwardly from the mid portion 103 and have a threaded inner surface 102 t for connection to the bottom of the production tubing 12 t . An outer surface of the production tubing bottom may also be threaded (not shown). The upper connector portion 102 may also have a fishing profile 102 p formed in an outer surface thereof to facilitate retrieval of the downhole assembly 50 d in case the downhole assembly becomes stuck in the production wellbore 3 p and cannot be removed using the production tubing 12 t . The lower connector portion 104 may have a flange 104 f formed in an outer surface thereof and a nose 104 n formed at a lower end thereof. The flange 104 f may have holes formed therethrough for receiving threaded fasteners, such as bolts 104 b . The nose 104 n may have a groove formed in an outer surface thereof for carrying a seal, such as an o-ring 104 s . A stopper 110 may be disposed in the mid portion 103 and longitudinally connected thereto, such as by a threaded connection. The stopper 110 may have a bore accommodating the shaft 105 and a flow passage formed therethrough for accommodating pumping of the bitumen 8 p .
The receptacle shaft 105 may include a solid core portion 105 c , splines 105 s formed along and spaced around an outer surface of the core portion, a guide nose 105 n formed at an upper end thereof, and a landing guide formed at a lower end thereof. The guide nose 105 n may be convex and have a spiral profile formed therein. The landing guide may be a serration 105 j formed in a lower end of each of the splines 105 s . When landing the rod coupling 62 into the rod receptacle 100 , the guide nose 105 n may engage the rod coupling splines 62 s and rotate the receptacle shaft 105 relative to the rod coupling to align the receptacle splines 105 s with spline-ways of the rod coupling (and vice versa). Mating of the splines 62 s , 105 s may torsionally connect the rod coupling 62 and the receptacle shaft 105 while allowing relative longitudinal movement therebetween. After mating of the receptacle and rod coupling splines 62 s , 105 s , lowering of the rod coupling 62 may continue until the lower end of the rod coupling body seats on the stopper 110 . The lowering may be accommodated by the extended splines 62 s of the rod coupling 62 . Once seated, the rod coupling 62 may be raised into the operational position shown and the continuous sucker rod 60 clamped 54 , thereby ensuring that the downhole assembly 50 d does not bear the weight of the continuous sucker rod. The receptacle shaft 105 may further include shaft retainers (not shown) for longitudinally restraining the shaft within the receptacle housing 101 during assembly and deployment of the downhole assembly 50 d . The shaft retainers may engage the stopper 110 while allowing limited relative longitudinal movement of the shaft 105 relative to the housing 101 to accommodate operation of the receptacle shaft.
FIG. 3B illustrates the pump 200 . The pump 200 may include a housing 201 and a shaft 205 disposed in the housing and rotatable relative thereto. To facilitate assembly, the pump housing 201 may include one or more sections 202 - 204 , each section longitudinally and torsionally connected, such as by a threaded connection and sealed, such as by as an o-ring. Each housing section 202 - 204 may further be torsionally locked, such as by a tack weld (not shown). An upper connector section 202 may have a flange 202 f formed at an upper end thereof and a seal face formed in an inner surface thereof. The flange 202 f may have threaded sockets 202 s formed therein for receiving shafts of the receptacle bolts 104 b , thereby fastening the flanges 104 f , 202 f together and forming a longitudinal and torsional flanged connection between the receptacle housing 101 and the pump housing 201 . The seal face may receive the receptacle nose 104 n and seal 104 s , thereby sealing the flanged connection. A lower connector portion 204 may have a flange 204 f , a nose 204 n , o-ring 204 s , and bolts 204 b similar to those discussed above for the receptacle 100 .
The pump 200 may further include a shaft coupling 262 for longitudinally and torsionally connecting the receptacle shaft 105 and the pump shaft 205 . The shaft coupling 262 may include a tubular body 262 b . Splines 262 s may be formed along and spaced around an inner surface of body 262 b . A guide profile, such as a serration 262 j , may be formed in an upper end of each of the splines 262 s and may correspond to the receptacle shaft serration 105 j . A support, such as a pin 262 p , may extend across a bore of the body 262 b . The pin 262 p may be longitudinally connected to the body 262 b , such as by fasteners 262 f . The body 262 b may have threaded holes formed through a wall thereof for receiving the fasteners 262 f and the pin 262 p may have a groove formed therein for receiving tips of the fasteners, thereby longitudinally connecting the pin and the body.
When assembling the downhole assembly 50 d for deployment into the production wellbore 3 p , the receptacle 100 may be lowered onto the pump 200 . As the receptacle 100 is lowered onto the pump 200 , the receptacle serrations 105 j may engage the shaft coupling serrations 262 j . Engagement of the serrations 105 j , 262 j may rotate the receptacle shaft 105 relative to the shaft coupling 262 to align the receptacle splines 105 s with spline-ways of the shaft coupling (and vice versa). Mating of the splines may torsionally connect the shaft coupling 262 and the receptacle shaft 105 while allowing relative longitudinal movement therebetween. After mating of the receptacle and shaft coupling splines 105 s , 262 s , lowering of the receptacle 100 may continue until a lower end of the receptacle shaft 105 seats on the shaft coupling pin 262 p , thereby longitudinally supporting the receptacle shaft 105 from the shaft coupling 262 . After seating of the receptacle shaft 105 , lowering of the receptacle 100 may continue until the receptacle flange 104 f is adjacent the upper pump flange 202 f . The flanges 104 f , 202 f may be manually aligned, seated, and fastened.
The pump shaft 205 may include a solid core portion 205 c , upper 205 u and lower 205 b splines formed at and spaced around respective ends of the core portion, a keyway 205 w ( FIGS. 2A and 2B ) formed along the core portion, and a landing guide formed at a lower end thereof. The landing guide may be a serration 205 j formed in a lower end of each of the splines 205 s . The shaft coupling 262 may be manually installed on the pump shaft upper end, thereby engaging the upper splines 205 u with the coupling splines 262 s and seating the coupling pin 262 p on the shaft upper end. The installation may longitudinally and torsionally connect the pump shaft 205 to the shaft coupling 262 .
The pump shaft 205 may be supported for rotation relative to the housing by radial bearings 206 u, b . Each radial bearing 206 u, b may include a body, an inner sleeve, and an outer sleeve. The sleeves may be made from a wear-resistant material, such as a tool steel, ceramic, or ceramic-metal composite (aka cermet). Each inner sleeve may be longitudinally connected to the pump shaft 205 , such as by retainers (i.e., snap rings) engaged with respective grooves formed in an outer surface of the shaft core 205 c , and torsionally connected to the shaft, such as by a press fit or key. Each outer sleeve may be longitudinally and torsionally connected to the bearing body, such as by a press fit. Each bearing body may be longitudinally and torsionally coupled to the respective housing sections 202 , 204 , such as by a press fit. Each bearing body may have flow passages formed therethrough for accommodating pumping of the bitumen 8 p and the bearings may utilize the pumped bitumen for lubrication.
The pump 200 may be centrifugal, such as a radial flow or mixed axial/radial flow centrifugal pump. The pump 200 may include one or more stages 210 a, b (six stages shown in FIGS. 2A and 2B ). Each stage 210 a, b may include an impeller 211 a diffuser 212 , and an impeller spacer. Each even stage 210 b may include a radial bearing 213 having an inner sleeve torsionally connected to the pump shaft, such as by a key (not shown) and keyway 205 w , and an outer sleeve longitudinally and torsionally connected to the respective diffuser, such as by a press fit. The bearing sleeves 213 may be made from the wear resistant material, discussed above for the radial bearings 206 u, b . Alternatively, each odd stage may include the bearing instead of the even stage or each stage may include the bearing. Each impeller 211 and impeller spacer may be torsionally connected to the pump shaft 205 , such as by a key (not shown) and keyway 205 w . The impellers 211 and impeller spacers may be longitudinally connected to the pump shaft 205 by compression between a compression fitting 207 and a retainer, such as a snap ring 208 .
The compression fitting 207 may include a sleeve 207 s , a nut 207 n , a retainer, such as a snap ring 207 r , and fasteners, such as set screws 207 f . The snap ring 207 r may be received in a groove formed in an outer surface of the shaft core 205 c after the rest of the fitting has been disposed on the shaft core. The snap ring 208 may be installed on the shaft core 205 c before the impellers 211 and may have a shoulder for receiving an impeller spacer. The snap ring 207 r may have a shoulder for receiving the nut 207 n . The sleeve 207 s may be torsionally connected to the shaft 205 , such as by a key (not shown) and keyway 205 w . The sleeve 207 s may have a threaded outer surface for receiving a threaded inner surface of the nut 207 n . Rotation of the nut 207 n relative to the sleeve 207 s may longitudinally drive the sleeve into engagement with an impeller spacer, thereby compressing the impellers, impeller bearings, and impeller spacers. Once tightened to a predetermined torque, the nut 207 n may be torsionally connected to the compression sleeve 207 s by installing or tightening the set screws 207 f . Rotation of the nut 207 n relative to the sleeve 207 s may longitudinally drive the sleeve into engagement with an impeller spacer, thereby compressing the impellers, impeller bearings, and impeller spacers. Once tightened to a predetermined torque, the nut 207 n may be torsionally connected to the compression sleeve 207 s by installing or tightening the set screws 207 f.
The diffusers 212 may be longitudinally and torsionally connected to the pump housing 201 , such as by compression between the upper 202 and lower 204 connector sections (and diffuser spacers). Rotation of each impeller 211 by the pump shaft 205 may impart velocity to the bitumen 8 p and flow through the stationary diffuser 212 may convert a portion of the velocity into pressure. The pump 200 may deliver the pressurized bitumen 8 p to the production tubing 12 t via the receptacle 100 .
FIG. 4A illustrates the thrust chamber 300 . The thrust chamber 300 may include a housing 301 and a shaft 305 disposed in the housing and rotatable relative thereto. To facilitate assembly, the chamber housing 301 may include one or more sections 302 - 304 , each section longitudinally and torsionally connected, such as by a threaded connection and sealed, such as by as an o-ring. Each housing section 302 - 304 may further be torsionally locked, such as by a tack weld (not shown). An upper connector section 302 may have a flange 302 f formed at an upper end thereof and a seal face formed in an inner surface thereof. The flange 302 f may have threaded sockets 302 s formed therein for receiving shafts of the lower pump flange bolts 204 b , thereby fastening the flanges 204 f , 302 f together and forming a longitudinal and torsional flanged connection between the pump housing 201 and the chamber housing 301 . The seal face may receive the lower pump flange nose 204 n and seal 204 s , thereby sealing the flanged connection. A lower connector portion 304 may have a flange 304 f , a nose 304 n , o-ring 304 s , and bolts 304 b similar to those discussed above for the receptacle 100 .
The thrust chamber 300 may further include a shaft coupling 362 for longitudinally and torsionally connecting the pump shaft 205 and the chamber shaft 305 . The chamber shaft coupling 362 may be similar to the pump shaft coupling 262 , discussed above and assembly of the pump 200 onto the thrust chamber 300 may be similar to assembly of the receptacle 100 onto the pump 200 , discussed above. The chamber shaft 305 may include a solid core portion 305 c , upper 305 u and lower splines formed at and spaced around respective ends of the core portion, a keyway 305 w ( FIGS. 2B and 2C ) formed along the core portion, and a landing guide formed at a lower end thereof. Alternatively, the lower splines and/or the lower landing guide may be omitted. The chamber shaft 305 may be supported for rotation relative to the chamber housing by radial bearings 306 u, b , similar to the pump radial bearings 206 u, b , discussed above.
The thrust chamber 300 may further include one or more thrust bearings 310 a - d . Each thrust bearing 310 a - d may include a thrust driver 311 , a thrust carrier 312 , a radial bearing 314 s , a runner thrust disk 314 d , and a carrier pad 313 . The thrust bearings 310 a - d may receive both impeller thrust and pressure thrust from the rotating pump shaft 205 via the shaft coupling 362 and be capable of transferring the thrusts to the stationary production tubing 12 t via housings 101 - 301 .
Each thrust driver 311 , radial bearing 314 s , and runner spacer may be torsionally connected to the chamber shaft 305 , such as by a key (not shown) and keyway 305 w . The thrust drivers 311 , radial bearings 314 s , and runner spacers may be longitudinally connected to the chamber shaft 305 by compression between a compression fitting 307 and a retainer, such as a snap ring 308 . The compression fitting 307 may be similar to the pump compression fitting 207 , discussed above. Each thrust disk 314 d may be received in a recess formed in the respective thrust driver 311 . Each thrust disk 314 d may be longitudinally connected to the thrust driver 311 , such as by a press fit. Each thrust disk 314 d may be torsionally connected to the thrust driver 311 , such as by a fastener (i.e., a pin 315 t ). Each pin 315 t may be received by a hole formed through the respective thrust driver 311 at a periphery thereof and extend into an opening formed through the respective thrust disk 314 d at a periphery thereof. The pin 315 t may be press fit into the thrust driver hole. The thrust disks 314 d , carrier pads 313 , and radial bearings 314 s may each be made from the wear resistant material, discussed above for the radial bearings 206 u, b.
Each thrust disk 314 d may have lubricating grooves 316 t formed in a bearing face thereof. The lubricating grooves 316 t may be radial, tangential, angled, or spiral and may extend partially or entirely across the bearing face. Each thrust driver 311 may have a lubrication passage 311 p formed therethrough in fluid communication with the recess. Each thrust driver 311 may further have a debris passage 311 e formed therethrough for exhausting debris from a thrust interface between the thrust disk 314 d and a thrust portion of the carrier pad 313 . Each radial bearing 314 s may be a sleeve and operable to radially support rotation of the thrust drivers 311 relative to the thrust carriers 312 by engagement with a radial portion of the respective carrier pad 313 .
The carriers 312 may be longitudinally and torsionally connected to the chamber housing 301 , such as by compression between the upper 302 and lower 304 connector sections (and spacers). Each carrier pad 313 may be received in a recess formed in the respective carrier 312 . Each carrier pad 313 may be longitudinally connected to the carrier 312 , such as by a press fit. Each carrier pad 313 may be torsionally connected to the carrier, such as by a fastener (i.e., a pin 315 c ). Each pin 315 c may be received by a hole formed through the respective carrier 312 at a periphery thereof and extend into an opening formed through the respective carrier at a periphery thereof. The pin 315 c may be press fit into the carrier hole. Each carrier pad 313 may have a thrust portion and a radial portion, each portion perpendicular to the other, thereby forming a T-shaped cross section. Alternatively, a separate carrier disk and a carrier sleeve may be used instead of the T-shaped carrier pad. A thrust portion of each carrier pad 313 may have lubricating grooves 316 c formed in a bearing face thereof, similar to the runner disk grooves 316 t , discussed above. Each carrier may have a lubrication passage 312 p formed therethrough in fluid communication with the recess. Each carrier 312 may also have a flow passage 312 f formed therethrough for accommodating pumping of the bitumen 8 p and the thrust bearings 310 a - d may utilize the pumped bitumen for lubrication via passages 311 p , 312 p.
FIG. 4B illustrates the intake 400 . The intake 400 may include a housing 401 and a flow tube 405 disposed in the housing and rotatable relative thereto. To facilitate assembly, the intake housing 401 may include one or more sections 402 - 404 , each section longitudinally and torsionally connected, such as by a threaded connection and sealed, such as by as an o-ring. Each housing section 402 - 404 may further be torsionally locked, such as by a tack weld (not shown). An upper connector section 402 may have a flange 402 f formed at an upper end thereof and a seal face formed in an inner surface thereof. The flange 402 f may have threaded sockets 402 s formed therein for receiving shafts of the lower chamber flange bolts 304 b , thereby fastening the flanges 304 f , 402 f together and forming a longitudinal and torsional flanged connection between the chamber housing 301 and the intake housing 401 . The seal face may receive the lower chamber flange nose 304 n and seal 304 s , thereby sealing the flanged connection. A lower connector portion 404 may have a flange 404 f , a nose 404 n , o-ring 404 s , and bolts 404 b similar to those discussed above for the receptacle 100 .
A mid housing section 403 may have one or ports 403 p formed through a wall thereof for receiving the bitumen 8 p from the production wellbore 3 p . The ports 403 p may be formed along and spaced around the mid housing section 403 . The flow tube 405 may one or more ports 405 p formed through a wall thereof. The flow tube may also have one or more weights 405 g formed in an outer surface thereof or disposed thereon, such as by a weld. The weights 405 g may be located adjacent each port 405 p . Each weight 405 j may include a pair of bands and fasteners (not shown) for assembly of the weight adjacent each port 405 p . Each tube port 405 p may also extend to a location adjacent the housing ports 403 p . The flow tube 405 may be supported for rotation relative to the housing 401 by one or more radial bearings 406 u, b . Each radial bearing 406 u, b may be rolling element bearing, such as a needle bearing. When the downhole assembly 50 d is deployed in the horizontal portion of the production wellbore 3 p , the weights 405 g may create eccentricity in the flow tube 405 , thereby causing the flow tube to rotate relative to the housing 401 such that the flow tube ports 405 p face downwardly in the production wellbore 3 p . This may utilize a natural separation effect in the production wellbore 3 p such that the flow tube ports 405 p intake the bitumen 8 p rather than steam vapor or other gas.
The downhole assembly 50 d may further include a guide shoe 450 . The guide shoe 450 may have a flange formed at an upper end thereof and a seal face formed in an inner surface thereof. The flange may have threaded sockets formed therein for receiving shafts of the lower intake flange bolts 404 b , thereby fastening the flanges together and forming a longitudinal and torsional flanged connection between the intake housing 401 and the guide shoe 450 . The seal face may receive the lower intake flange nose 404 n and seal 404 s , thereby sealing the flanged connection.
FIGS. 5A-5D illustrate the stabilizer 61 . The stabilizer 61 may include a collar 501 , a sleeve 502 , and a clamp 503 . The collar 501 may be rotatable relative to the sleeve 502 . The sleeve 502 may be operable to engage an inner surface of the production tubing 12 t and radially support rotation of the collar 501 therefrom. The collar 501 may include a pair of bands 501 a, b . Each band 501 a, b may be semi-tubular and include a hole 501 h formed tangentially through a wall thereof and a threaded socket 501 s tangentially formed in the wall. Each hole 501 h and mating socket 501 s may receive a threaded fastener 504 , thereby longitudinally and torsionally connecting the collar bands 501 a, b together. Connection of the collar bands 501 a, b around the continuous sucker rod 60 may longitudinally and torsionally connect the collar 501 to the rod 60 by compressing an inner surface of the bands 501 a, b against the rod 60 .
The sleeve 502 may include a pair of bands 502 a, b . Each band 502 a, b may be semi-tubular and have connector profiles, such as dovetails 502 d , formed therealong. Engagement of the dovetails 502 d may torsionally connect the sleeve bands 502 a, b together. The sleeve bands 502 a, b may be longitudinally connected by entrapment between a shoulder formed at an upper end of the collar 501 and the clamp 503 . The entrapment may also longitudinally connect the sleeve 502 and the collar 501 . The sleeve 502 may further have ribs 502 r formed along and spaced around an outer surface thereof. The ribs 502 r may engage an inner surface of the production tubing 12 t while minimizing obstruction to pumping of the bitumen 8 p through the production tubing.
The clamp 503 may include a pair of bands, such as a major band 503 a and a minor band 503 b . Each band 503 a, b may be arcuate and the major band 503 a may include a pair of holes 503 h formed through a wall thereof. Correspondingly, the minor band may include pair of threaded sockets 503 s formed in a wall thereof. Each hole 503 h and mating socket 503 s may receive a threaded fastener 505 , thereby longitudinally and torsionally connecting the bands 503 a, b together. The collar 501 may have a pair of flats formed in an outer surface thereof and located at a lower end thereof. The major band 503 a may have a pair of bosses formed in an inner surface thereof for engaging the flats. Connection of the clamp bands 503 a, b around the collar 501 may longitudinally and torsionally connect the clamp 503 to the collar by engagement of the bosses with the flats.
The collar 501 and clamp 503 may be made from a metal or alloy, such as steel, stainless steel, or a nickel based alloy. The sleeve 502 may be made from a high-temperature and wear-resistant polymer, such as a cross-linked thermoplastic, a thermoset, or a copolymer.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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A method of pumping production fluid from a wellbore includes deploying a centrifugal pump into a production wellbore; and pumping hydrocarbons from the production wellbore by rotating an impeller of the centrifugal pump in the production wellbore from surface using a drive string, wherein the impeller is rotated at a speed less than or equal to seventeen hundred fifty revolutions per minute.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This Application is a Continuation-In-Part of the Co-Pending patent application U.S. Ser. No. 10/885,355, filed on Jul. 6, 2004, which in turn is a Continuation-In-Part of the Co-Pending patent application U.S. Ser. No. 10/418,852, filed Apr. 18, 2003 (now issued U.S. Pat. No. 6,918,899), which in turn is a Continuation-In-Part of patent application U.S. Ser. No. 10/369,240 filed Feb. 19, 2003 (now issued U.S. Pat. No. 6,706,027) and claiming priority from Provisional Patent Application No. 60/359,672 which was filed on Feb. 26, 2002.
BACKGROUND ART
[0002] The use of human urinary collection and disposal systems is known in the prior art. For example U.S. Pat. No. 4,886,508 (Washington, 1989) discloses a ladies' external catheter assembly, however this device does not use a vacuum pump for drainage or utilize a moisture sensor. Also U.S. Pat. No. 4,610,675 (Triunfol, 1986) teaches a device for collecting fluid discharged from female organs that is designed solely for incontinent women, not female aircrew members and the design includes a pad, vacuum pump and liquid sensor, however, the pad is more invasive because it is formed of plastic and has ridges to move the labia to an open position for free flow of liquid. The vacuum pump of the Triunfol patent is powered by an electrical outlet and does teach battery operation of these devices. In U.S. Pat. No. 5,662,631 (Marx, Sep. 2, 1997) a male external catheter assembly with vacuum retention is disclosed wherein a male external catheter attachment incorporates a vacuum or a means to produce reduced pressure to aid in installing and keeping the device in place. U.S. Pat. No. 5,499,977 (Marx, Mar. 19, 1996) teaches another form of male external catheter with vacuum assist utilizing a rubber bulb that functions as a vacuum. As such, the basic concept of bladder discharge collection systems and their use are disclosed.
[0003] There are no acceptable bladder relief systems for incontinent adults. Urinary incontinence affects more than 13 million Americans in community and institutional settings. Thirty-eight percent of non-institutionalized patients older than 60 years of age experienced urinary incontinence, and almost 50 percent of institutionalized patients. The annual costs of bladder control problems in the United States for people older than years of age was estimated at $26.3 billion in 1995, or $3,565 per affected person. Many incontinent males use commercially available diapers, which cannot contain urine from multiple urinations, and become heavy and uncomfortable when wet.
[0004] While each of these prior art patents disclose bladder relief systems which fulfill their respective particular objectives and requirements, and are most likely quite functional for their intended purposes, it will be noticed that none of the prior art cited disclose an apparatus and/or method that allow a user the comfort of automatic operation and large volume capacity. As such, there apparently still exists the need for new and improved bladder relief system to maximize the benefits to the user and minimize the risks of injury from its use.
[0005] There is also no acceptable bladder relief system for male aircrew members flying extended flight operations in single or dual-seat fighter and reconnaissance aircraft that do not have toilet facilities. Male aircrew members use two types of bladder relief devices, “piddle pack” bag systems and uncomfortable external catheters with tubing. The entire procedure for using the piddle pack takes several minutes. During this procedure the pilot is significantly distracted from flying the aircraft, which can place both himself and his aircraft in danger. The current piddle pack bag system can also be dangerous to use if the pilot needs to eject from the aircraft while urinating. The optimum bladder relief system would allow the pilot to eject from the aircraft even while urinating, which would require it to be hands-free and at least semi-automatic. In this respect, the present invention disclosed herein substantially fulfills this need.
[0006] None of the prior art teaches a device that self cleans the urine pumping unit. The high concentration of urea and ammonia in decomposing urine is very destructive to pumps that are utilized to transport urine as well as the tubing and collection means utilized by these devices. Also, there is a long felt need in the art for a device that also rinses and sanitizes the exposed skin of the user after urination. Prolonged exposure to urine can cause irritation and possible infection. In this respect, the present invention disclosed herein substantially fulfills these needs as well.
[0007] A significant problem with the prior art devices that have self contained powering systems, such as rechargeable batteries, is that users often neglect to recharge the unit and when the unit is needed it fails to work because the batteries have not been recharged. Therefore there is a significant need in the art for a device that has a reliable power source that minimizes if not eliminates a failure of the unit because of user error or neglect to properly maintain the power system in a charged state. In this respect, the present invention disclosed herein substantially fulfills this need.
[0008] An automated or semi-automated bladder relief device is important not just for the aircrew member's comfort, health and safety, but also for the safety of the aircraft and squadron. The system will significantly reduce the pilot's distraction or downtime during bladder relief, which will improve pilot and aircraft safety.
[0009] Similarly, there is also no acceptable bladder relief system for female aircrew members flying extended flight operations in aircraft that do not have toilet facilities. Male aircrew members use two types of bladder relief devices, piddle pack bag systems and external catheters with tubing. Female aircrew members cannot use the catheter/tubing assemblies designed for males. Instead, most use commercially available adult diapers. These diapers have the following drawbacks:
1 Neither the Disposable Absorption Containment Device (DACD) developed by NASA nor commercially available diapers have the capacity to hold the 1000 cc of urine produced during some long duration flights. 2 High g maneuvers force the female aircrew member downward into the seat, displacing urine from the diaper and leaving the female to sit in a wet flight suit and seat for the duration of the flight. 3 Prolonged exposure to urine can cause skin irritation and may develop into more serious conditions such as ulcers.
In this respect, the present invention disclosed herein substantially corrects these problems and fulfills the need for such a device.
[0013] Lastly the present invention may also be effectively used by passengers in aircraft without toilet facilities, glider pilots, non-ambulatory patients, incontinent adults, astronauts, rescue workers in hazmat suits, and long-distance truckers and race car drivers.
DISCLOSURE OF THE INVENTION
[0014] In view of the foregoing limitations inherent in the known types of bladder relief systems now present in the prior art, the present invention provides an apparatus that has been designed to automatically or semi-automatically collect urine in an environmentally challenging setting in a sanitary, safe and comfortable manner which are improvements which are patently distinct over similar devices and methods which may already be patented or commercially available. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a field designed apparatus and method of use that incorporates the present invention. There are many additional novel features directed to solving problems not addressed in the prior art.
[0015] To attain this the present invention generally comprises a secure gender specific leakproof urine collection means, a fluid sensing unit, a suction means, and a storage and disposal means.
[0016] Several objects and advantages of the present invention are:
[0017] unlike the prior art urinary collection and disposal systems the present invention provides an automated or semi-automated collection system with a large urinary storage capacity. Also, unlike prior art this invention does provide a comfortable collection system that requires no manipulation to utilize leaving the user's hand free for vital tasks;
[0018] one embodiment of the present invention also provides for an inflatable urine collection or depository means that provides for maximum comfort for the user by allowing the urine collection or depository means to be maintained in its deflated condition while not in use thus minimizing the bulk and discomfort of prior art urine collection or depository systems and yet providing an effective leak resistant urine collection or depository area for evacuation by a urine transport means when inflated;
[0019] in yet another embodiment of the inflatable urine collection or depository means, air cushion tubing surrounds an open cell foam as a failsafe measure in the event of a failure of the inflation pump, such that a user may slightly elevate their body allowing the air cushion tubing to decompress as the open cell foam takes on its decompressed shape and size once relieved of the user's body weight thereby forming an effective leak resistant urine collection or depository area for evacuation by a urine transport means when inflated;
[0020] also unlike prior art urine collection or depository means the inflatable embodiment of the present invention may have more than one air cushion tube in the event that another air cushion tube fails to inflate or ruptures;
[0021] in the most preferred embodiment this invention automatically detects the completion of urination and the pump mechanism reverses itself closing the one way valve to its urine storage compartment in a disposable bag. By doing this the pump then draws a cleaning fluid from a cleaning fluid storage compartment in the disposable bag through the device and against the user effectively rinsing and sanitizing the user and the device and then the pump reverses itself once again and deposits the used cleaning fluid in the disposable urine storage bag.
[0022] another novel feature of the most preferred embodiment of this invention is the utilization of a battery power system that is attached to either the disposable bag or the disposable male cup or disposable female pad. This invention's battery power system can use batteries that are rechargeable, standard batteries that may be changed or replaced, or batteries that are integrated into the bag, female pad or male cup which may then be discarded after one or more uses. The battery provides ample power to pump up to 1.6 liters of urine and sufficient cleaning fluid to effectively rinse and sanitize the user and the system and then deposit the used cleaning fluid into the storage bag. Prior art devices that utilized rechargeable battery packs were not only heavy and expensive, but in many applications user's often neglect to charge the unit effectively, or at all, and hence experience unit failure when they need it most.
[0023] In all embodiments of the invention the disposable urine bag utilizes super absorbent polymer crystals that have a gelling affect on the urine and may further have a urine deodorizer mixed within the crystals. To further eliminate odors from the invention it utilizes a charcoal air filter to filter the air that exits the disposable urine storage bag while in use.
[0024] the present invention also provides for ease of set up, use, urine storage and disposal; and
[0025] the present invention also provides an advancement in ecological protection by eliminating the need for disposal of environmentally damaging and bulky diaper materials.
[0026] These together with other objects of the invention, along with the various features of novelty which characterize the invention, will be pointed out with particularity in the claims which will be annexed to and forming a part of the full patent application once filed. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a perspective view of the female user embodiment depicting the female pad with internally placed batteries.
[0028] FIG. 1A is a perspective view of the female user embodiment utilizing the fully inflated inflatable embodiment of the female pad also depicting the inflated inflatable female pad with internally placed batteries.
[0029] FIG. 1B is a perspective view of the female user embodiment utilizing the fully deflated inflatable embodiment of the female pad also depicting the deflated inflatable female pad with internally placed batteries.
[0030] FIG. 2 is a perspective view of the invention attached to a user and in use.
[0031] FIG. 3 is an expanded cut-away perspective view of the female pad of the female user embodiment depicted in FIG. 1 , and also depicting the female pad with internally placed batteries.
[0032] FIG. 3A is a perspective view of the inflatable embodiment of the female pad of the female user embodiment when fully inflated as depicted in FIG. 1A , and also depicting the inflatable female pad with internally placed batteries.
[0033] FIG. 3B is a perspective view of the inflatable embodiment of the female pad of the female user embodiment when fully deflated as depicted in FIG. 1B , and also depicting the deflated inflatable female pad with internally placed batteries.
[0034] FIG. 4 is a perspective view of the male user embodiment also depicting the male cup with internally placed batteries.
[0035] FIG. 5 is a cut-away perspective view of the male cup of the male user embodiment depicted in FIG. 4 , and also depicting the male cup with internally placed batteries.
[0036] FIG. 6 is a cut-away perspective view of the suction control unit.
[0037] FIG. 7 is a cut-away perspective view of the flow chamber.
[0038] FIG. 8 is a perspective view of the urine and cleaning fluid storage bag of the self cleaning embodiment.
[0039] FIG. 9 is a perspective view of the female user self cleaning embodiment utilizing the fully inflated inflatable embodiment of the female pad with the urine and cleaning fluid storage bag attached.
BEST MODES FOR CARRYING OUT THE INVENTION
I. Preferred Embodiments
[0040] With reference now to the drawings, and in particular to FIGS. 1-9 thereof, a new and novel apparatus for an automatic bladder relief system embodying the principles and concepts of the present invention and generally designated collectively comprising two main components in the female user embodiment by the reference numeral 1 and 11 in FIG. 1 , and in the male user embodiment by the reference numeral 1 and 57 in FIG. 4 .
[0000] List and Description of:
GENERAL DESCRIPTION OF REFERENCE NUMERALS IN THE DESCRIPTION AND DRAWINGS
[0041] Any actual dimensions listed are those of the preferred embodiment. Actual dimensions or exact hardware details and means may vary in a final product or most preferred embodiment and should be considered means for so as not to narrow the claims of the patent.
( 1 ) Suction Control Unit ( 1 A) Air Pump ( 2 ) Suction Vacuum Pump ( 3 ) Urine Collection Bag ( 5 ) DC Motor ( 7 ) Rechargeable Battery Pack ( 9 ) Recharge Circuitry ( 11 ) Female Pad ( 11 A) Inflatable Female Pad ( 13 ) Suction Hose ( 13 A) Combination Suction and Air Pressure Hose ( 13 B) Pad Wires ( 17 ) Quick-Disconnect Hose Couplings ( 19 ) Power ON/OFF Button ( 21 ) Timed Interval ON/OFF Button ( 23 ) Vacuum Pump Impeller ( 25 ) Filter ( 27 ) Battery Pack ( 29 ) LCD Status Display ( 31 ) Flow Chamber ( 33 ) Suction Control Unit Air/Liquid Inlet ( 35 ) Suction Control Unit Liquid Outlet ( 37 ) Suction Control Unit Air Exhaust Outlet ( 39 ) Facing Layer (Female User Embodiment) ( 39 M) Facing Layer (Male User Embodiment) ( 41 ) Wicking Layer (Female User Embodiment) ( 41 M) Wicking Layer (Male User Embodiment) ( 42 ) Stability Wings ( 43 ) Urine Collection Layer (Female User Embodiment) ( 43 A) Base Pad ( 43 M) Urine Collection Layer (Male User Embodiment) ( 44 ) Air Cushion Tubing ( 44 A) Air Pressure Hose Connection ( 45 ) Moisture-Proof Outer Layer (Female User Embodiment) ( 45 M) Moisture-Proof Outer Layer (Male User Embodiment) ( 46 ) Outer Layer Wall (Female User Embodiment) ( 46 M) Outer Layer Wall (Male User Embodiment) ( 47 ) One-Way Airflow Inlet Holes (Female User Embodiment) ( 48 ) One-Way Airflow Inlet Holes (Male User Embodiment) ( 49 ) Soft Sealing Strips ( 50 ) Isolation Membrane ( 51 ) Quick-Disconnect Plug ( 52 ) Cup Front ( 53 ) Inside Cup Area (Female User Embodiment) ( 53 M) Inside Cup Area (Male User Embodiment) ( 55 ) Moisture Sensor ( 56 ) Urine Cavity ( 57 ) Male Cup ( 58 ) Air Exit Hole ( 59 ) Cleaning Fluid Compartment ( 60 ) One Way Cleaning Fluid Valve ( 61 ) Quick Connect Fluid and Electrical Connection ( 62 ) Super Absorbent Polymer Crystals ( 63 ) Urine Deodorizer ( 64 ) One Way Flow Valve Into Urine Collection Bag ( 65 ) Battery Pack ( 65 A) Female Pad Battery Pack ( 65 B) Male Cup Battery Pack ( 66 ) Charcoal Air Filter
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. Suction Control Unit
[0101] The Suction Control Unit ( 1 ) is a re-usable piece of hardware containing a suction vacuum pump ( 2 ), DC motor ( 5 ), rechargeable battery pack ( 7 ) and recharge circuitry ( 9 ). A built-in, battery-powered suction vacuum pump ( 2 ) sucks the urine from the Male Cup ( 57 ) in the male user embodiment and Female Pad ( 11 ) of the female user embodiment through a suction hose ( 13 ) and deposits the collected fluid into a Urine Collection Bag ( 3 ). Quick-disconnect hose couplings ( 17 ) connect and disconnect the Urine Collection Bag ( 3 ) and suction hose ( 13 ) from the Suction Control Unit ( 1 ). The Suction Control Unit ( 1 ) has two modes of operation: one power “ON/OFF” button ( 19 ) and one button that turns the unit “ON” and then “OFF” after a timed interval ( 21 ). A small, high-power DC motor is used, similar to those used in cordless vacuum cleaners. The DC motor ( 5 ) spins the vacuum pump impeller ( 23 ) to provide the suction required to draw the urine from the urine cavity ( 56 ) of the Male Cup ( 57 ). The system uses a filter ( 25 ) of charcoal or other material to deodorize the exhaust air. In the preferred embodiment, a battery pack ( 27 ) of rechargeable Nickel-Metal Hydride (NIMH) batteries are used to provide the power supply for the DC motor ( 5 ). A two-digit LCD Status Display ( 29 ) with backlight indicates the amount of time remaining in the battery charge, and the number of bladder relieves left in the power supply charge. There are other power supplies available for other applications of this invention, from lithium batteries to 110-volt wall outlets. The recharge circuitry allows the battery pack to be plugged into a wall outlet for recharging without damaging the batteries.
[0102] A flow chamber ( 31 ) is contained in the Suction Control Unit ( 5 ). The flow chamber ( 31 ) begins at the Suction Control Unit Air/Liquid Inlet ( 33 ) and ends at both the Suction Control Unit Liquid Outlet ( 35 ) and the Suction Control Unit air exhaust outlet ( 37 ). This flow chamber ( 31 ) separates moisture from the vacuum airflow and channels the liquid to the Suction Control Unit Liquid Outlet ( 35 ) and the air to the Suction Control Unit Air Exhaust Outlet ( 37 ). The Suction Control Unit Air Exhaust Outlet ( 37 ) is fitted with a deodorizing air Filter ( 25 ).
2. Male Cup
[0103] The Male Cup ( 57 ) is a disposable soft cup, approximately the same size and shape as a men's athletic protective cup. FIG. 5 shows a cut-away view of a Male Cup ( 37 ). The cup has four layers: a facing layer ( 39 M), wicking layer ( 41 M), urine collection layer ( 43 M) and Moisture Proof Outer Layer ( 45 M). The Moisture Proof Outer Layer ( 45 M) is attached to and contains the facing layer ( 39 M), wicking layer ( 41 M), urine collection layer ( 43 M) along the edges thereof by means of the Outer Layer Wall ( 46 M). A Urine Cavity ( 56 ) is defined by the urine collection layer ( 43 M) and the Moisture Proof Outer Layer ( 45 M) in the inside cup area ( 53 M). The facing layer ( 39 M), which lies against the skin, is made of a soft, non-woven, non-absorbent polymer. The wicking layer ( 41 M) is made of a woven polymer. It pulls moisture away from the facing layer ( 39 M) and prevents it from going back through the facing layer ( 39 M), much like a one-way fluid check valve. The urine collection layer ( 43 M) is made of an open cell foam material or other material capable of collecting fluid, and provides a Urine Cavity ( 56 ) in its placement juxtaposed to the Moisture Proof Outer Layer ( 45 M) for the vacuum suction airflow produced by the Suction Vacuum Pump ( 2 ) to suck fluids and moisture out of the Male Cup ( 57 ) and away from the body.
[0104] One-way airflow inlet holes ( 48 ) in the top of the Male Cup ( 57 ) facilitate the evacuation of liquids and provide air flow for drying the Male Cup's ( 57 ) layers. An isolation membrane ( 50 ) made of a thin, flexible material such as silicon rubber comfortably keeps a man's penis inside the Male Cup ( 57 ) compartment and prevents any leaking. The cup front ( 52 ) is made of a stretchable material such as silicon rubber that opens automatically to accommodate size changes.
[0105] The suction hose ( 13 ) at the front of the Male Cup ( 57 ) is connected to the Suction Control Unit ( 1 ). The Suction Control Unit ( 1 ) sucks all fluids from the Male Cup ( 57 ) through the suction hose ( 13 ) and deposits them into the Urine Collection Bag ( 3 ). In the preferred embodiment, the flexible, disposable suction hose ( 13 ) is outfitted with a quick-disconnect plug ( 51 ) on the end that connects to the Suction Control Unit ( 1 ). The suction hose ( 13 ) may be made of a convoluted, easily bendable material with spiral construction. This allows a smaller bending radius so that the suction hose ( 13 ) can be stowed in a person's clothing or flight suit while not in use, and permits all of the urine to drain out of the suction hose ( 13 ).
[0106] The Moisture-Proof Outer Layer ( 45 M) of the Male Cup ( 57 ) is made of dense rubber to hold the Male Cup ( 57 ) in place. The Male Cup ( 57 ) is also held in place with a standard athletic jock strap. Most of the outer portion of the Male Cup ( 57 ) is constructed of soft rubber.
3. Urine Collection Bag in Male User Embodiment
[0107] The system is compatible with many types of Urine Collection Bags ( 3 ) including a disposable plastic bag containing super absorbent polymer crystals with a 500 cc urine capacity, and a larger, 1600 cc capacity Urine Collection Bag ( 3 ). Users who do not want to wear a Urine Collection Bag ( 3 ) for a long period of time can use smaller Urine Collection Bags ( 3 ). A zip lock top on the smaller Urine Collection Bags ( 3 ) allows its use as a standard piddle pack. Users who prefer not to change Urine Collection Bags ( 3 ) after each urination can wear a larger leg or pocket Urine Collection Bag ( 3 ). A quick-disconnect similar to the quick-disconnect plug ( 51 ) can also be built into the Urine Collection Bags ( 3 ) for easy attachment and replacement.
Use By Male Air Crew Members
[0108] The Suction Control Unit ( 1 ) can be packaged to double as a pilot's kneeboard as depicted in FIG. 2 . The knee-board is molded and adjustable to fit the curve of the thigh. The aircrew member can carry the Suction Control Unit ( 1 ) in his helmet bag or wear it strapped to a thigh without giving the appearance of wearing bladder relief equipment. The quick-disconnect plug ( 51 ) hose couplings allow aircrew members to wait until they are seated in their aircraft or until they have to urinate to connect the Urine Collection Bag ( 3 ) and the suction hose ( 13 ) of the Male Cup ( 57 ) to the Suction Control Unit ( 1 ). The size and shape of the Urine Collection Bag ( 3 ) is designed to fit within the limited confines of the aircraft cockpit and navigator's seat. Piddle packs used by some male pilots are too long and difficult to open to its full length in a cockpit.
Use for Male Urinary Incontinence
[0109] Wheelchair users require a quieter, more discreet version of the Suction Control Unit ( 1 ) (i.e. with concealed hoses). The Suction Control Unit ( 1 ) can be mounted to the person's wheelchair and the hoses concealed under the person's clothing. Many urinary incontinent adults are not in wheelchairs, but are bedridden. A larger urine collection bag ( 3 ) that does not contain super-absorbent polymer can be attached to the Suction Control Unit ( 1 ) that can be emptied and reused. For ambulatory adults and children, a quiet Suction Control Unit ( 1 ) can be housed in a fanny pack that can also hold a concealed Urine Collection Bag ( 3 ).
[0110] Many urinary incontinent adults do not know in advance that they are about to urinate. It is therefore impractical to expect them to activate the Suction Control Unit ( 1 ) before urinating. Instead, a moisture sensor ( 55 ) is installed in the Male Cup ( 57 ) to automatically activate the Suction Control Unit ( 1 ) when moisture is sensed in the urine cavity ( 56 ).
4. Suction Control Unit in Use With Female User Embodiment
[0111] The Suction Control Unit ( 1 ) is a reusable piece of hardware containing a suction vacuum pump ( 2 ), DC motor ( 5 ), rechargeable battery pack ( 7 ) and recharge circuitry ( 9 ). A built-in, battery-powered suction vacuum pump ( 2 ) sucks the urine from the Female Pad ( 11 ) through a suction hose ( 13 ) at the front of pad and deposits the urine into a Urine Collection Bag ( 3 ). Quick-disconnect hose couplings ( 17 ) connect and disconnect the Urine Collection Bag ( 3 ) and the suction hose ( 13 )from the Suction Control Unit ( 1 ). The Suction Control Unit ( 1 ) has two modes of operation: one power “ON/OFF” button ( 19 ) and one button that turns the unit “ON” and then “OFF” after a timed interval ( 21 ).
[0112] A small, high-power DC motor ( 5 ) is used, similar to those used in cordless vacuum cleaners. The DC motor ( 5 ) spins the vacuum pump impeller ( 23 ) to provide the suction required to draw the urine from the Female Pad ( 11 ). The system uses a filter ( 25 ) of charcoal or other material to deodorize the exhaust air. In the preferred embodiment, a battery pack ( 27 ) of rechargeable Nickel-Metal Hydride (NIMH) batteries are used to provide the power supply for the DC motor. A two-digit LCD Status Display ( 29 ) with backlight indicates the amount of time remaining in the battery charge, and the number of bladder relieves left in the power supply charge. There are other power supplies available for other applications of this invention, from lithium batteries to 110-volt wall outlets. The recharge circuitry allows the battery pack ( 27 ) to be plugged into a wall outlet for recharging without damaging the batteries.
[0113] A flow chamber ( 31 ) is contained in the Suction Control Unit ( 1 ). The flow chamber ( 31 ) begins at the Suction Control Unit Air/Liquid Inlet ( 33 ) and ends at both the Suction Control Unit Liquid Outlet ( 35 ) and the Suction Control Unit Air Exhaust Outlet ( 37 ). This flow chamber ( 31 ) separates moisture from the vacuum airflow and channels the liquid to the Suction Control Unit Liquid Outlet ( 35 ) and the air to the Suction Control Unit Air Exhaust Outlet ( 37 ). The Suction Control Unit Air Exhaust Outlet ( 37 ) is fitted with a deodorizing air filter ( 25 ).
5. Female Pad
[0114] The Female Pad ( 11 ) is a disposable urine collection pad similar in size to a large feminine pad used for menstruation. FIG. 3 shows an expanded view of the Female Pad ( 11 ). The Female Pad ( 11 ) has four layers: a facing layer ( 39 ), wicking layer ( 41 ), urine collection layer ( 43 ) and moisture-proof outer layer ( 45 ). The Moisture Proof Outer Layer ( 45 ) is attached to and contains the facing layer ( 39 ), wicking layer ( 41 ), urine collection layer ( 43 ) along the edges thereof by means of the Outer Layer Wall ( 46 ). A Urine Cavity ( 56 ) is defined by the urine collection layer ( 43 ) and the Moisture Proof Outer Layer ( 45 ) in the inside cup area ( 53 ). The facing layer ( 39 ), which lies directly against the skin, is made of a soft, non-woven, non-absorbent polymer. The wicking layer ( 41 ) is made of a woven polymer. It pulls moisture away from the facing layer ( 39 ) and prevents it from going back through the facing layer ( 39 ), much like a one-way fluid check valve. The urine collection layer ( 43 ) is made of open cell foam or other material or other material capable of collecting fluid, and provides a Urine Cavity ( 56 ) in its placement juxtaposed to the Moisture Proof Outer Layer ( 45 ) for the vacuum suction airflow produced by the Suction Vacuum Pump ( 2 ) to suck fluids and moisture out of the Female Pad ( 11 ) and away from the body. The Moisture Proof Outer Layer ( 45 ), a moisture-proof barrier made of soft, flexible plastic, wraps around the sides of the Female Pad ( 11 ) to prevent side leakage.
[0115] One-way airflow inlet holes ( 47 ) in the back end of the Female Pad ( 11 ) facilitate the evacuation of liquids and provide air flow for drying the Female Pad's ( 11 ) layers. The Female Pad ( 11 ) has a contoured shape for a more comfortable and reliable fit. Soft sealing strips ( 49 ) around the Female Pad ( 11 ) face perimeter prevent side leaks. The Female Pad ( 11 ) is held in place with a comfortable but sturdy undergarment available in women's apparel stores.
[0116] The suction hose ( 13 ) at the front of the Female Pad ( 11 ) is connected to the Suction Control Unit ( 1 ). The Suction Control Unit ( 1 ) sucks all fluids from the Female Pad ( 11 ) through the suction hose ( 13 ) and deposits them into the Urine Collection Bag ( 3 ). In the preferred embodiment, the flexible, disposable suction hose ( 13 ) is outfitted with a quick-disconnect plug ( 51 ) on the end that connects to the Suction Control Unit ( 1 ). The suction hose ( 13 ) may be made of a convoluted, easily bendable material with spiral construction. This allows a smaller bending radius so that the suction hose ( 13 ) can be stowed in a person's clothing or flight suit while not in use, and permits all of the urine to drain out of the suction hose ( 13 ).
6. Urine Collection Bag in Female User Embodiment
[0117] The system is compatible with many types of Urine Collection Bags ( 3 ) including a disposable plastic bag containing super absorbent polymer crystals with a 500 cc urine capacity, and a larger, 1600 cc capacity bag. Users who do not want to wear a Urine Collection Bag ( 3 ) for a long period of time can use smaller Urine Collection Bags ( 3 ). Users who prefer not to change Urine Collection Bags ( 3 ) after each urination can wear a larger leg or pocket Urine Collection Bags ( 3 ). A quick-disconnect similar to the quick-disconnect plug ( 51 ) can also be built into the Urine Collection Bags ( 3 ) for easy attachment and replacement.
7. Inflatable Urine Collection Means Embodiment
[0118] As depicted in FIGS. 1A, 1B , 3 A, & 3 B the urine collection means of the present invention may also be made of a Base Pad ( 43 A) to which is attached at least one inflatable Air Cushion Tubing ( 44 ) that are inflated by the user prior to urination by activation of the Air Pump ( 1 A) that is housed inside Suction Control Unit ( 1 ). The activated Air Pump ( 1 A) pumps air into one or more Air Cushion Tubing ( 44 ) through the air hose portion of the Combined Suction and Air Pressure Hose ( 13 A) and is connected by the Air Pressure Hose Connection ( 44 A), which Air Cushion Tubing ( 44 ) when inflated forms an area where discharged urine from the user may pool without contact with the user and then be transported by suction through the suction hose portion of the Combined Suction and Air Pressure Hose ( 13 A) by the vacuum suction airflow produced by the Suction Vacuum Pump ( 2 ) of the Suction Control Unit ( 1 ) that suck fluids and moisture out of the Inflatable Female Pad ( 11 A) and away from the user's body. The Suction Control Unit ( 1 ) then transports the suctioned urine into the Urine Collection Bag ( 3 ). After use the Air Pump ( 1 A) is deactivated and the Air Cushion Tubing ( 44 ) deflates by means of compression brought on by the user's body weight after use returning the urine collection means to a flatter and more comfortable condition for the user. In its inflated condition the inflatable urine collection means provides a contained area for the pooling of the user's urine away from the body permitting the urine to be transported by the urine transport means and minimizing the opportunity for the urine to come in contact with the user's body or genital area. The Inflatable Female Pad ( 11 A) has a contoured shape for a more comfortable and reliable fit. Stability Wings ( 42 ) attached to the sides of the Inflatable Female Pad ( 11 A) serve to hold the Inflatable Female Pad ( 11 A) in proper position on the user and prevent side leaks. The Inflatable Female Pad ( 11 A) is held in place with a comfortable but sturdy undergarment available in women's apparel stores.
[0119] The Combination Suction and Air Pressure Hose ( 13 A) at the front of the Inflatable Female Pad ( 11 A) is connected to the Suction Control Unit ( 1 ). The Suction Control Unit ( 1 ) sucks all fluids from the Inflatable Female Pad ( 11 A) through the Combination Suction and Air Pressure Hose ( 13 A) and deposits them into the Urine Collection Bag ( 3 ). In the preferred embodiment, the flexible, disposable Combination Suction and Air Pressure Hose ( 13 A) is outfitted with a connection means on the end that connects to the Air Pressure Hose Connection ( 44 A). The Combination Suction and Air Pressure Hose ( 13 A) may be made of a convoluted, easily bendable material with spiral construction. This allows a smaller bending radius so that the Combination Suction and Air Pressure Hose ( 13 A) can be stowed in a person's clothing or flight suit while not in use, and permits all of the urine to drain out of the Combination Suction and Air Pressure Hose ( 13 A).
[0120] In yet another embodiment the Air Cushion Tubing ( 44 ) contains an open cell foam as a failsafe measure in the event of a failure of the Air Pump ( 1 A), such that a user may slightly elevate their body allowing the Air Cushion Tubing ( 44 ) to decompress as the open cell foam takes on its decompressed shape and size once relieved of the user's seated body weight thereby forming an effective leak resistant urine collection or depository area for evacuation by the urine transport means when inflated.
[0121] While not depicted, one ordinarily skilled in the art could apply this inflatable design to a cup designed to accommodate a male user and based upon the teaching of this invention such a male embodiment would be obvious.
Use By Female Air Crew Members
[0122] The Suction Control Unit ( 1 ) can be packaged to double as a pilot's kneeboard as depicted in FIG. 2 . The kneeboard is molded and adjustable to fit the curve of the thigh. The aircrew member can carry the Suction Control Unit ( 1 ) in her helmet bag or wear it strapped to a thigh without giving the appearance of wearing bladder relief equipment. The quick-disconnect plug ( 51 ) suction hose ( 13 ) couplings allow aircrew members to wait until they are seated in their aircraft or until they have to urinate to connect the Urine Collection Bag ( 3 ) and the Female Pad ( 11 ) suction hose ( 13 ) to the Suction Control Unit ( 1 ). The size and shape of the Urine Collection Bag ( 13 ) is designed to fit within the limited confines of the aircraft cockpit and navigator's seat
Use for Female Urinary Incontinence
[0123] Wheelchair users require a quieter, more discreet version of the Suction Control Unit ( 1 ) (i.e. with concealed hoses). The Suction Control Unit ( 1 ) can be mounted to the person's wheelchair and the hoses concealed under the person's clothing. Many urinary incontinent adults are not in wheelchairs, but are bedridden. A larger urine collection bag ( 3 ) that does not contain super absorbent polymer can be attached to the Suction Control Unit ( 1 ) that can be emptied and reused. For ambulatory adults and children, a quiet Suction Control Unit ( 1 ) can be housed in a fanny pack that can also hold a concealed Urine Collection Bag ( 3 ).
[0124] Many urinary incontinent adults do not know in advance that they are about to urinate. It is therefore impractical to expect them to activate the Suction Control Unit ( 1 ) before urinating. Instead, a moisture sensor ( 55 ) is installed in the Female Pad ( 11 ) to automatically activate the Suction Control Unit ( 1 ) when moisture is sensed in the urine cavity ( 56 ).
Summary of Incontinent User Embodiments
[0125] A quieter, more discreet version of the Suction Control Unit ( 1 ) for wheelchair users (i.e. with concealed hoses). The Suction Control Unit ( 1 ) could be mounted to the person's wheelchair and the suction hoses ( 13 ) concealed under the person's clothing. Many urinary incontinent adults are not in wheelchairs, but are bedridden. A larger urine collection bag ( 3 ) that does not contain super-absorbent polymer can be used that can be emptied by staff/care-givers and reused.
[0126] Many urinary incontinent adults do not know in advance that they are about to urinate. It is therefore impractical to expect them to activate the suction control unit ( 1 ) before urinating. Instead, a moisture sensor ( 55 ) can be installed in the Female Pad ( 11 ) and Male Cup ( 57 ) that will automatically activate the Suction Control Unit ( 1 ) when moisture is sensed in the urine cavity ( 56 ).
8. Most Preferred Embodiment—Collection Bag and Pad and Cup Power Sources and Self Cleaning
[0127] The most preferred embodiment of the invention utilizes the Inflatable Urine Collection Means Embodiment as depicted in FIG. 9 wherein the urine collection means of the present invention is comprised of a Base Pad ( 43 A) to which is attached at least one inflatable Air Cushion Tubing ( 44 ) that are inflated either automatically or by the user prior to urination by activation of the Air Pump ( 1 A) that is housed inside Suction Control Unit ( 1 ).
[0128] The Urine Collection Bag ( 3 ) in this embodiment provides four important functions for the invention; 1) it serves as a storage area for user discharged urine; 2) it serves as a power source for the invention having operatively attached thereto one or more batteries; 3) it serves as a storage area for a cleaning fluid; and 4) it contains a gelling agent and a deodorizing agent to contain and control the user's discharged urine and any effluvia that it may produce. As depicted in FIGS. 8 & 9 , the Urine Collection Bag ( 3 ) is attached to the Suction Control Unit ( 1 ) by means of a Quick Connect Fluid and Electrical Connection ( 61 ) which electrically connects the Urine Collection Bag ( 3 ) Battery Pack ( 65 ) to the Suction Control Unit ( 1 ) providing electrical current for all electrically operated components of the Suction Control Unit ( 1 ). The Quick Connect Fluid and Electrical Connection ( 61 ) also provides a leakproof connection to the Suction Control Unit ( 1 ) such that as fluids pass in and out of the Urine Collection Bag ( 3 ) do not leak from the invention. Once the invention is activated and a user is urinating, the Suction Control Unit ( 1 ) either by pumping or discharge from suction causes the urine to flow into the Urine Collection Bag ( 3 ) passing it through the Quick Connect Fluid and Electrical Connection ( 61 ) through the One Way Flow Valve Into the Urine Collection Bag ( 64 ) where the urine is then absorbed by the Super Absorbent Polymer Crystals ( 62 ) which urine is in turn deodorized by the Urine Deodorizer ( 63 ) that is mixed in with the Super Absorbent Polymer Crystals ( 62 ). Upon completion of urination, either manually or automatically, the Suction Control Unit ( 1 ) begins the cleaning process by reversing the pumping or suction direction thereby drawing a cleaning fluid from the Cleaning Fluid Compartment ( 59 ) of the Urine Collection Bag ( 3 ) through the One Way Cleaning Fluid Valve ( 60 ) into the Suction Control Unit ( 1 ) and ultimately back to the user thereby rinsing, cleaning and sanitizing the user and all parts of the invention not intended to store urine that have come in contact with the user's urine. Once the user and the invention are rinsed, cleaned and sanitized the pumping or suction action of the Suction Control Unit ( 1 ) is once again either manually or automatically reversed and the used cleaning fluid is then pumped or discharged from suction back into the Urine Collection Bag ( 3 ) passing it through the Quick Connect Fluid and Electrical Connection ( 61 ) through the One Way Flow Valve Into the Urine Collection Bag ( 64 ) where the used cleaning fluid is also absorbed by the Super Absorbent Polymer Crystals ( 62 ) which used cleaning fluid also is in turn deodorized by the Urine Deodorizer ( 63 ) that is mixed in with the Super Absorbent Polymer Crystals ( 62 ). Air pressure in the Urine Collection Bag ( 3 ) is regulated by the flow of air through the Air Exit Hole ( 58 ) and the effluvia is further controlled by causing the air that exits the Air Exit Hole ( 58 ) to first pass through a Charcoal Air Filter ( 66 ).
[0129] During urination the activated Air Pump ( 1 A) pumps air into one or more Air Cushion Tubing ( 44 ) through the air hose portion of the Combined Suction and Air Pressure Hose ( 13 A) and is connected by the Air Pressure Hose Connection ( 44 A), which Air Cushion Tubing ( 44 ) when inflated forms an area where discharged urine from the user may pool without contact with the user and then be transported by suction through the suction hose portion of the Combined Suction and Air Pressure Hose ( 13 A) by the vacuum suction airflow produced by the Suction Vacuum Pump ( 2 ) of the Suction Control Unit ( 1 ) that suck fluids and moisture out of the Inflatable Female Pad ( 11 A) and away from the user's body. The Suction Control Unit ( 1 ) then transports the suctioned urine into the Urine Collection Bag ( 3 ) and the cleans the unit as stated above. After use and cleaning the Air Pump ( 1 A) is deactivated and the Air Cushion Tubing ( 44 ) deflates by means of compression brought on by the user's body weight after use returning the urine collection means to a flatter and more comfortable condition for the user. In its inflated condition the inflatable urine collection means provides a contained area for the pooling of the user's urine away from the body permitting the urine to be transported by the urine transport means and minimizing the opportunity for the urine to come in contact with the user's body or genital area. The Inflatable Female Pad ( 11 A) has a contoured shape for a more comfortable and reliable fit. Stability Wings ( 42 ) attached to the sides of the Inflatable Female Pad ( 11 A) serve to hold the Inflatable Female Pad ( 11 A) in proper position on the user and prevent side leaks. The Inflatable Female Pad ( 11 A) is held in place with a comfortable but sturdy undergarment available in women's apparel stores.
[0130] The Combination Suction and Air Pressure Hose ( 13 A) at the front of the Inflatable Female Pad ( 11 A) is connected to the Suction Control Unit ( 1 ). The Suction Control Unit ( 1 ) sucks all fluids from the Inflatable Female Pad ( 11 A) through the Combination Suction and Air Pressure Hose ( 13 A) and deposits them into the Urine Collection Bag ( 3 ). In this most preferred embodiment, the flexible, disposable Combination Suction and Air Pressure Hose ( 13 A) is outfitted with a connection means on the end that connects to the Air Pressure Hose Connection ( 44 A). The Combination Suction and Air Pressure Hose ( 13 A) may be made of a convoluted, easily bendable material with spiral construction. This allows a smaller bending radius so that the Combination Suction and Air Pressure Hose ( 13 A) can be stowed in a person's clothing or flight suit while not in use, and permits all of the urine to drain out of the Combination Suction and Air Pressure Hose ( 13 A).
[0131] In this most preferred embodiment the Air Cushion Tubing ( 44 ) contains an open cell foam as a failsafe measure in the event of a failure of the Air Pump ( 1 A), such that a user may slightly elevate their body allowing the Air Cushion Tubing ( 44 ) to decompress as the open cell foam takes on its decompressed shape and size once relieved of the user's seated body weight thereby forming an effective leak resistant urine collection or depository area for evacuation by the urine transport means when inflated.
[0132] Alternatively the power source, ideally disposable batteries, can be located in the Female Pad ( 11 ), the Inflatable Female Pad ( 11 A), and the Male Cup ( 57 ) as opposed to the Urine Collection Bag ( 3 ). As depicted in FIGS. 1 , 1 A, 1 B, 3 , 3 A, 3 B, 4 & 5 , the Female Pad ( 11 ), the Inflatable Female Pad ( 11 A), and the Male Cup ( 57 ) is attached to the Suction Control Unit ( 1 ) by means of either a Suction Hose ( 13 ) or a Combination Suction and Air Pressure Hose ( 13 A) which electrically connects with internal Pad Wires ( 13 B) the Female Pad Battery Pack ( 65 A) in the female embodiment and in the male embodiment the Male Cup Battery Pack ( 65 B) to the Suction Control Unit ( 1 ) providing electrical current for all electrically operated components of the Suction Control Unit ( 1 ). The two Quick Connect Plugs ( 51 ) also provide a leakproof fluid connection and electrical connection to the Suction Control Unit ( 1 ) such that as fluids pass out of the Female Pad ( 11 ), the Inflatable Female Pad ( 11 A), or the Male Cup ( 57 ), it does not leak from the invention and further, electrical connectivity to the Female Pad Battery Pack ( 65 A) in the female embodiment and in the male embodiment the Male Cup Battery Pack ( 65 B) is made securely, fast and easy.
[0133] While my above descriptions of the invention, its parts, and operations contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of present embodiments thereof. Many other variations are possible, for example, other embodiments, shapes, and sizes of the device can be constructed to fit on a user and work with a unit designed to work by the principles of the present invention; various materials, pumps, colors and configurations can be employed in the unit's design that would provide interesting embodiment differences to users including such practical designs as would, for instance conceal the unit.
[0134] Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the claims and their legal equivalents as filed herewith.
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This invention is an automatic or semi-automatic bladder relief system which increases sanitation and comfort for users requiring a means to dispose of urine in the absence of sanitary facilities, such as aircraft pilots and incontinent individuals. This invention incorporates an inflatable urine collection means that may be deflated after use. The power unit incorporates a battery that is integrated into a disposable urine storage bag or into a disposable female pad or male cup. This invention utilizes a disposable urine storage bag with an isolated cleaning fluid chamber with a directional valve and pump system automatically rinsing and sanitizing the pump, hoses, collection means and the user with a cleaning fluid stored in the cleaning fluid chamber of the disposable urine storage bag. The disposable urine storage bag contains absorbent polymer crystals absorbing the urine as it is deposited in the bag during use.
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BACKGROUND OF THE INVENTION
The present invention refers to an electronic thread travel monitoring device on a weaving machine provided with stationary weft yarn supply means and intermittently actuatable thread storing means arranged on the same side of the weaving machine. Generally, such monitoring devices serve for stopping the weaving machine in the event of yarn breaks.
Weaving machines of the type which are known as shuttleless weaving machines are used in practice on a large scale, e.g. gripper shuttle weaving machines, gripper weaving machines and jet weaving machines. With the first named gripper shuttle weaving machines, the weft or filling thread is inserted into the weaving shed by a flying gripper shuttle or projectile. On the gripper weaving machines, weft inserting devices are provided which are positively driven by rigid rapiers or flexible tapes.
Moreover, it is known to provide a thread storing device on such a weaving machine between the supply bobbin and the start position of the weft inserting device. On a thread winding drum of this thread storing device a winding of the weft yarn drawn off the supply bobbin is formed. During the weft or filling insertion, a yarn end is drawn from the drum and inserted into the weaving shed. The axial dimension of the winding is monitored by an electronic light barrier which controls the drive of the thread storing device. By means of such a thread storing device, the tension of the weft yarn which occurs during the weft insertion is reduced, such minimizing the danger of weft breaks within the shed.
However, it appears that yarn breaks may also occur between the supply bobbin and the thread storing device when thin places are present in the yarn. Now it is desirable to detect such yarn breaks as early as possible. Modern weaving machines are normally fitted with a weft monitor which detects breaks of the weft or filling thread only upon insertion in the weaving shed, and stops the machine. When such an event occurs with a gripper shuttle weaving machine provided with a dobby, firstly the yarn end inserted in the shed by the projectile must be manually removed. Then the dobby must be reset such that the last correctly entered weft thread is exposed in the shed, and thereupon a new weft end is to be drawn from the supply bobbin to and through the thread storing device and a following thread brake and yarn guides of the weaving machine. After all this, the weaving machine may be started again. The analogous procedure is still more time-consuming with a Jacquard machine.
Now when such an early yarn break in advance of the thread storing device can be detected and the weaving machine stopped in time, the said procedures at the weaving machine as well as at the dobby or Jacquard machine are avoided since the weft or filling thread is correctly inserted in the weaving shed. In this event, only the thread end connected to the supply bobbin must be drawn towards or eventually through the thread storing device and knotted to the other thread end.
SUMMARY OF THE INVENTION
It is a primary object of the invention to provide a device for immediately detecting thread breaks which occur in advance of the thread store and stopping the machine in such an event.
This and other objects which will be apparent as the description proceeds may be realized by the inventive electronic thread travel monitoring device comprising thread sensing means arranged between the weft yarn supply means and thread storing means, for producing signals indicative of thread travel; store control means for producing actuating signals indicative of the condition "storing means depleted of yarn"; and logic means controlled by the thread travel signals and actuating signals, for producing output signals when no thread travel signal is present at any moment of the existence of an actuating signal.
Since yarn breaks occurring in advance of the thread store are immediately detected by the inventive monitoring device or inlet monitor, it is easy to eliminate such breaks since a broken yarn end cannot be inserted into the weaving shed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood upon consideration of the following detailed description thereof which makes reference to the annexed drawings wherein:
FIG. 1 illustrates a thread storing device associated with an optoelectrical control device, and a therewith combined inventive thread monitoring device or inlet monitor in block schematic;
FIG. 2 illustrates the arrangement of the electronic circuits of the thread monitoring device, represented by functional units;
FIG. 3 is a pulse diagram illustrating the mode of operation of the thread monitoring device; and
FIG. 4 illustrates the arrangement of a multiple thread monitoring device on a so-called shuttleless multicolour weaving machine.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, there are shown only those components and circuits in schematic representation which are essential for understanding the invention. A single weft or filling thread supply bobbin 1 is associated with a thread storing device or store 2. Generally, this representation holds also in the case that a plurality of supply bobbins and individually associated thread stores are provided as shown in FIG. 4 and as will still be described in the following context.
FIG. 1 shows a winding device which may be of known construction comprising the components 2-7 in the idle condition thereof. From supply bobbin 1 a thread end S1 runs to and is introduced through an inlet tube 3 provided with a flyer to winding W on thread store 2. The outgoing thread end S2 runs to an insertion device, such as a gripper shuttle, which enters the thread end S2 into the shed upon actuation of a picking device (not shown).
Winding device 2-7 operates independent of the drive of the weaving machine in the following manner. Prior to operation, thread end S1 is introduced into thread store 2 through inlet tube 3. Thereafter, the electrical components 4-6 are switched to a voltage supply. Optoelectrical sensor 4 monitors thread store 2; as long as there is no winding W present, a store control circuit 5 actuates a switching device 6 so that contact 7 thereof is closed and a drive means (not shown) in thread store 2 is actuated. Thus, flyer inlet tube 3 is rotated and a winding W is formed proceeding in a direction from left to right. Now when winding W has proceeded thus far that sensor 4 can detect the same, contact 7 is opened and the store drive stopped. The ready condition prior to starting the weaving machine, i.e. prior to the first weft insert, thus is established. Since weft yarn end S2 is drawn off thread store 2 with any weft insertion, winding W is intermittently reduced, and winding device 2-7 is actuated for replenishing winding W.
In addition to known winding device 2-7 an inventive electronic thread monitor comprising the components 8-12 is provided. The electronic thread monitor 8-12 detects yarn breaks of the thread end S1 upstream of the thread store 2, and in such an event causes the weaving machine to stop. Electronic thread monitor 8-12 comprises as main components a thread sensor 8, a sensor electronic circuit 9, a logic circuit 10 and a stop device 12 which, in this sequence, are serially connected. In addition, an optical indicator 11 is connected to the output of logic circuit 10. The latter has a second input connected to the output of store control unit 5.
On the whole, the equipment shown in FIG. 1 operates with the weaving machine in action as follows. So long as there is no or only a short winding on thread store 2, store control unit 5 produces an output motor pulse A' which actuates thread store 2 such that thread end S1 is drawn from supply bobbin 1. The running thread end S1 excites sensor 8, and sensor electronic circuit 9 produces a travel pulse L'. Motor pulse A' and travel pulse L' are combined in logic circuit 10; no ouput stop pulse S' is delivered when both pulses A' and L' occur simultaneously, and stop device 12 remains idle. However, when thread end S1 breaks or there is no thread end S1 at all, a stop pulse S' is produced causing, through stop device 12, the weaving machine to stop. The same process takes place when, with running drive of thread store 2, thread end S1 is drawn off by thread store 2 without being wound up thereon. Simultaneously with the occurrence of a stop pulse S', indicator 11 responds e.g. by flashing a glow lamp or light-emitting diode. Preferably, such an optical indicating device is also provided on sensor 8 and/or thread store 2.
FIG. 2 shows the thread sensor 8 and the set-up of sensor electronic circuit 9 and logic circuit 10 with functional units.
Thread sensor 8 may comprise a known transducer, such as a capacitive, triboelectrical, piezoelectrical or optoelectrical transducer, for producing a sensing signal having noise signal wave form when the thread is travelling. Sensor electronic circuit 9 operatively connected to thread sensor 8 comprises a series arrangement of amplifier 13, rectifier 14, smoothing circuit 15 and pulse shaper, e.g. a Schmitt-trigger 16. Thread sensor 8 and sensor electronic circuit 9 may be assembled in a structural unit. By the travelling thread end S1, a rectangular travel pulse L' is produced at the output of pulse shaper 16.
Logic circuit 10 has two inputs, a first travel pulse L' input connected to sensor electronic circuit 9, and a second motor pulse A' input connected to store control circuit 5. The L' input transfers travel pulse L' to a negator 19 for inverting travel pulse L' into a pulse L". The output of negator 19 is connected to the first input of a first AND-gate 20. The second input of logic circuit 10 is directly connected to the first input of a second AND-gate 17 and further, through a delay circuit 18, to the second input of the second AND-gate 17. The output K' of the latter is connected to the second input of the first AND-gate 20.
With reference to FIG. 2, the pulses produced in the interior of logic circuit 10 are denominated by A", K' and L". The meaning of these pulses will be apparent from the following description referring to the pulse diagrams of FIG. 3. Therein, motor pulse A' of thread store 2 is represented by a rectangular pulse. Travel pulse L' is delayed by a short start time interval v relative to motor pulse A' since thread store 2 starts and stops, because of its mechanical inertia, with some retardation. Thus, travel pulse L' starts by an interval v later than motor pulse A'. A vertical dashed line at breaking point B represents a premature end of travel pulse L' in the event of a break of thread end S1, FIG. 1. The variable or adjustable delay t effected by delay circuit 18 is to be chosen such that it is safely greater than the longest possible start delay v, as shown in FIG. 3 by the pulse A" delayed relative to motor pulse A'. Logic addition of the pulses A' and A" in second AND-gate 17 gives rise to a control pulse K' whose leading edge is delayed by the interval t and whose rear edge coincides with the one of motor pulse A'. Control pulse K' defines the time interval in which travel pulse L' is monitored. For this purpose, control pulse K' is combined with the inverted travel pulse L" in the first AND-gate 20. In case of undisturbed operation of the weaving machine, pulse L" is negative during the entire duration of control pulse K', and the first AND-gate 20 does not produce a logic stop pulse S'. However, when thread end S1 breaks during control pulse K' as represented by the dashed vertical line through point B, a positive stop pulse S' is generated which, by means of stop circuit 12, FIG. 1, causes the weaving machine to stop.
It may occur as mentioned above that thread store 2 does not wind up the thread end S1 though the drive of thread store 2 is working. No travel signal L' is produced, FIG. 3, however a stop pulse S' is produced in this event, and the weaving machine is stopped. Thus, so-called tensioning inserts which cause delayed weft or filling insertion or weft break are avoided.
With reference to FIG. 4, there is shown the circuitry of a multiple electronic device for monitoring a multiplicity of alternatively insertable weft or filling thread ends, such as thread end S1 in FIG. 1, on a shuttleless so-called multicolour weaving machine. Such machines are known, and generally they are provided with a multiplicity of supply bobbins, such as supply bobbin 1 in FIG. 1, and with a colour changing device which selects one of the weft threads and places the same in position for insertion in the weaving shed. Any supply bobbin is associated with an individual complete winding device, such as shown in FIG. 1 by the components 2-7. All these winding devices operate independent of each other and the drive of the weaving machine.
FIG. 4 shows only the store control circuits 5-1 to 5-n of the winding devices equivalent to store control circuit 5 in FIG. 1. The multiple thread monitoring device comprises sensors 8-1 to 8-n each of which senses one of the n weft threads, n sensor electronic circuits 9-1 to 9-n, and n logic circuits 10-1 to 10-n. The arrangement of any set of components, such as 5-1, 8-1, 9-1 and 10-1, corresponds to the analogous one of the components 5,8,9 and 10 in FIG. 1.
Normally only the one of the weft threads which is positioned for insertion into the weaving shed is sensed such that a travel pulse L-1, L-2 etc. is produced. In the event of a thread break in advance of the thread store a stop signal on one of the output lines S-1 to S-n is generated.
To each of the output lines S-1 to S-n of the logic circuits 10-1 to 10-n there is connected one of the n inputs of an OR-gate 21. Now when a stop signal appears on one of these output lines S-1 to S-n, this stop signal passes the OR-gate 21, and a stop signal S' appears at the output thereof which actuates stop device 12 and stops the weaving machine. Thus, only a single stop device 12 is necessary.
Normally, gripper shuttle weaving machines, as mentioned above in the introduction, are provided with a conventional electronic device for monitoring the weft insert. In FIG. 4, the supply circuit 22 and the stop device 12 may be components of such a weft monitoring device. In such case, the stop signal S' is supplied to the yet existing stop device 12, and the supply circuit 22 energizes the circuits 9-1, 10-1 etc. and OR-gate 21 through the dotted line SL. Such a common use of the components 12 and 22 for both said monitoring devices provides for an essential saving of structural elements.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly,
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An electronic thread travel monitoring device on a shuttleless weaving machine which comprises at least one weft yarn supply bobbin and thread storing device serves for detecting yarn breaks occurring between supply bobbin and storing device. In the event of such a yarn break, the monitoring device causes the machine to stop before the broken yarn end enters the weaving shed.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Reference is made to and priority claimed from German patent application Ser. No. 10 2006 054 776.4, filed Nov. 17, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The invention concerns an apparatus for and a method of sigma-delta modulation, in particular an electronic circuit for sigma-delta modulation.
[0004] 2. Discussion of Related Art
[0005] Sigma-delta modulators (SDMs) are used in a large number of applications and usually serve for analog-digital conversion (A/D conversion) of electrical signals. Sigma-delta modulators (also referred to as delta-sigma modulators) convert analog time-continuous and value-continuous input signals into digital time-discrete and value-discrete output signals. They usually consist of a summing or subtracting member, a loop filter, an A/D converter and a digital-analog converter (D/A converter). The specified components are arranged in a closed loop, within which the digital output signal is converted back into an analog signal again and deducted from the input signal. That affords from the input to the output of the modulator given transfer functions which form the power density spectrum from various input to output points of the modulator in a characteristic fashion. Thus there is a so-called signal transfer function (STF) between the signal input of the useful signal and there is the so-called noise transfer function (NTF) between the A/D converter, to the output. The aim of the modulator loop is to transfer the input signal to the output with as little disturbance as possible while the noise or interference contributions of the modulator, in relation to the output, should be as low as possible. In many applications a 1-bit A/D converter (comparator) is used. That A/D converter (like also other parts of the circuit which are clock controlled) operates with a markedly higher sampling rate (oversampling) than the signal bandwidth of the input signal at least requires on the basis of the sampling theorem. By virtue of oversampling and the configuration of the STF and the NTF it is possible for example to use a 1-bit A/D converter and nonetheless achieve a very high level of resolution or a very high dynamic range of the sigma-delta A/D converter. Besides the sigma-delta modulator, a complete sigma-delta analog-digital converter also requires a downstream-connected filter (for example a decimator) which suppresses the interfering noise components which are outside the useful range and if desired also converts the flow of sampling values at a high sampling rate into a flow of wider bit words with a lower sampling rate (for example at the Nyquist frequency). The mode of operation for dimensioning and assembling the components, in particular the degree of oversampling, and the required properties of the loop filter in order to achieve a correspondingly high dynamic range have long been known. A conventional SDM operates with a constant clock (that is to say at a constant frequency) for the A/D converter and for the D/A converter. Admittedly in principle a distinction is drawn between continuous and time-discrete sigma-delta modulators but that difference only concerns the loop filter which is constructed either in time-continuous mode or clock-controlled mode (for example in the form of what is referred to as a switched capacitor filter). At least the A/D converter which is contained in the loop of the sigma-delta modulator must however be clock-controlled; typically however the D/A converter is also clock-controlled. It is possible to use z-transformation for modeling of the transfer functions of the system. A usual representation of the transfer function of the loop filter is then H(z).
[0006] Sigma-delta modulators, based on their order and the sampling rate, under some circumstances cause a very high degree of noise suppression in the signal bands of the useful signal. The noise transfer function can have a high-pass characteristic or also a band-pass characteristic or band-rejection characteristic. With a correct choice of the noise and signal transfer functions, the noise of the sigma-delta modulator, in particular the quantization noise of the A/D converter in the loop of the modulator, can be suppressed at certain frequencies which are in a fixed relationship to the clock rate of the sigma-delta modulator. Narrow-band ranges in which local minima of the noise occur are referred to as notches. The sigma-delta modulator is then usually dimensioned and operated in such a fashion that such a noise minimum coincides with the signal band of the input or useful signal. Ideally then the middle of the frequency band of the input signal is within such a notch. An aim of sigma-delta modulation is to achieve as small amount of noise as possible in the signal band. If the bandwidth of the input signal rises or the frequencies of the input signal vary, noise components also occur in the signal range of the input signal. The attainable signal-to-noise ratio or the resolution or the dynamic range of the sigma-delta modulator suffers therefrom.
[0007] In order to achieve a low level of noise and a greater bandwidth for the useful signal it is possible to modify the properties of the loop filter of the modulator. A known measure for example involves raising the order of the loop filter. That makes it possible to achieve a noise transfer function which suppresses the noise components in the signal band to a progressively greater degree, within increasing order. There is however the disadvantage that sigma-delta modulators can become unstable at an order which is greater than 2. In addition the power consumption of the modulators increases with a rising order. In the case of sigma-delta modulators of fixed, low (for example first or second) order, the signal-to-noise ratio which can be achieved is to be improved only by an increase in oversampling. In other words, in the conventional sigma-delta modulator, the ratio of the width to the depth of the desired minimum is limited in the power density spectrum of the noise signal and can only be improved by an increase in the sampling rate (oversampling). An increase in the sampling rate or oversampling however entails an increase in the power loss. There is thus a conflict between power consumption, technology parameters, order and oversampling as well as the attainable level of performance of a sigma-delta modulator. In order to do justice to various input signals it is therefore known for example to switch over between two fixed clock rates, depending on the amplitude of the respective input signal. In that case, two fixed clock rates are applied to the sigma-delta modulator.
DISCLOSURE OF INVENTION
[0008] The object of the present invention is to provide a sigma-delta modulator, which for variable input signals, has a lower level of noise than conventional sigma-delta modulators.
[0009] In accordance with an advantageous aspect of the present invention, the object is attained by an electronic circuit comprising a sigma-delta modulator and a clock generator which is adapted to output a clock signal which is suitable for clock control of the sigma-delta modulator, wherein the clock generator is additionally adapted to set the clock rate of the clock signal variably in dependence on an instantaneous frequency of the input signal. In that respect, an input signal (for example a time-continuous and value-continuous input signal) is temporarily viewed as a quasi-periodic signal. That is possible to a very good approximation in many applications. Frequently the input signal is a signal (for example a sine signal) which is modulated in respect of frequency, phase and amplitude. Thus, for example in the case of modulation methods of wired or wireless transmission of data, a high carrier frequency is frequently modulated within a comparatively narrow band. The present invention can be used to particular advantage for uses of that kind. In such a case it is possible at any moment in time to associate with the input signal a frequency which corresponds to the reciprocal value of the instantaneous period duration of the oscillation which has just occurred. For short time portions (for example two period durations) the input signal can then be represented in an adequate approximation by a signal at a fixed frequency. The input signal is then deemed to be quasi-periodic for that period of time. In the most frequent case of a sine signal, the signal is then to be viewed as quasi-sinusoidal. Subsequent periods of the sine signal do not differ from the currently prevailing period in the qualitative curve shape (which for example is always a sine curve), but only in frequency and amplitude. In accordance with the invention now a clock signal is produced for the sigma-delta modulator, which is produced in response to the, for example, comparatively slight frequency shift or phase shift of the input signal. A suitable variation in the clock rate of the clock signal makes it possible, for example, to displace a local minimum in respect of the noise power density in the noise transfer function (NTF) of the sigma-delta modulator so that the frequency or frequency band of the input signal always optimally coincides with the noise minimum. Advantageously, the sigma-delta modulator and the clock generator can be provided in an integrated circuit. In accordance with the invention, the terms “variably” and “in dependence on” an instantaneous frequency of the input signal are to be interpreted as meaning that the clock rate of the sigma-delta modulator is adapted in such a way that the noise minimum of the noise transfer function of the sigma-delta modulator advantageously matches the altered instantaneous frequency of the input signal. The time relationships required for that purpose can vary depending on the respective application involved but can be ascertained by the person skilled in the art without involving major complication and expenditure from the instantaneous frequency, which is to be expected, of the input signal, the shift to be expected or the time progress in respect of the shift and the average duration for which a given frequency of the input signal is maintained. In addition, consideration is to be given to the architecture of the modulator as well as the sampling rate or the oversampling rate of the modulator.
[0010] In accordance with a further advantageous aspect of the present invention, the clock generator includes a clock multiplication circuit which detects the instantaneous frequency of the input signal and produces the clock signal for the sigma-delta modulator by multiplication of the detected frequency of the input signal. That aspect of the present invention takes account of the requirement that the sigma-delta modulator is an oversampling modulator, for the function of which a suitable relationship between the frequency of the input signal and the oversampling rate is desirable. In particular in that respect account is to be taken of the fact that there is a characteristic relationship between the change in the clock rate of the modulator and adaptation of the noise transfer function, that is to say, for example, the local minimum in the noise transfer function (notch etc.) and the shift in respect of phase and frequency of the input signal. That relationship is connected to the degree of oversampling and the order and transfer characteristic of the modulator.
[0011] In accordance with an advantageous aspect of the present invention the clock generator is adapted to set the clock rate of the clock signal variably from a digital data stream which represents the instantaneous frequency of the input signal. Accordingly, the clock rate of the sigma-delta modulator can be set to the instantaneous frequency of the input signal with a suitable clock generator in the same manner as discussed hereinbefore, wherein in accordance with this aspect of the invention the required information is generated from a digital data stream.
[0012] In accordance with another advantageous aspect of the invention, the digital data stream which contains the information about the instantaneous frequency of the input signal can contain in particular the period duration and the amplitude of the input signal as digital information. In that respect the present invention embraces a digital data stream which still has to be evaluated to ascertain the required items of information but also a digital data stream which directly contains the required information. The information about the instantaneous frequency is then appropriately in the period duration of the input signal.
[0013] In accordance with a further advantageous aspect of the invention there is provided a converter circuit which converts the analog input signal of the modulator into a digital data stream before it is applied to the sigma-delta modulator. Accordingly in accordance with the invention, consideration is advantageously given to the fact that, for example, a simple periodic input signal can be easily converted into a digital signal in order then to ascertain the instantaneous frequency. By way of the example it is possible for that purpose to use comparators or limiter circuits which detect the zero-crossings of the input signal and output a corresponding square-wave signal. In accordance with a further advantageous configuration the digital data stream defined in that way then contains explicit information about the instantaneous frequency of the input signal. That digital information can be very easily used to adapt the lock rate in accordance with the instantaneous frequency.
[0014] In accordance with a further advantageous aspect of the invention, the clock generator is so designed that in addition to the periodic clock signal a clock event is inserted upon a zero-crossing of the input signal. In particular a clock event is inserted outside the clock period to be expected. In accordance with this aspect of the present invention, a clock event includes a rising or a falling clock edge or rising and falling clock edges. In accordance with this advantageous aspect of the invention, the sigma-delta modulator is therefore admittedly operated irregularly in given intervals between the clocks (that is to say derivation of the instantaneous frequency is not steady), but the arrangement ensures that the signal is sampled with fewer errors than in the case of conventional sigma-delta modulators. The reason for this is that, at each additionally generated clock, the sampling error is reduced, which, in the proximity of the zero position, acts similarly to oversampling. That means that the quasi-periodic components of the input signal are taken into consideration in an improved form in the sampling procedure and the noise of the sigma-delta modulator in the proximity of the multiple of the instantaneous frequency of the input signal becomes less.
[0015] In accordance with a further advantageous configuration for each piece-wise quasi-periodic portion of the input signal, but at least for half a period, the period duration and the amplitude of the input signal are digitally represented. The input signal is then expressed as a series of half-periods of respectively constant period duration and amplitude. That also simplifies the use of the present invention for certain classes of input signals.
[0016] In accordance with a further advantageous aspect of the invention the clock generator includes a plurality of delay elements which are arranged as a ring oscillator, wherein the delays of the delay elements are adjustable in response to the instantaneous frequency of the input signal and the clock signal for the sigma-delta modulator is derived from the oscillator frequency of the ring oscillator. Concealed behind that aspect of the present invention is a further advantageous configuration which permits simple adaptation of the clock rate by adaptation of the delays of the ring oscillator.
[0017] In accordance with a further aspect of the invention, the clock generator includes a clock divider which produces the clock for the sigma-delta modulator from a constant clock by division by a variable rational number, wherein the clock divider is determined in response to the instantaneous frequency of the input signal. That advantageous configuration permits fine fractional adaptation of the clock rate, which can produce an improvement in the performance of the SDM.
[0018] Behind the invention there is inter alia the realization that adapting the clock frequency of the modulator to the instantaneous frequency of the quasi-steady input signal provides that a specific noise minimum of the spectrum of the SDM is shifted simultaneously with the change in the instantaneous frequency of the input signal so that the SDM has its noise minimum substantially closer to the instantaneous frequency than in the conventional SDM. In that way the SDM can flexibly deal with altered input signals and has a lower level of inherent noise for the respective input signal than a conventional SDM of the same order. Considered in a different way, the order of a conventional SDM can be reduced with this invention while nonetheless achieving equal or better noise performance, in relation to the input signal. That makes it possible to save on chip area and power, which is of great use in particular for mobile applications.
[0019] It is to be noted that, as sampling no longer takes place at a constant frequency, z-transformation can no longer be readily used. The loop filter can then no longer be described as usual by H(z). It is however not out of the question to nonetheless approximately use a z-transformation for this system, for example by definition of a temporarily constant frequency so that the z-transformation approximately applies. At another moment in time for an altered instantaneous frequency in respect of the input signal, that z-transformed frequency is superceded by a z-transformation with a different time base. The smaller the signal bandwidth in relation to the carrier frequency, the correspondingly better does that approximation apply and at very small bandwidths relative to the carrier frequency, even a constant transfer function H(z), as in conventional SDMs, could be an adequate approximation.
[0020] In accordance with the invention the object is also attained by a method of operating a sigma-delta modulator comprising the steps: determining the instantaneous frequency of an input signal of the sigma-delta modulator and producing a clock signal for the sigma-delta modulator at a clock rate which is variably established in dependence on the instantaneous frequency of the input signal.
[0021] Furthermore, the object is also attained by a method of designing an integrated circuit comprising the steps: arranging a sigma-delta modulator on an integrated circuit, arranging a clock generator circuit for generating a clock signal on the integrated circuit; and designing the clock generator circuit in such a way that in operation it generates a clock signal for the sigma-delta modulator which is at a clock rate which is variably adapted in response to the instantaneous input frequency of the input signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Further advantageous method steps of the aforementioned methods correspond to the foregoing design configurations of the electronic circuit in accordance with the advantageous aspects of the present invention.
[0023] The embodiments by way of example of the present invention are described hereinafter with reference to the accompanying Figures in which:
[0024] FIG. 1 shows a simplified block diagram of a conventional sigma-delta modulator,
[0025] FIG. 2 shows a simplified block diagram of an embodiment in accordance with the present invention, and
[0026] FIG. 3 shows the power density spectrum of a conventional sigma-delta modulator with a band-pass characteristic.
DETAILED DESCRIPTION
[0027] FIG. 1 shows a simplified block diagram of a conventional sigma-delta modulator 100 . The input signal x(t) at the point 101 goes to a summing member 103 which subtracts from the input signal x(t) the output signal y(t) which is present at the node 102 . The sum or difference formed in that way goes to circuit components 104 which form a transfer function H(z). After filtering of the signal with the transfer function H(z) in the block 104 , it is converted into a digital signal by an analog-digital converter 105 with the clock rate fClk. That causes quantization noise to be added to the useful signal. The sampling rate fClk of the analog-digital converter 105 is kept constant. The output signal y(t) is converted into a, for example, value-continuous or value- and time-continuous signal ya(t) again by way of the digital-analog converter 106 and subtracted from the input signal x(t) in the summing member 103 , as described hereinbefore. That implements a modulator loop. That provides for specific shaping of the power density spectrum between the input 101 and the output 102 and the quantization noise of the analog-digital converter 105 with respect to the output 102 . Those relationships are generally known. The sigma-delta modulator 100 is adapted to given input signals x(t) by the selection of the transfer function H(z) in the block 104 . Transfer functions with a low-pass characteristic for the input signal x(t) and a high-pass characteristic for the quantization noise with respect to the output 102 are typical. There also exist transfer functions for the quantization noise with a band-pass or a band-rejection characteristic so that a minimum in respect of the quantization noise (notch) occurs at a specific frequency for the input signal x(t).
[0028] FIG. 2 shows a simplified block diagram of an embodiment by way of example of the present invention. In accordance therewith the sigma-delta modulator 200 is supplemented by a clock generator 210 . The input signal x(t) which is applied at the input 201 is again summed in the summing member 203 with the output signal y(t) which is converted back by way of the digital-analog converter 206 and which occurs at the output 202 or the output signal ya(t) is subtracted from the input signal x(t). The difference signal produced in that way is filtered in the block 204 with a transfer function H(t) which is now applied to an analog-digital converter 205 , the output of which in turn outputs the output signal y(t) to the node 202 . Unlike the conventional design configuration of the sigma-delta modulator, the analog-digital converter 205 is now clock-controlled with a variable clock clk(t) at the input 211 . That variable clock is generated in the clock generator 210 . The clock generator 210 generates the clock clk(t) based on the input signal x(t). In accordance with advantageous configurations of the invention, the instantaneous frequency of the input signal x(t) is taken into consideration and the clock rate from the clock generator flexibly adapted to the variable clock rate. Thus—unlike the situation in FIG. 1 —the clock clk(t) is not at a constant frequency but is a time-variable signal which is only temporarily periodic or also not periodic at all. Those properties depend on the configuration of the input signal x(t). The variable clock clk(t) can also optionally be used for the filter 204 or the D/A converter 206 . That is appropriate when those components are clock-controlled and are to run synchronously with the A/D converter. In that case the clock clk(t) is also passed to the filter 204 by means of the line 212 and to the D/A converter 206 by means of the line 213 .
[0029] A modification which is also possible to the example according to the invention shown in FIG. 2 provides that it is not the A/D converter 205 but one of the other components in the signal path of the feedback loop, for example the D/A converter 206 or the block 204 , that is clock-controlled with the variable clock x(t). In that case also the variable clock x(t) then acts on the characteristic and the position of the noise minima of the SDM. In that case the A/D converter 205 operates either without its own clock or with a further clock which is not shown in FIG. 2 and which, for example, is a fixed clock at a substantially higher frequency than that of the clock clk(t).
[0030] In regard to the procedure of the clock generator 210 in accordance with the invention there are provided various configurations which are described hereinafter. An advantageous embodiment of the invention provides that the variable frequency fClk of the clock clk(t) of the SDM is produced as a multiple of the instantaneous and time-variable frequency f(t). In that case the variable frequency f(t) is the instantaneous frequency of the input signal x(t). A number of clock multiplier circuits are known for clock multiplication purposes. By way of example it is possible to use a train of clock doublers. Each clock doubler can operate for example in such a way that it rectifies the signal, for example a sine or triangular signal at its input and displaces the offset of the result in such a way that zero-crossings occur at the output at double the frequency to the input. If a comparator is connected downstream of that clock doubler, the result is a square-wave signal, which is highly suitable for a clock. In addition, a pulse shaper of integrating character can in turn be connected downstream of that comparator so that triangular signals of the same frequency as the square-wave signals occur at the output thereof. They in turn can be applied to a subsequent clock doubler which rectifies those signals so that the result is double frequency, and so forth. In that fashion k doubling stages produces an output signal at a frequency fClk(t)=2 k ·f(t) and the SDM operates at a variable sampling rate of 2 k ·f(t).
[0031] The resulting noise spectrum can be similar from the point of view of shape to that of a conventional SDM, as is shown in FIG. 3 , as FIG. 3 involves an oversampling of 4 (fClk=1 GHz, f=250 MHz). It is only in the case of the SDM according to the invention, because of the variable clock control, that the location of the noise minimum is displaced on the frequency axis depending on the respective instantaneous value of f(t) which for example can depend on the degree of modulation of x(t), more or less slightly on the frequency scale towards the left or right.
[0032] In accordance with another embodiment of the invention the clock of the modulator clk(t) is basically generated from a fixed frequency fClk_a=const., in which case however a clock is additionally generated for clk(t) at zero-crossings of x(t). That means that the SDM operates with abruptly irregularly sized intervals between the clocks (or the derivation of the instantaneous frequency fClk(t) is not steady). This arrangement nonetheless ensures that the signal is sampled with fewer errors than in the case of conventional SDMs, for the sampling error is reduced at each additionally generated clock at clk(t). That measure acts similarly to oversampling in the proximity of the zero locations. That takes account of the quasi-periodic components of x(t) in the sampling procedure and the noise of the SDM in the proximity of the multiple of the instantaneous frequency f(t) is less.
[0033] A further embodiment of the invention is based on the fact that x(t) is no longer applied as usual in the form of an analog value to the SDM but in the form of a digital data stream, preferably already entailing explicit information about the instantaneous frequency f(t). A simple case in that respect is that, for each portion-wise periodic part of x(t) or for each part of x(t) which can be approximated by a portion of a periodic function, for example in the case of a sine function at least for a half-wave, the period duration and amplitude is specified. The function x(t) is then expressed as a series of half-waves or longer periodic sequences of respectively constant period duration and amplitude. Then clk(t) can be generated by way of the digital value of f(t), for example by digital setting of the delay of elements of a delay line which closed as a ring acts as an oscillator and generates the clock clk(t).
[0034] In accordance with a further configuration the arrangement does not involve a train of delay elements (delay line) but a clock divider which produces the clock clk(t) from a fixed master clock clk 0 ( t ) by division by a rational number. The division of clocks with fractions can be achieved by the integral part of the quotient being produced and an additional clock delay being added for the fractioned part. That principle is also used inter alia in conventional fractional N-phase lock loops.
[0035] FIG. 3 shows by way of example a spectral distribution of the power density of the quantization noise of a conventional SDM for a specific choice of the signal transfer function and the noise transfer function respectively for a given H(z). Standardized frequency is plotted on the X-axis and the power density pwr in dB is plotted on the Y-axis. The view is intended to illustrate a signal and noise transfer characteristic in respect of which the quantization noise has a minimum in a given frequency range (band BW). Ideally, the spectral signal components of the useful signal (that is to say of the input signal x(t)) lie in that band. That is indicated in FIG. 3 by a peak which projects out of the noise minimum (trough). The useful signal is for example at 250 MHz. The local minimum of the noise is also there. Subsequent filtering (for example in a decimator) of the illustrated spectrum provides that the spectral components of the quantization noise, which lie outside the useful signal band, are suppressed so that a desired signal-to-noise ratio is achieved. The subsequent processing step involves digital filtering which, as mentioned above, is implemented for example by means of what are referred to as decimators. If the frequency or the spectral components of the input signal are not in a region in which the quantization noise involves a minimum, the signal-to-noise ratio or the attainable dynamic range of the sigma-delta modulator is worsened.
[0036] The position of the noise minimum is altered by an SDM according to the invention, for example insofar as it is entrained with the frequency of the input signal by clock multiplication. With a sufficiently slow change in the frequency of the input signal the form shown by way of example in FIG. 3 for the minimum of the quantization noise of a conventional SDM can be qualitatively maintained, but in that case there is then a shift with the clock frequency which now variable instead of being fixed. That new shape of the quantization noise of an SDM according to the invention could approximately be described with a spectrum as shown in FIG. 3 if, instead of the fixed frequency as in FIG. 3 , a frequency which is standardized to the input signal is used for the X-axis.
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The invention concerns an electronic circuit comprising a sigma-delta modulator ( 200 ) and a clock generator ( 210 ) which outputs a clock signal (clk(t)) which is suitable for clock control of the sigma-delta modulator ( 200 ), wherein the clock generator is adapted to set the clock rate of the clock signal (clk(t)) variably in dependence on an instantaneous frequency of the input signal (x(t)).
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application derives priority from U.S. provisional patent application 61/268,419 filed 12 Jun. 2009, and is a continuation-in-part of U.S. application Ser. Nos. 11/818,582 and 12/378,275.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to energy absorbers and energy absorption systems, and more particularly, to a rotary magnetorheological damper for shock and vibration energy absorption systems.
[0004] 2. Description of Prior Art
[0005] The primary function of a shock and vibration protection system is to minimize the potential for equipment damage and/or personnel injury during shock and vibration loading. Such systems are important for vehicular applications, including aircraft, ground vehicles, marine vehicles, etc. Severe shock events may include harsh vertical or crash landings of aircraft, under body explosions of military ground vehicles, horizontal collisions of automobiles, and severe wave-to-hull impact of high speed watercraft. Lower amplitude shock and vibration tend to result from normal operation of such vehicles, including aircraft air loads or rotor loads, ground vehicles traversing rough terrain, etc. The severity of equipment damage and/or personnel injuries can be considerably minimized if the vehicles are equipped with shock and vibration protection systems.
[0006] Most current shock and vibration protection systems are passive, in that they cannot automatically adapt their energy absorption as a function of payload weight or as a function of real-time environmental measurements such as shock level, impact velocity, vibration levels, etc. Moreover, some energy absorbers are essentially rigid and do not stroke until the load reaches a tuned threshold. Because of this, these systems provide no isolation of vibration. This motivates the development of a shock and vibration protection system that utilizes an electronically adjustable adaptive energy absorber that can provide adaptive energy absorption for enhanced crashworthiness as well as vibration mitigation.
[0007] Magnetorheological (MR) technology is particularly attractive for shock and vibration protection systems as an MR fluid based device can offer an innovative way to achieve what is effectively a continuously adjustable energy absorber, in combination with a real-time feedback controller, can automatically adapt to payload weight and respond to changing excitation levels. With its ability to smoothly adjust its load-stroke profile, MR energy absorbers can provide the optimum combination of short stroking distance and minimum loading while automatically adjusting for the payload weight and load level. Furthermore, MR energy absorbers offer the unique ability to use the same system for vibration isolation.
[0008] One key challenge in vehicular applications involving MR energy absorbers is the device weight and size associated with providing sufficient stroke and force capability. Often, a large and massive energy absorbing device is not a possibility due to design and structural constraints. MR energy absorbers having large controllable range, stroke, and bandwidth are needed to provide adaptation to payload weight, shock energy, speed, and required energy absorption. Many MR energy absorbers for shock and vibration isolation mounts have been disclosed such that the damping level can be controlled in feedback by applying a magnetic field (U.S. Pat. No. 5,277,281 to J. D. Carlson et al., U.S. Pat. No. 6,279,700 to H. Lisenkser et al., U.S. Pat. No. 6,311,810 to P. N. Hopkins et al., U.S. Pat. No. 6,694,856 to P. C. Chen and N. M. Wereley, U.S. Pat. No. 6,953,108 to E. N. Ederfass and B. Banks, U.S. Pat. No. 6,481,546 to M. L. Oliver and W. C. Kruckemeyer, and U.S. Pat. No. 6,983,832 to C. S. Namuduri et al). See also, U.S. Pat. No. 6,694,856 issued Feb. 24, 2004 to Chen et al. which includes test data obtained from a COTS Lord Rheonetics® MR damper including force vs. piston behavior. The size and weight of these conventional linear-piston MR damper designs for such applications can make their use prohibitive. Hence, the development of more compact MR devices with the capability to adapt to shock and vibration conditions is of great interest.
SUMMARY OF THE INVENTION
[0009] Disclosed herein is a novel compact rotary vane MR energy absorber in which linear motion is converted into rotary motion so as to increase damper stroke while maintaining a compact profile. In this MR energy absorber, a rotor seated inside a hollow MR-fluid-filled body is equipped with “vanes” that rotate on a shaft inside the hollow body (vane herein being defined as any blade, fin or fluid foil mounted in a fixed position or movable, and extending either radially or axially with respect to an axis and operative on a fluid). The rotating vane(s) operate on the MR fluid interdependently with an internal stator (for example, a fixed vane) to propagate MR fluid flow through defined channel(s). Solenoid coils also mounted within the body control the MR fluid flow through those channels by changing the rheological properties of the fluid with the presence of a magnetic field, allowing control over the a reaction force on rotor vanes which, because the vanes are offset from the shaft, cause a reaction torque-moment on the shaft. The torque-moment serves as a damping force and can be further converted into a linear damping force with a rotary-to-linear motion converting mechanism.
[0010] A variety of different configurations are possible for the rotating vane(s) and internal stator.
[0011] In one exemplary embodiment, the internal stator comprises fixed vanes protruding inward from the body. The fixed vanes and rotary vane(s) separate the internal volume into two or more fluid chambers. The rotary vane(s) create a pressure-differential between the chambers. The fluid chambers are in communication with each other through either internal valves enclosed in the vanes or external by-pass valves, allowing MR fluid to flow from chamber to chamber. For example, a throttle valve mode is utilized (see, e.g., U.S. Pat. No. 5,842,547) in order to increase damping force due to a hydro-amplification effect. Different throttle valves including typical tubular or rectilinear flow mode valves and porous valves are disclosed. Electro-magnetic solenoid coils are enclosed in the corresponding valves to provide a variable magnetic field to control the rheology (apparent viscosity) of the MR fluid. As a shaft rotates along the center axis of the cylindrical body, radially-protruding rotary vane(s) mounted thereon force the MR fluid to flow through one or more valves from one fluid chamber to another. Thus, the pressure difference between the valve(s) leads to a resistant torque moment of the MR energy absorber. The torque moment can be further converted into a linear damping force with a rotation/linear motion converting mechanism such as, but not limited to a cable reel, a mechanical gearing, helical screw, etc. The resulting damping force can be varied as the applied electro-magnetic field is varied.
[0012] In another exemplary embodiment, the rotary vanes are mounted axially on the shaft and the internal stator includes fixed vanes protruding proximate the rotary vanes. The cooperating rotary and fixed vanes operate in shear mode such that, as the shaft and rotary vane(s) rotate, the MR fluid between the rotary vane(s) and the fixed vane(s) and/or body is sheared such that a resistant torque can be applied on the shaft. Electro-magnetic solenoid coils provide a variable magnetic field to control the rheology (apparent viscosity) of the MR fluid and hence the torque moment on the rotary vanes and shaft. Again, the torque moment of the shaft can be further converted into a linear damping force with a rotation/linear motion converting mechanism as described above. The resulting damping force can be varied as the applied electro-magnetic field is varied.
[0013] The key benefits and payoffs of the proposed rotary vane MR energy absorber technology are as follows:
increases stroke limit of the energy absorber while maintaining a compact damper profile; reduces device weight compared to conventional linear stroke MR energy absorbers for a given stroke and force requirement; provides a controllable damping force for shock and vibration protection applications in which protection for personnel and/or equipment can be significantly enhanced; eliminates the requirement of the air accumulator (used for compensating rod volume in linear stroke energy absorbers), which increases device size and can provided unwanted stiffness and/or preload force; passive damping for fail-safe, reduced or no power operation.
[0019] Other features, advantages and characteristics of the present invention will become apparent after the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and certain modifications thereof when taken together with the accompanying drawings in which:
[0021] FIG. 1 is an isometric view (with a transparent body) of one embodiment of the rotary vane MREA;
[0022] FIG. 2 is a cross sectional view of the embodiment of the rotary vane MREA in FIG. 1 ;
[0023] FIG. 3 is an isometric view (with a transparent body) of one optional embodiment of the rotary vane MREA with a by-pass valve body;
[0024] FIG. 4 is a cross sectional view of the optional embodiment of the rotary vane MREA in FIG. 3 ;
[0025] FIG. 5 is a cross-sectional view of a rectilinear flow valve in the by-pass valve body of the optional embodiment;
[0026] FIG. 6 is a cross-sectional view of a porous flow valve in the by-pass valve body of the optional embodiment.
[0027] FIG. 7 is a perspective drawing with a sectioned quarter of a fourth embodiment of the rotary vane MREA of the present invention.
[0028] FIG. 8 is a cross-sectional view of the axial rotary vane structure used in the fourth embodiment of FIG. 7 .
[0029] FIG. 9 is a perspective side cross section of the rotary vane MREA incorporating a multiple-concentric-axial rotary vane structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Generally, the invention disclosed herein is a novel compact rotary vane magnetorheological (MREA) energy absorber in which linear motion is converted into rotary motion and is subjected to a rotary damping force, the rotary configuration allowing increased damper stroke within a compact mechanical profile. A rotor is seated inside a hollow MR-fluid-filled body. The rotor includes vanes mounted on a shaft that together rotate inside the hollow body. The rotating vane(s) operate interdependently with an internal stator (for example, one or more fixed vanes) to propagate MR fluid flow through defined channel(s). Solenoid coils mounted within the body control the rheology (apparent viscosity) of the MR fluid flowing through those channels, allowing control over the reaction force on the vanes. Since the rotary vanes(s) are offset from the shaft, the controllable force allows adjustment of the torque-moment on the shaft. This allows adjustment of the damping force, which can be further converted into a linear damping force with a rotary-to-linear motion converting mechanism.
[0031] The invention provides a rotary vane MR energy absorber to provide adaptive damping force for shock and vibration protection applications. The conversion of the rotary motion to the linear motion makes it possible to construct a shock absorber to provide a larger stroke within a compact profile.
[0032] A first embodiment of the rotary vane MREA of the present invention is depicted in FIG. 1 . In this embodiment, the MREA comprises a cylindrical damper body 10 defining an internal cylindrical volume containing MR fluid. An internal stator comprising one or more fixed vane structures 22 protrudes radially into the internal volume of damper body 10 . A shaft 30 is rotatably mounted in the damper body 10 and traverses the internal volume and one or more rotary vane structures 24 protrude radially from the shaft 30 within the cylindrical volume. In addition, a rotation/linear motion converting mechanism (here a cable reel including a cable reel wheel 52 equipped with a cable 54 ) is coupled to the shaft 30 . Both vanes 22 , 24 are rectangular structures seated radially across the cylindrical volume, and the rotary vane 24 is driven by the center shaft 30 which is made of magnetic steel. Each vane 22 , 24 is made of vertical magnetic steel plates 26 arranged in columns and mounted in parallel within a non-magnetic metal frame 21 . The vanes 22 , 24 partition the internal volume into chambers. Between the steel plates 26 are defined fluid channels, here valve openings 28 , through which MR fluid in the cylindrical volume can communicate from chamber-to-chamber. The boundary edges of the fixed vane 22 may be attached to or integrally formed with the cylindrical body 30 . Each rotary vane 24 as well as the center shaft 30 can rotate along the center axis of the cylindrical body 30 . The edges of the rotary vane 24 in contact with the interior cylinder surfaces may be configured with wiper seals 33 . It should be apparent that turning the shaft 30 counterclockwise will rotate the rotary vane(s) 24 toward the fixed vane 22 , creating a pressure differential in the chambers there between. This pressure differential prompts the MR fluid within the cylindrical volume of body 30 to flow through the valve openings 28 between steel plates 26 , equalizing the chambers.
[0033] A solenoid 40 comprising a plurality of coils is wound about the middle of the center shaft 30 , and a protective plastic anti-abrasion tube 42 is placed around the solenoid coils 40 . The center shaft 30 , the vertical plates 26 in the vane structures 22 , 24 , and the MR fluid in the valve openings 28 constitute a closed-loop magnetic field path. In this configuration, a magnetic field is generated when an electric current is applied to the solenoid coil 40 , and the magnetic field across the valve openings 28 is perpendicular to the flow direction of the MR fluid. The upper and lower end of the center shaft 30 may be supported by ball bearings 31 located in upper and lower end plates of the cylindrical body 10 , respectively. One end of the center shaft 30 is extended out of the upper end plate of the cylindrical body 10 through a rod seal, and is connected with the rotation/linear motion converting mechanism (here a cable reel). As mentioned above, the cable reel comprises a cable reel wheel 52 and a high-strength steel cable 54 , the cable reel wheel 52 being rotatably fixed to the upper end of the center shaft 30 .
[0034] As shown in the top cross-sectional view of FIG. 2 , given one fixed vane 22 and one rotary vane 24 , the internal volume of the cylindrical body 10 is divided into two fluid chambers by the vane structure. The MR fluid in the fluid chamber 1 can communicate with the MR fluid in the fluid chamber 2 through the valve openings 28 . As a magnetic field is applied to the MR fluid through the valve openings 28 , the iron particles in the MR fluid form column-like structures along the magnetic field such that its apparent viscosity is increased.
[0035] Thus the valve opening 28 in this embodiment work as a magnetic field-regulated flow valve. In operation, a linear motion of the cable 54 due to a shock/crash event can is converted into a rotation by the cable reel wheel 52 , and then further transferred to the center shaft 30 and rotary vane 24 . The rotation of the rotary vane 24 in the cylindrical volume forces MR fluids in one fluid chamber to flow through the valve openings 28 into the other fluid chamber. The flow resistance as the MR fluid flows through the valve opening 28 leads to a pressure difference across the flow valve. The pressure difference yields a torsional moment applied to the rotary vane 24 and further a linear stroking force applied to the cable 54 of the reel wheel 52 . The stroking force can be regulated as the current applied to the solenoid coil 40 is varied since the pressure difference required to force the MR fluid to flow through the valve can be influenced by the magnetic field. Since the apparent viscosity of the MR fluid is a monotonic increasing function of the magnetic field, the pressure resistance in the flow valve and then the resultant stroking force can increase as the applied magnetic field increases.
[0036] One skilled in the art should readily understand that there are other suitable vane structures, as well as mechanical means for conversion of linear motion due to a shock/crash event into rotation. For example, rather than a cable reel wheel 52 and cable 54 a rack and pinion gear may be used, or a shaft and ballscrew may be used, such that linear motion of the rack/shaft or pinion/ballscrew turns the other.
[0037] Referring to FIG. 3 , a second embodiment of the invention is a rotary vane MREA with an external by-pass valve body 60 , rather than internal valve openings 28 . This embodiment likewise comprises a cylindrical damper body 10 with an internal cylindrical volume, fixed/rotary vane structures 22 , 24 , a rotation/linear motion converting mechanism (cable reel 52 and cable 54 ). The by-pass valve body 60 is external to body 30 and forms a conduit in which a rectilinear flow valve 62 is embedded. The vane structure may be identical, similarly including a fixed vane 22 and a rotary vane 24 . Both vanes 22 , 24 are rectangular and seated across the radial direction of the cylindrical volume, and between the fixed and rotary vane 22 , 24 is a center shaft 30 . The vane structures 22 , 24 and center shaft 30 can be made of light metal materials, but there are no valve openings on or in the vanes themselves (as ref. 28 in FIGS. 1-2 ). The boundary edges of the fixed vane 22 are integrated with the internal surface of the cylindrical volume of the damper body 10 . The rotary vane 24 as well as the center shaft 30 can rotate along the center axis of the shaft 30 . The edges of the rotary vane 24 in contact with the internal wall of damper body 10 are again configured with wiper seals 33 . The by-pass valve body 60 is connected to the cylindrical damper body 10 using hydraulic tubes 72 . One end of the by-pass valve body 60 is connected to the internal volume of the damper body 10 at one side of the fixed vane 22 by a through hole 74 , and the other end of the by-pass valve body is connected to the internal bore at the other side of the fixed vane 22 by the another through hole 74 . The upper and lower end of the center shaft 30 is supported by ball bearings 31 located in the upper and lower end plates of the cylindrical body 10 , respectively. One end of the center shaft 30 is extended out of the upper end plate of the cylindrical body 10 through a rod seal, and is connected with a rotation/linear motion converting mechanism, such as a cable reel as per above. The cable reel may comprise a cable reel wheel 52 and a high-strength steel cable 54 , and the cable reel wheel 52 is fixed to the upper end of the center shaft 30 .
[0038] As shown in the top cross-sectional view of the second embodiment in FIG. 4 , the internal bore in the cylindrical body 10 is divided into two fluid chambers 1 , 2 by the vane structure 22 , 24 . At each side of the fixed vane 22 , there is a through hole 74 on the wall of the cylindrical damper body 10 . On the outer surface of the cylindrical body 10 , each hole 74 is connected with one end of the by-pass valve body 60 , respectively. Given this configuration, the MR fluid in the fluid chamber 1 can communicate with the fluid in the fluid chamber 2 through the by-pass valve 62 .
[0039] FIG. 5 is a cross-sectional view of a rectilinear flow valve 62 in the by-pass valve body 60 as in FIGS. 3-4 . In the by-pass valve body 60 as shown in FIG. 5 , a typical rectilinear valve 62 is included. The rectilinear valve 62 comprises a coil bobbin 64 , a flux return tube 65 and an electro-magnetic solenoid of one or more coils 66 . Both the coil bobbin 64 and flux return tube 65 are made of magnetic steel. The flow valve 62 is configured such that the coil bobbin 64 , flux return tube 65 and the MR fluid flowing through the flow path constitute a closed-loop magnetic field path, and the magnetic field generated by the solenoid 66 is perpendicular to the flow direction of the MR fluid. In operation, a linear motion of the cable ( FIG. 3 , ref. 54 ) due to a shock/crash event can be converted into a rotation by the cable reel wheel 52 and further transferred to the center shaft 30 and rotary vane 24 . The rotation of the rotary vane 24 in the cylindrical volume forces MR fluids in one fluid chamber to flow through the by-pass flow valve(s) 62 into the other fluid chamber. The flow resistance as the MR fluid flows through the by-pass valve(s) 62 leads to a pressure difference across the flow valve 62 . The pressure difference yields a torsional moment applied to the rotary vane 24 and further a linear stroking force applied to the cable 54 of the reel wheel 52 . The stroking force can be regulated as the current applied to the solenoid coil 66 is varied since the pressure difference required to force the MR fluid to flow through the valve 62 can be influenced by the magnetic field. As the applied magnetic field is stronger, the pressure resistance in the flow valve 62 is bigger since the apparent viscosity of the MR fluid is a increasing monotonic function of the magnetic field.
[0040] A third embodiment of the rotary vane MREA is similar to the second embodiment except that a porous flow valve 82 is employed in the by-pass valve body 60 instead of a rectilinear valve 62 as in FIG. 5 . As shown in FIG. 6 , the by-pass valve body 60 here contains a porous flow valve 82 comprising a nonmagnetic metal tube 84 internal to the valve body 60 , a solenoid coil 86 about the tube 84 , a flux return tube 87 , porous media 88 and valve-to-body hydraulic tube connections 72 as above. The porous media 88 may comprise multiple sphere beads or other fillers randomly or orderly-packed inside the non-magnetic metal tube 84 . The solenoid coil 86 is wrapped around the metal tube 84 , and the flux return tube 87 is placed around the solenoid coil 86 . The hydraulic tubes 72 are used to connect the by-pass valve body 60 to the cylindrical damper body 10 as previously described. An important feature of the porous valve of FIG. 6 is that both the MR fluid and the porous media 88 are placed in the center of the solenoid and function as a magnetic flux guide. Since a tortuous flow path exists through the packed porous media 88 , the flow of the MR fluid through the porous valve 82 is not unidirectional and the local magnetic field has various orientations relative to the velocity of the MR fluid. In such a configuration, mean values of the magnetic field applied to the MR fluid depend on material properties and the geometric shape of the porous media 88 , and the valve design is flexible. Comparatively, in conventional rectilinear flow mode valves, the fluid channel has to be configured so that the MR fluid flows perpendicular to the magnetic field, which places numerous geometric constraints on valve and magnetic coil design. Another feature of the porous valve 82 that improves efficiency and effectiveness is the tortuous fluid channels existing in the porous media. First, the active fluid channel length can be increased by the curvedness of the fluid channel, and second, both yield and viscous behavior of the MR fluid can be affected by the applied magnetic field due to the capillary style of channel.
[0041] One skilled in the art should readily understand that there are other suitable configurations for the porous valve.
[0042] For example, rather than porous media included in center nonmetal tube and a coil wrapped around the tube, a tubular valve may be use, in which the porous media is sandwiched between an inner tube and a outer tube and the coil is wrapped around the inner tube. A variety of porous valve configurations are shown and described in Applicant's co-pending U.S. application Ser. No. 11/818,582, which is herein incorporated by reference.
[0043] In operation, when the cable reel wheel 52 rotates due to a shock/crash event, the rotary vane 24 pushes the MR fluid from, for example, the MR fluid chamber into one end of the by-pass valve body 60 through the hydraulic tube. As the MR fluid flows into the porous valve 82 , the MR fluid passes through the packed porous media 88 and is exposed by an applied magnetic field. The MR fluid then exits the porous valve 82 and enters the MR fluid chamber 2 through the hydraulic tube 72 . As shown above, when the rotary vane 24 rotates, the MR fluid must pass through the flow path in the porous media 88 in which the yield stress and viscosity of the MR fluid therein are controlled by an applied magnetic field.
[0044] A fourth embodiment of the rotary vane MREA comprises one or more axially-mounted rotary vane(s) mounted on the shaft (rather than radial vanes 24 , and a cooperating stator structure, which operate by a shear motion rather than pressure differential. The axially-mounted rotary vane(s) shear through the MR fluid, and shear resistance creates a torque-moment and damping force. A solenoid-induced magnetic field controls the shear resistance to rotation of the axially-mounted rotary vane(s), as before allowing control over the torque moment on rotor and shaft. The torque-moment can be further converted into a linear damping force with a rotary-to-linear motion converting mechanism.
[0045] The fourth embodiment of the rotary vane MREA of the present invention is depicted in the perspective drawing of FIG. 7 . In this embodiment, the MREA comprises a cylindrical damper body 10 defining an internal cylindrical volume containing MR fluid. The cylindrical damper body 10 may or may not be equipped (or formed) with an internal stator structure as described below. In the illustrated embodiment the damper body 10 is comprises of three separate parts: a cylindrical midsection 11 , and opposing disk end plates 13 screwed or otherwise attached to midsection 11 .
[0046] As above, a shaft 30 is rotatably mounted in the damper body 10 via shaft bearings 31 (and/or bearing seals) and traverses the internal volume. At least one axially-oriented (generally cup-shaped) rotary vane structure 124 is driven by the shaft 30 within the cylindrical volume, and may be attached to the shaft 30 by its closed end. As described below, a plurality of progressively smaller rotary vane structures 124 may optionally be mounted on the same shaft 30 in a concentric manner.
[0047] FIG. 8 is a cross-sectional view of the axial rotary vane structure 124 including a closed end 128 with keyed aperture 129 for attachment to shaft 30 , and annular sidewalls 126 that rotate within the confines of the cylindrical body 10 . The axial rotary vane structure 124 is defined by a plurality of annular grooves 130 spaced along the interior surface of the annular sidewalls 126 .
[0048] Referring back to FIG. 7 , the rotary vane structure 124 rotates about an internal stator which is herein formed as solenoid coils 40 wound about a bobbin 150 . Bobbin 150 is stationery with respect to the body 10 and may be attached or integrally formed with end plate 12 . Bobbin 150 is defined by a plurality of annular grooves 160 for winding the solenoid coils, and the grooves 160 in bobbin 150 correspond to the annular grooves 130 spaced along the interior surface of the annular sidewalls 126 . The rotary vane structure 124 is very slightly smaller in diameter than the interior of the body 10 to allow free rotation and to define an MR fluid gap 140 between the rotary vane structure 124 and body 10 . Similarly, the rotary vane structure 124 is very slightly larger in diameter than the bobbin 150 to allow free rotation there about and to define an MR fluid gap 140 between the rotary vane structure 124 and bobbin 150 . The solenoid coils 40 in the grooves 160 of bobbin 150 may be connected externally through a central wire path 172 through the bobbin 150 , and sealed by a wire seal plug 174 or suitable filler to prevent fluid leakage between the wire and cylindrical body 10 . In this manner, the coils 40 may be connected to an external power supply. The shaft 30 protrudes out at one end of the body 10 , here through side plate 13 .
[0049] In operation, fluid shear flow occurs down the entire axial length of the rotary vane structure 124 within MR fluid gap 140 occurring between the rotary vane 124 and the cylindrical body 10 as well as the gap 140 between the rotary vane structure 124 and the bobbin 150 .
[0050] As above, a rotation/linear motion converting mechanism such as a cable reel may be coupled to the protruding end for linear-to-rotary motion translation. The axial rotary vane 124 is made of magnetic steel, and rotates along with the center shaft 30 along the center axis of the cylindrical body 10 . Turning the shaft 30 will turn the rotary vane 124 and create a shearing effect against the MR fluid resident in the gap 140 between the rotary vane structure 124 and body 10 , as well as that between the rotary vane structure 124 and bobbin 150 . Thus, both internal and external surfaces of the rotary vane structure 124 contact the MR fluid.
[0051] The cylindrical body 10 , the rotary vane 124 , and the MR fluid in the in the MR fluid gaps 140 constitutes a closed-loop magnetic flux path around each coil 40 (shown by arrows). In this configuration, a magnetic field is generated when an electric current is applied to the solenoid coils 40 in the grooves 160 of bobbin 150 , and the magnetic field across the rotary vane 124 is perpendicular to the flow direction of the MR fluid in the flow gaps between the rotor vane and the body/fixed vane 130 . As the magnetic field is applied to the MR fluid in the MR fluid gaps 140 , the iron particles in the MR fluid form column-like structures along the magnetic field such that its apparent viscosity is increased. In operation, a linear motion imparted to the rotation/linear motion converting mechanism (such as cable reel, not shown) is converted to rotary motion transmitted to the center shaft 30 and axial rotary vane 124 . The rotation of the rotary vane 124 in the cylindrical volume creates a shearing action against the MR fluids in flow gaps 140 . The shear resistance of the MR fluid yields a torsional moment applied to the rotary vane 124 and further a linear stroking force applied to the rotation/linear motion converting mechanism. The stroking force can be regulated as the current applied to the solenoid coils 40 is varied since the MR fluid shear resistance can be influenced by the magnetic field.
[0052] The annular grooves 130 in the rotary vane 124 serve to increase the flux density in the outer gap 140 between the rotary vane structure 124 and body 10 .
[0053] The number of solenoid coils 40 is preferably a multiple of the number of the grooves 130 in vane 124 , and may be equal in number. The variable magnetic field leads to a controllable shear stress in the MR fluid and a controllable resistive torque of the damper.
[0054] If desired, optional features such as a fluid level indicator (window) may be provided in body 10 to monitor the quantity of the MR fluid in the damper, and/or an MR fluid vent may be employed to compensate fluid volume variation due to temperature fluctuation.
[0055] As mentioned briefly above, multiple co-axial rotary vanes 124 may be mounted concentrically on the shaft 30 for combined rotation. In this case to ensure maximum shear resistance, the stator structure is preferably expanded to extend a stationery vane between each concentric pair of rotary vanes.
[0056] FIG. 9 is a perspective side cross section of a rotary vane MREA incorporating a multiple-concentric-axial rotary vane structure. A shaft 30 is rotatably mounted in the damper body 10 via shaft bearings 31 and bearing seals 32 , and traverses the internal volume. The rotary vane structure 224 here comprises three concentric cup-shaped annular sidewalls 225 - a ,b,c riding on the shaft 30 within the cylindrical volume, all attached to the shaft 30 by their closed end in a concentric manner for common rotation within the confines of the cylindrical body 10 . Both walls of the innermost sidewalls 225 - b ,c, plus the inner wall of the outermost sidewall 225 - a are defined by grooves 230 spaced along the surface which provide increased magnetic flux density. The rotary vane structure 124 rotates about an internal stator structure which is herein formed as solenoid coils 40 wound about a bobbin 150 . Bobbin 150 is stationery with respect to the body 10 and may be attached or integrally formed with end plate 12 . Bobbin 150 is defined by a plurality of annular grooves 160 for winding the solenoid coils, and the grooves 160 in bobbin 150 correspond to the grooves 230 in annular sidewalls 225 - a ,b,c. Sidewalls 225 - a ,b,c are progressively smaller in diameter to allow free rotation and to define an MR fluid flow path between each and body 10 . The stator structure also includes one or more stationary vanes 222 - a ,b (here two) each fixed to the cylinder body 10 and each dividing the interim space between sidewalls 225 - a ,b,c into two gaps. Similar grooves 260 are applied in stationary vanes 222 - a ,b to increase flux density in the gaps. The increased shear area of the rotary vane structure 224 increases the output resistant torque or damping force while maintaining a compact damper volume.
[0057] The solenoid coils 40 in the grooves 160 of bobbin 150 may be connected externally through a central wire path 172 and sealed by a wire seal plug 174 for connection to an external power supply. If necessary, additional bearings 250 may be provided to support the rotor vane structure 224 . The shaft 30 protrudes out at one end of the body 10 and a rotation/linear motion converting mechanism as per above may be connected. Turning the shaft 30 will turn all the annular sidewalls 225 - a ,b,c of rotary vane 224 and will create an enhanced shearing effect against the MR fluid between the rotary vane structure 224 , body 10 , and bobbin 150 . The cylindrical body 10 , the rotary vane 224 , and the MR fluid the in the MR fluid flow paths 140 constitutes a closed-loop magnetic flux path (shown by arrows). The magnetic field is generated when an electric current is applied to the solenoid coils 40 in the grooves 160 of bobbin 150 , and the magnetic field across the rotary vane 124 is perpendicular to the flow direction of the MR fluid in the flow gaps between the annular sidewalls 225 - a ,b,c of rotary vane 224 and the interim fixed vanes 222 - a ,b and bobbin 150 . Operation is similar to the embodiment of FIG. 7 . The rotation of the rotary vane 224 in the cylindrical volume creates a shearing action against the MR fluids, the shear resistance of the MR fluid yields a torsional moment applied to the rotary vane 224 and a stroking force applied to the rotation/linear motion converting mechanism. The stroking force can be regulated as the current applied to the solenoid coils 40 is varied since the MR fluid shear resistance can be influenced by the magnetic field.
[0058] Other optional features for this embodiment are similar to the single rotary vane damper of FIG. 7 .
[0059] In all the above-embodiments, a rotary MR energy absorber is disclosed that increases stroke limit of the energy absorber while maintaining a compact damper profile, thereby reducing weight compared to conventional linear stroke MR energy absorbers for a given stroke and force requirement.
[0060] Therefore, having now fully set forth the preferred embodiment and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It is to be understood, therefore, that the invention may be practiced otherwise than as specifically set forth in the appended claims.
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A rotary vane magnetorheological energy absorber, which enables a longer stroke capability in a more compact configuration than conventional magnetorheological devices, is disclosed. This novel device design is attractive for applications where long stroking capability, high force dynamic range, device size, and device weight are important. The improved magnetorheological energy absorber comprises an internal or external flow valve and a hollow body enclosing fixed and rotary vanes as well as magnetorheological fluid. Fluid flow in the valve is restricted as a solenoid is activated, thus adjusting the capability of the device to react torque. Various flow valve configurations are disclosed, as well as various motion translation mechanisms for translating linear motion to rotary motion for use of the rotary vane magnetorheological energy absorber. The improved design minimizes the amount of magnetorheological fluid required as compared to conventional linear stroke energy absorbers, thus minimizing device weight.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to vehicle engine fuel supply systems and, particularly, to a fuel supply system having a reserve fuel container and fuel pump located within the vehicle fuel tank.
2. Description of Prior Developments
It is known to provide a fuel container in a vehicle fuel tank for supplying fuel to a fuel pump when the tank is essentially empty, or when the fuel in the tank is sloshing or thrown away from the pump inlet chamber due to vehicle turning maneuvers.
U.S. Pat. No. 4,974,570 to Szwargulski shows a reserve fuel supply system that includes a pressure responsive valve for conveying fuel from a reserve container to the fuel pump when a float valve in the tank closes due to lack of fuel in the tank. The reserve fuel container has an open top such that fuel vapors associated with heated fuel can circulate between the reserve container and the surrounding space in the fuel tank.
Conventional engine fuel systems have fuel pumps that are sized to deliver more fuel than the engine can use. Excess fuel not used by the engine is returned to the fuel tank via a return line. The excess fuel is usually heated as a result of its travel through the engine fuel injectors or other heated passageways. Consequently, the returned fuel tends to heat the fuel in the tank.
Under some conditions, fuel vapors from the heated fuel can form in the tank to such an extent that, when the motorist opens the gas cap on the tank to add fuel, the accumulated vapors can escape into the ambient atmosphere. Such vapor escape represents an air pollution problem that the present invention is designed to reduce.
Fuel supply systems having reserve fuel containers within the fuel tanks are disclosed in various patents, e.g., U.S. Pat. Nos. 3,443,519; 4,672,937; 4,747,388; 4,776,315; 4,807,582; and 4,831,990. It is not believed that any of these patent disclosures address the problem of fuel vapor accumulation and vapor escape from the fuel tank.
SUMMARY OF THE INVENTION
The present invention is directed to an automotive engine fuel supply system that includes a reserve fuel container located within a conventional fuel tank, such that excess fuel not used by the engine is returned only to the reserve fuel container where it is isolated from the main body of fuel in the tank. A system of valves is provided so that the fuel pump normally draws its fuel supply partly from the tank and partly from the reserve container.
Part of the fuel supplied to the pump is in a heated condition due to its having come from the reserve container instead of from the fuel tank. Therefore, since the returned fuel from the engine is continually being recycled through the fuel pump, the general temperature of the fuel in the tank is kept relatively low, such that vapor generation is reduced. Also, most of the vapors that are produced are confined to the reserve container or are carried away by the fuel pump. As a result of these factors, there is a lessened potential for fuel vapor escape when the tank filler cap is opened for adding fuel to the tank.
In a preferred arrangement, the fuel tank is connected to the fuel pump via a float-operated poppet valve located below the reserve fuel container and in open communication with the pump inlet chamber. The reserve fuel container has a second poppet valve axially aligned with the first mentioned poppet valve, with both valves being adapted to feed fuel to the pump inlet chamber.
A lost motion connection is provided between the two poppet valves, whereby the valves can be selectively opened and closed depending on the condition of the float and fuel levels in the tank and reserve container. The system is designed to minimize the formation or accumulation of fuel vapors in the fuel tank from heated fuel and provides a reserve fuel supply for the fuel pump when the tank is in a near empty condition that would otherwise deprive the pump of fuel.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a sectional view taken through a reserve fuel container and control valve assembly used in an engine fuel supply system in accordance with the present invention.
FIG. 2 is a fragmentary view taken in the same direction as FIG. 1, but showing the valve assembly in a different operational mode.
FIG. 3 is a fragmentary view taken in the same direction as FIG. 1, but showing the valve assembly in another operational mode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The engine fuel system shown in FIG. 1 includes an upright cylindrical fuel container 11 positioned within a fuel tank 13. The container includes a hollow partitioned base structure 15 that seats on the bottom wall 17 of the fuel tank. The top wall of the fuel tank (not shown) has an access opening therein for the purpose of installing the fuel container into the tank.
After the container has been inserted downwardly through the access opening, a cover (not shown) is mounted over the access opening. The cover has fittings and electrical connections for fuel lines and wiring associated with a fuel pump 19 located within container 11. A coil spring 21 can be positioned between container 11 and the cover to firmly position the container within the fuel tank. The overall installation may be similar to that depicted in U.S. Pat. No. 4,974,570.
Base structure 15 includes an internal partition 23 that forms a valve opening 25. Seated on the valve opening is a poppet valve 27. Fuel can flow freely from the fuel tank space 29 through a filter screen 31 into the space below poppet valve 27. When the valve is open, as shown in FIGS. 2 and 3, the fuel can flow upwardly through the valve opening 25 into an internal chamber 33 that is in open communication with the inlet chamber 35 of fuel pump 19.
Fuel pump 19 may be a gear pump constructed as shown in U.S. Pat. No. 4,820,138 to Bollinger. The pump includes an electric motor 37 that drives an external gear 39, whereby liquid fuel is pumped upwardly into an annular space 41 and through motor 37 for motor cooling and eventually into a fuel line 43 going to the engine.
The quantity of fuel delivered by the pump is greater than the quantity required by the engine. Excess or unused fuel is returned to fuel container 11 through a return line 44 where it collects in the container space 45. All of the returned fuel goes into container 11, effectively none goes back to the fuel tank.
A lower wall 47 of the fuel container has a valve opening or valve seat that receives a poppet valve 49. When poppet valve 49 is open, as shown in FIG. 3, fuel can flow downwardly from container space 45 into chamber 33. FIG. 3 shows one condition wherein both poppet valves 27,49 are open. The fuel pump then draws fuel from the fuel tank and from container 11.
FIG. 2 shows a second condition wherein poppet valve 49 is closed and poppet valve 27 is open. The fuel pump then draws fuel solely from the fuel tank space 29 through valve 27. There is a third condition (not shown) wherein valve 49 is open and valve 27 is closed. The pump then draws fuel solely from container 11 through valve 49. Valve 27 is referred to as a lower valve, and valve 49 is referred to as an upper valve. The two valves are vertically aligned on a common movement axis.
Valve 27 is opened and closed by a buoyant float member 51 that has a generally C-shaped configuration in top plan view. A horizontal pivot pin 53 extends through the float member 51 and across the space within the C-shaped float member for connection with a lever arm 55. The lever arm is swingable in a vertical arc around a fixed pivot axis 57, whereby the float member 51 is enabled to move vertically up or down depending partly on the quantity of fuel in tank 13 and the degree to which the fuel might be sloshing back and forth in the tank. Pivot pin 53 enables float member 51 to maintain a level attitude throughout its vertical stroke.
FIG. 1 shows float member 51 in a lowered position produced by an empty tank or by a tank fuel level less than the predetermined value required for normal operation of the fuel pump. FIG. 2 shows float member 51 in a raised position produced by higher than minimum fuel levels in the tank. FIGS. 1 and 2 represent the limits of the float member stroke.
Poppet valve 27 has a stem 58 that has a pivot connection with lever arm 55. A neck portion of the stem extends within a slot in arm 55, whereby arcuate motion of the arm translates into vertical motion of the poppet valve.
The two poppet valves 27 and 49 are interconnected by a lost motion connection that includes a coil spring 59 and a hollow sleeve-like rod 61. As shown, hollow rod or tube 61 extends upwardly from poppet valve 27 for slidable motion on a pin 60 that extends downwardly from poppet valve 49, whereby the two poppet valves have relatively good axial and radial alignments with the associated valve seats. The length of rod 61 is less than the spacing between valves 27 and 49 when the valves are in their closed positions as shown in FIG. 1.
Coil spring 59 exerts an upward biasing force on poppet valve 49 and a downward biasing force on poppet valve 27. The force of spring 59 is less than the upward buoyant force developed by float member 51 such that the float member is enabled to lift poppet valve 27 to an open condition, as shown in FIG. 2.
Referring to FIG. 1, container 11 has a cage structure 63 depending from its upper wall 64 for slidably supporting a closure means such as float valve 65. Valve 65 has a cup shape that forms an air chamber 67 when the fuel level rises in container space 45 to a point where it reaches the lower edge of the cup. A rising fuel level in container space 45 lifts valve 65 so that it seals a vent opening 69 in container wall 64. When the fuel level in the container is lowered, the float valve 65 returns to the open position as shown.
Float valve 65 could also take the form of a dynamic flow valve which remains open for vapor flow when container space 45 is filling, but closes when liquid tries to flow past it.
The spring force of spring 59 is sufficient to support the head of liquid in container 11 until the container is completely filled, i.e. until vent opening 69 is closed by valve closure means 65. However, when vent opening 69 is closed, continued flow of fuel through return line 44 toward container 11 produces a pressure in line 44 that slightly pressurizes the container space 45. Such pressure is sufficient to open the upper poppet valve 49 for feeding the pump 19 with fuel from container 11 as depicted in FIG. 3.
The above discussion on the force of spring 59, and the action of poppet valve 49, is somewhat simplified in that it does not take into account the suction force produced by the fuel pump, i.e. the suction condition existing in chamber 33. Under some conditions, valve 49 will be open even when container space 45 is at atmospheric pressure.
Referring to the general operation of the illustrated system, FIG. 1 represents the condition of an empty fuel tank with essentially no fuel in tank space 29 or container space 45. As new fuel is added to the tank, float member 51 will be lifted to the FIG. 2 position wherein poppet valve 49 is opened by the buoyant force of the float member. Hollow rod 61 is of such a length that poppet valve 27 can move up to the open position without disturbing valve 49. If sufficient fuel is added to the tank, some of the fuel may enter container 11 through the vent opening 69. The addition of fuel into container 11 is, however, not necessary for operation of fuel pump 19. The pump can draw fuel from tank space 29 through the open poppet valve 27.
FIG. 2 represents the operating condition when there is an adequate supply of fuel in tank space 29 and less than a complete filling of container 11. During normal operation of the fuel pump, excess or unused fuel returns from the engine through return line 44 such that, after a period of operation, container 11 is completely filled. Float valve 65 then seals vent opening 69 such that continued return of fuel slightly pressurizes the fuel in container space 45.
FIG. 3 represents the condition of poppet valves 27 and 49 during normal operation of the fuel pump with container space 45 slightly pressurized. The force of the liquid fuel on the upper face of poppet valve 49 causes valve 49 to open such that the valve assembly moves slightly downwardly to the FIG. 3 condition. The fuel pump is then drawing fuel from the tank through valve 27 and also from container 11 through valve 49. The valve assembly may reciprocate slightly depending on fuel demand by the engine.
As the fuel level in tank 13 gradually lowers due to consumption of fuel by the engine, there comes a time when the tank fuel level falls below the level required to keep float member 51 in a buoyant condition. Due to fuel sloshing back and forth in the tank or due to the absence of fuel in the tank, the float member will gravitate to the FIG. 1 condition, wherein valve 27 is closed. However, the upper poppet valve 49 will remain in the open condition until container 11 is essentially emptied of fuel.
With valve 27 closed and container 11 having a reserve fuel supply in space 45, the pump suction force in chamber 33 has an increased effect on valve 49. Also, float member 51 exerts no buoyant force on the poppet valve assembly because the float member is deprived of the fuel that produces the buoyant condition. The float member 51 will exert a downward force on valve 27, thereby allowing the pump to pull fuel through valve 49 when no fuel is around float member 51. Pump suction force in chamber 33, together with the liquid head in container 11 and downward force exerted on valve 27 by float member 51, overcomes the force of spring 59 whereby valve 49 is open until and after container 11 is in an essentially empty condition.
The illustrated fuel supply system achieves several purposes. During normal pump operation, reserve container 11 is maintained in a filled condition and is thus able to supply reserve fuel to the pump when the tank is in a near empty condition or when fuel is sloshing back and forth in the tank.
During normal operations (FIG. 3), the pump is drawing an appreciable portion of its fuel supply from container 11 through valve 49. The fuel returning from the engine is somewhat hotter than the fuel in tank space 29. Vapor pressure increases are confined to the fuel in container 11 so that the fuel in tank space 29 is relatively cool and vapor-free. There is thus a lessened potential for fuel vapors to escape from the tank into the atmosphere when the motorist opens the gas tank cap to refill the tank.
The valve assembly of the present invention has, as a principal objective, the minimization of fuel vapor emission from the fuel tank into the atmosphere through the opened gas tank cap. This objective is achieved without sacrificing the feature of having a reserve fuel supply that prevents pump inoperability due to an insufficient fuel supply.
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An engine fuel system includes a fuel pump located within an upright reserve fuel container located in a fuel tank. Fuel is admitted to the inlet chamber of the pump through separate poppet valves associated with the fuel tank and the reserve fuel container. The container is a sealed construction that isolates the fuel in the container from the fuel in the tank. The poppet valve leading from the tank to the pump is operated by a float that is responsive to the fuel level in the tank. At low tank fuel levels (empty or near empty), the float-operated poppet valve is closed. The two valves are interconnected by a lost motion connection such that the poppet valve associated with the reserve container is openable by pressures generated in the return fuel line, or by suction forces generated by the fuel pump. The reserve container is maintained in a filled condition ready for supplying fuel to the pump when the fuel tank is in a near empty condition.
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This is a divisional of application Ser. No. 752,282, filed Aug. 29, 1991 abandoned.
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
The present application is related to U.S. patent application Ser. No. 752,419, filed on Aug. 30, 1991, by Furtek and Camarota for PROGRAMMABLE LOGIC CELL AND ARRAY, which is a continuation-in-part of U.S. patent application Ser. No. 07/608,415, filed on Nov. 2, 1990.
Both of the above-cited related applications are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to user programmable integrated circuit devices and, in particular, to the provision of flexible high impedance control in the core cells at a configurable logic array.
2. Discussion of the Prior Art
A configurable logic array (CLA) is a matrix of interconnected, programmable logic cells. The individual logic function and the active inputs and outputs of each logic cell are determined by parameter flip-flops and logic gates within the cell, rather than by physically customizing the array during manufacture. Thus, the individual cell functions and the interconnections between cells are dynamically programmable to provide a wide variety of functions. The greater the number of cells in the array, the greater the functional flexibility of the CLA device.
The configurable logic array concept was first introduced by Sven E. Wahlstrom in 1967. Wahlstrom, Electronics, Dec. 11, 1967, pp. 90-95.
Since then, Xilinx Inc., Actel Inc., Pilkington Micro-electronics Ltd. and Concurrent Logic, Inc., among others, have proposed implementations of CLA devices.
The basic Xilinx CLA architecture is disclosed in U.S. Pat. No. 4,870,302, which issued to Ross H. Freeman on Feb. 19, 1988.
The CLA device described by the Xilinx '302 patent and shown in FIG. 1 includes an array of configurable logic elements that are variably interconnected in response to control signals to perform selected overall logic functions. Each configurable element in the array is capable of performing a number of logic functions depending upon the control information provided to that element. The array can have its function varied at any time by changing its control information.
FIG. 2 shows a CLA interconnect structure currently utilized in the Xilinx array. In addition to the single-length interconnect lines between logic elements, as shown in FIG. 2, the Xilinx array utilizes lines that connect switch matrices, e.g., two vertical and two horizontal double-length lines per logic-element column. The Xilinx array also utilizes "global" interconnect lines, e.g., six vertical global lines and six horizontal global lines per logic-element column, for clocks, resets and other global signals. Two of the horizontal global lines may be placed in a high impedance state.
FIG. 3 shows a logic-element currently utilized in the Xilinx array. The Xilinx logic element has three function generators, two flip-flops, and several multiplexers. The first two function generators can perform a Boolean function of four inputs. The function generators are implemented as memory look-up tables. The outputs of these two function generators are provided to the multiplexers and to a three-input function generator which can perform a Boolean function of G', F', and an external input. The output of the third function generator is also provided to the multiplexers. The multiplexers select whether the signals are provided to the output of the logic element or to the input of the flip-flops. The flip-flops have common clock, enable, and set or reset inputs. The configuration bits that determine the function of the logic element also determine how the C1 through C4 inputs are mapped into the four inputs. H1, DIN, S/R, and EC.
The basic Pilkington CLA architecture is disclosed in U.S. Pat. No. 4,935,734, which issued to Kenneth Austin on Sep. 10, 1986.
An implementation of the CLA architecture disclosed in the Pilkington '734 patent is shown in FIG. 4. Each logic element in the Pilkington array accepts inputs from four other logic elements in the illustrated pattern. Each logic element output drives multiple other elements as illustrated. In the array disclosed in the '734 patent, there is no additional wiring. However, the Plessey Company, under license from Pilkington, has marketed a product wherein bus wiring is added as shown in FIG. 4; i.e. in every third column, a bus provides inputs to every right-direction logic element in that column, and every third row has a bus providing inputs to every left-direction logic element in that row.
FIG. 5 shows a logic cell currently utilized in the FIG. 4 array. As shown in FIG. 5, each of the two inputs to a NAND gate are provided by a user configured multiplexer the inputs of which are provided by other logic elements or inputs. Plessey has also added circuitry to the logic element to permit it to be a latch or a 2-input NAND gate.
The basic Actel CLA architecture is disclosed in U.S. Pat. No. 4,873,459, issued to El Gamal et al on Oct. 10, 1989.
The Actel architecture relies on one-time programmable anti-fuses for configurability and, thus, is not re-programmable.
The Concurrent Logic, Inc. (CLI) CLA architecture, which is most relevant to the present invention, is discussed below in conjunction with FIGS. 6-17. Features of the CLI CLA architecture are disclosed in the following U.S. patents issued to Frederick C. Furtek: U.S. Pat. No. 4,700,187, issued Oct. 13, 1987; U.S. Pat. No. 4,918,440, issued Apr. 17, 1990; and U.S. Pat. No. 5,019,736, issued May 28, 1991.
As discussed in above-cited related application Ser. No. 07/608,415, a CLA may be viewed as an array of programmable logic on which a flexible bussing network is superimposed. As shown in FIG. 6, the heart of the CLI CLA 10 is a two-dimensional array of logic cells 12 each of which receives inputs from and provides outputs to its four adjacent neighbors. The core logic cell 12, which is shown in detail in FIG. 7, can be programmed to provide all the wiring and logic functions needed to create any digital circuit.
Each logic cell 12 in the array, other than those on the periphery, receives eight inputs from and provides eight outputs to its North (N), East (E), South (S), and West (W) neighbors. These sixteen inputs and outputs are divided into two types, "A" and "B", with an A input, an A output, a B input and a B output for each neighboring cell 12. Between cells 12, an A output is always connected to an A input and a B output is always connected to a B input.
As further shown in FIG. 7, within a cell 12, the four A inputs enter a user-configurable multiplexer 14, while the four B inputs enter a second user-configurable multiplexer 16. The two multiplexer outputs feed the logic components of the cell 12. In logic cell 12, these components include a NAND gate 18, a register 20, an XOR gate 22, and two additional user-configurable multiplexers 24 and 26.
The two four-input multiplexers 24 and 26 are controlled in tandem (unlike the input multiplexers), giving rise to four possible logic configurations, shown in FIGS. 8A-8D.
In the FIG. 8A configuration, corresponding to the "0" inputs of the multiplexers 24 and 26, the A outputs are connected to a single A input and the B outputs are connected to a single B input.
In the FIG. 8B configuration, corresponding to the "1" inputs of the multiplexers 24 and 26, the A outputs are connected to a single B input and the B outputs are connected to a single A input.
In the FIG. 8C configuration, corresponding to the "2" inputs of the multiplexers 24 and 26, the A outputs provide the NAND and the B outputs the XOR of a single A input and a single B input. This is the equivalent of a half adder circuit.
In the FIG. 8D configuration, corresponding to the "3" inputs of the multiplexers 24 and 26, the Q output of edge-triggered D flip-flop 20 is connected to the A outputs, the D input of the flip-flop 20 is connected to a single A input, the enable (EN) input of the flip-flop 20 is connected to a single B input and the B outputs provide the logical constant "1". A global clock input and register reset are provided for this configuration, but are not illustrated in FIG. 8D. This configuration is equivalent to a one bit register.
The cell 12 thus provides the most fundamental routing and logic functions: extensive routing capabilities, NAND and XOR (half adder), a one-bit register, the logical constant "1" and fan-out capabilities.
These functions permit the basic CLA array 10 to implement arbitrary digital circuits. A register and half adder (NAND and XOR) included in each cell 12, together with a high cell density, make the array 10 well adapted for both register-intensive and combinatorial applications. In addition, signals passing through a cell 12 are always regenerated, ensuring regular and predictable timing.
Although the basic logic array 10 is completely regular, routing wires through individual cells 12 can cause increased delays over long distances. To address this issue, the neighboring interconnect provided by the array 10 is augmented with three types of programmable busses: local, turning, and express.
Local busses provide connections between the array of cells and the bussing network. They also provide the wired-AND function.
Turning busses provide for 90° turns within the bussing network, enabling T-intersections and corners. Turning busses provide faster connections than do local busses, since they do not have the delays associated with using a cell as a wire.
Express busses are designed purely for speed. They are the fastest way to cover straight-line distances.
There is one bus of each type described above for each row and each column of logic cells 12 in the array 10. Connective units, called repeaters, are spaced every eight cells 12 and divide each bus into segments spanning eight cells 12. Repeaters are aligned into rows and columns, thereby partitioning the basic array 10 into 8×8 blocks of cells 12 called "superblocks". FIG. 9 illustrates a simplified view of a bussing network containing four superblocks. Cell-to-cell connections are not shown.
As shown in FIG. 10, each local bus segment 13 is connected to eight consecutive cells 12. As shown in FIG. 11, each turning bus segment 15 is connected to eight orthogonal turning busses through programmable turn points. As shown in FIG. 12, each express bus segment 17 is connected only to the repeaters at either end of the 8×8 superblock. FIG. 13 shows the three types of busses combined to form the bussing network of the array 10.
In order for the bussing network to communicate with the array 10, each core logic cell 12 is augmented as shown in FIG. 14 to permit the reading and writing of local busses L. The cell 12 reads a horizontal local bus through the "L X " input of the B input multiplexer 16 and reads a vertical local bus through the "L Y " input of the B input multiplexer 16. The cell 12 writes to a local bus through the driver 28 connected to the A output.
While the cell 12 may read either a horizontal or a vertical bus under program control, the cell 12 may write to only one bus of fixed orientation. Whether a cell 12 writes to a horizontal or vertical bus is determined by its location with the array 10. Referring back to FIG. 10, the cell 12 in the upper-left corner of the illustrated superblock writes to a horizontal local bus. If a particular cell 12 writes to a horizontal local bus, then its four immediate neighbors write to vertical local busses, and vice versa.
As shown in FIG. 13, the two types of cells 12 are thus arranged in a checker-board pattern where the black cells 12 write to horizontal busses and the white cells 12 write to vertical busses.
The CLA busses can be driven by the bus driver 28 in two ways. The bus driver 28 has two control bits, "TS" and "OC" which provide high impedance and open-collector capabilities, respectively. The high impedance capability, which is independently programmable for each cell 12, allows the bus driver to be disconnected from the bus when the cell 12 is not being used to write to the bus.
The open-collector capability provides the wired-AND function when multiple cells 12 are driving the same local-bus simultaneously. Unlike the high impedance function, which is controlled at the cell level, the open-collector function is controlled at the bus level; all cells 12 driving the same local bus are in the same open-collector state. The programming environment insures that if there is exactly one driver 28 driving a local bus, then that driver 28 provides active pull-up and active pull-down. (The open-collector capability is turned off.) In all other cases, the drivers 28 driving a local bus provide passive pull-up and active pull-down. (The open-collector capability is turned on.)
In the special case when there are no drivers 28 driving a local bus (that is, when the bus is not used), the open-collector capability is turned on and the bus is pulled high through the passive pull-up resistor. An unused local bus, therefore, provides a logical "1" to those cells reading the bus.
As stated above, repeaters provide connections between busses. Each repeater is programmable so that any bus on one side of a repeater can be connected to any bus on the other side of the repeater, as shown in FIG. 15. Each connection is unidirectional (direction is not depicted in FIG. 15) since repeaters always provide signal regeneration. The direction, like the connection itself, is programmable. Including direction, there are 18 (2×9) repeater configurations providing one connection, 72 (4×18) providing two connections, and 48 (8×6) providing three connections.
As shown in FIG. 16, logic 19 for distributing clock signals to the D flip-flops 20 in the logic cells 12 is located along one edge of the array 10. The distribution network is organized by column and permits columns of cells 12 to be independently clocked. At the head of each column is a user-configurable multiplexer 30 providing the clock signal for that column. There are four inputs to each multiplexer 30: an external clock supplied from off chip, the logical constant "0", the express bus adjacent to the distribution logic, and the A output of the cell 12 at the head of the corresponding column.
Through the global clock, the network provides low-skew distribution of an externally supplied clock to any or all of the columns of the array 10. The constant "0" is used to reduce power dissipation in columns containing no registers. The express bus is useful in distributing a secondary clock to multiple columns when the external clock line is used as a primary clock. The A output of a cell is useful in providing a clock signal to a single column.
All D flip-flops 20 of the cells 12 of the array 10 may be globally reset through an externally supplied signal entering the RESET control pin.
The CLA array 10 provides a flexible interface between the logic array, configuration control logic and the I/O pads of the CLA device. As shown in FIG. 17, two adjacent cells, an "exit" cell 12a and an "entrance" cell 12b, on the perimeter of the logic array are associated with each I/O pad 32. The A output of the exit cell 12a is connected, under program control, to an output buffer 34. The edge-facing A input of the adjacent entrance cell 12b is connected to an input buffer 36. The output of the output buffer 34 and the input to the input buffer 36 are both connected to the I/O pad 32. Control of the I/O logic is provided by various control signals and bits, as shown in FIG. 17.
While the CLA array 10 described above provides a wide range of configuration options, it would be desirable to have available a CLA device that provides an even greater level of programmable flexibility.
The present invention provides a configurable logic array that includes a plurality of individually configurable logic cells arranged in a matrix that includes a plurality of horizontal rows of logic cells and a plurality of vertical columns of logic cells. The array further includes at least one horizontally aligned local bus running between adjacent rows of logic cells, the logic cells in the adjacent rows being connectable thereto, and at least one vertically aligned local bus running between adjacent columns of logic cells, the logic cells in the adjacent columns being connectable thereto. The array further includes a dynamic tristate bus driver associated with each logic cell and connectable to the local busses associated with the corresponding logic cell and means for controlling the dynamic tri-state driver through one or more combinations of inputs to the logic cell.
A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description and accompanying drawings which set forth an illustrative embodiment in which the principles of the invention are utilized.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a portion of a first type of conventional configurable logic array architecture.
FIG. 2 is a schematic diagram illustrating a cell-to-cell interconnect structure utilizable in the FIG. 1 CLA array.
FIG. 3 is a logic diagram illustrating a logic cell utilizable in the FIG. 1 CLA array.
FIG. 4 is a logic diagram illustrating a portion of a second type of conventional configurable logic array architecture.
FIG. 5 is a logic diagram illustrating a logic cell utilizable in the FIG. 4 CLA array.
FIG. 6 is a block diagram illustrating a portion of third type of conventional configurable logic array.
FIG. 7 is a logic diagram illustrating a logic cell utilizable in the FIG. 6 CLA array.
FIGS. 8A-8D are simple logic diagrams illustrating four possible logic configurations of the FIG. 7 logic cell.
FIG. 9 is a schematic diagram illustrating a bussing network for the FIG. 6 CLA array.
FIG. 10 is a schematic diagram illustrating local bus segments for the FIG. 9 bussing network.
FIG. 11 is a schematic diagram illustrating turning bus segments for the FIG. 9 bussing network.
FIG. 12 is a schematic diagram illustrating express bus segments for the FIG. 9 bussing network.
FIG. 13 is a schematic diagram illustrating the combination of the local, turning and express bus segments of the FIG. 9 bussing network.
FIG. 14 is a schematic diagram illustrating the FIG. 7 logic cell augmented to permit read/write of local busses.
FIG. 15 illustrates the multiple possible repeater configurations for inter-bus connections in the FIG. 9 bussing network.
FIG. 16 is a block diagram illustrating clock distribution logic utilizable in the FIG. 6 CLA array.
FIG. 17 is a logic diagram illustrating "exit" and "entrance" cells associated with each I/O pad of the FIG. 6 CLA array.
FIG. 18 is a block diagram illustrating a portion of a configurable logic array in accordance with the present invention.
FIG. 19 is a block diagram illustrating the bus turning capability of a logic cell of the FIG. 18 CLA array.
FIG. 20 is a schematic representation illustrating the interface between a cell and local busses in the FIG. 18 CLA array.
FIG. 20A is a schematic representation illustrating an alternate interface between a cell and the local buses of the FIG. 18 CLA array.
FIG. 21 is a schematic representation illustrating the implementation of individual control of the local busses in the FIG. 18 CLA array
FIG. 22 is a block diagram illustrating express busses in the FIG. 18 CLA array.
FIG. 23A is a schematic representation illustrating utilization of repeaters in the FIG. 18 CLA array.
FIG. 23B is a schematic representation illustrating repeaters utilized in the FIG. 18 CLA array.
FIG. 24 is a schematic representation illustrating diagonal connections between abutting logic cells in the FIG. 18 CLA array.
FIG. 25 is a schematic representation illustrating diagonal local busses in the FIG. 18 CLA array.
FIG. 26 is a functional diagram illustrating a logic cell utilizable in the FIG. 18 CLA array.
FIG. 27 illustrates sixteen basic configurations of the FIG. 26 logic cell.
FIG. 28 is a schematic representation of a possible modification to the FIG. 26 logic cell.
FIG. 29 is a logic diagram illustrating an alternate embodiment of a logic cell utilizable in the FIG. 18 CLA array.
FIG. 30 is a logic diagram illustrating a tristatable output buffer circuit utilizable in the FIG. 18 CLA array.
FIG. 31 is a schematic representation of the sequential configuration of multiple CLA arrays of the type shown in FIG. 18.
FIG. 32 is a schematic diagram illustrating a power up sensing circuit utilizable in the FIG. 18 CLA array.
FIG. 33 is a graph illustrating the hysteresis of the FIG. 32 power up sensing circuit.
FIG. 34 is a block diagram illustrating edge core cells and I/O cells in the FIG. 18 CLA array.
FIG. 35 is a block diagram illustrating express bus I/O cells in the FIG. 18 CLA array.
FIG. 36 is a block diagram illustrating configuration logic for the FIG. 18 CLA array.
FIG. 37 is a schematic representation illustrating the loading of a configuration file into the internal configuration SRAM within the FIG. 18 CLA array.
FIG. 38 is a schematic representation illustrating the bit sequential, internal clock configuration mode of the FIG. 18 CLA array.
FIG. 39 is a schematic representation illustrating the bit sequential, external clock configuration mode of the FIG. 18 CLA array.
FIG. 40 is a schematic representation illustrating the cascaded configuration of multiple CLAs of the type shown in FIG. 18,
FIG. 41 is a schematic representation illustrating the parallel configuration of multiple CLAs of the type shown in FIG. 18.
FIG. 42 is a schematic representation illustrating the address count-up, internal clock configuration mode of the FIG. 18 CLA array.
FIG. 43 is a schematic representation illustrating the address count-up, external clock configuration mode of the FIG. 18 CLA array.
FIG. 44 is a schematic representation illustrating the byte-sequential, external clock configuration mode of the FIG. 18 CLA array.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 18 shows a configurable logic array 100 comprising a matrix of individual programmable logic cells 102. As shown by the "typical" logic cell 102 in FIG. 18, each logic cell 102 receives eight inputs from and provides eight outputs to its North (N), East (E), South (S) and West (W) neighbors.
These sixteen inputs and outputs are divided into two types, "A" and "B" with an A input, an A output, a B input and a B output for each neighboring cell. Between cells 102, an A output is always connected to an A input and a B output is always connected to a B input.
As further shown in FIG. 18, the CLA array 100 includes two local busses L N , L S in the x direction and two local buses L E , L W in the y direction running between each row and column of cells 102, respectively, in the array 100. Thus, each cell 102 has access to four local busses. The local busses allow efficient interconnections between cells 102 that are not nearest neighbors cells in the same row or column.
Any of these local busses may be active within any given cell 102. However, a cell's connections to local busses must be selected either only as inputs or only as outputs if they are used at all by the cell 102, except when used as a bus-to-bus connection or when the FIG. 21 alternative scheme, described below, is used. If selected as inputs, then only one of the local busses can be enabled. If selected as outputs, then a cell 102 can drive up to all four of its accessible local busses.
As shown in FIG. 19, a cell 102 may allow a turn from a local bus L N , L S running in the x direction to a local bus L E , L W running in the y direction. This type of connection is useful when two non-neighboring cells 102 must be connected to one another and the cells 102 are not in the same row or the same column. In this case, the cell 102 that facilitates the turn cannot use the local busses as an input or an output. If a cell 102 is using its local busses for anything other than an input, then the output of the local bus input mux (Lin in FIG. 26) is forced to a "1."
FIG. 20 shows the functional implementation of the interface between a cell 102 and the local busses.
As shown in FIG. 20, a cell 102 can drive signal A onto any combination of its associated local busses, L N , L S , L E and L W by activating various combinations of the transmission gates controlled by signals CL N , CL S , CL E , CL W and CL OUT . A cell 102 can receive input from any one of its associated local busses L N , L S , L E and L W by activating the transmission gate controlled by signal CL IN along with activating one of the transmission gates controlled by signals CL N , CL S , CL E , and CL W . If signal CL IN disables its transmission gate, then p-channel pullup transistor P provides a logic "1" level on signal Lin.
If the transmission gates controlled by signals CL OUT and CL IN are both disabled, then the local bus interface shown in FIG. 20 can facilitate a connection from any of its associated local busses to any or all others. This capability allows turns from a horizontal local bus to a vertical local bus.
The cell/bus connection scheme shown in FIG. 20 can be extended to accommodate a larger number of busses and to allow multiple simultaneous turns between horizontal and vertical busses.
FIG. 20A illustrates an interface scheme that assumes four horizontal local buses (EW0, EW1, EW2 and EW3) and four vertical local buses (NS0, NS1, NS2 and NS3). For each pair of corresponding busses, e.g. NS0 and EW0, there are three bidirectional pass gates connected in a tree, as illustrated. Each of the eight upper pass gates, i.e. those connected directly to the busses, are controlled by a separate configuration bit. The four lower pass gates, i.e. those connected directly to the cell, may be controlled either by individual bits or, in order to conserve configuration bits, by control signals derived from the configuration bits controlling the upper pass gates.
For example, assume that "A" and "B" are the configuration bits controlling the upper pass gates associated with NS0 and EW0, respectively. Then either A XOR B or A NAND B can be used to control the corresponding lower pass gate. Note that, in both cases, the lower pass gate is turned off when both upper pass gates are turned on -- this is a bus turn. Note also that when exactly one of the upper pass gates is turned on, the lower pass gate is also turned on -- this is either a read or a write to the cell. When both upper pass gates are turned off, the state of the lower pass gate is a "don't care".
As in the FIG. 20 scheme, the FIG. 20A scheme uses the same pass gates for both reading and writing. In addition, however, it is now possible to have up to four simultaneous bus turns when the cell is not accessing the bus, or up to three simultaneous turns when the cell is accessing the bus.
Alternatively, as shown in FIG. 21, rather than constraining all four local bus connections to all being inputs or all being outputs, configuration memory and multiplexors can be added so that the bus connections can be individually controlled. In this way, one bus connection could be an input and, simultaneously, another bus connection could be an output in situations other then bus-to-bus connections. This would reduce the number of cells 102 required for routing in the array 100.
As shown in FIG. 22, in addition to the local busses described above, the array 100 includes two express busses X N , X S running in the x direction and two express busses X E , X W running in the y direction between each row and column, respectively, of cells 102 in the array 100. Each express bus is associated with one local bus. Entry to/from an express bus is only possible from/to its associated local bus at the repeater.
As shown in FIG. 23A, repeaters R are spaced eight cells 102 apart. A block of cells 102 surrounded by repeaters R is referred to as a "superblock". An express bus allows a signal to travel a distance of eight cells 102 without additional variable loads, giving it the highest speed possible for the full length of the superblock.
Repeaters R are used to regenerate bus signals and to drive the different bus segments at the superblock interface. A repeater R is shown in FIG. 23B. Under configuration control, the following paths in the repeater are possible:
______________________________________Description: Path in FIG. 23B______________________________________Local Bus L1 drives Local Bus L2 D1-PG3Local Bus L2 drives Local Bus L1 D3-PG6Express Bus X1 drives Express Bus X2 D2-PG5Express Bus X2 drives Express Bus X1 D4-PG8L1 drives Local Bus L2 & Express Bus X2 D1-PG3 & PG2L2 drives Local Bus L1 & Express Bus X1 D3-PG6 & PG7X1 drives Express Buss X2 & Local Bus L2 D2-PG5 & PG4X2 drives Express Buss X1 & Local Bus L1 D4-PG8- & PG9Local Busses L1 & L2 are single PG1 bidirectional bus (This latter path can be used to make a long busses spanning multiple repeaters.)______________________________________
Additionally, as shown in FIG. 24, the CLA array 100 can include diagonal interconnections between abutting cells 102. With diagonal cell interconnection, a substantially smaller number of cells 102 are used by certain macros for interconnections, thereby improving performance and gate array utilization and increasing the interconnect resources.
As shown in FIG. 24, data flows diagonally from left to right. Each cell 102 requires an additional input to the input mux and an additional output to the bottom right. The diagonal interconnect concept can be extended to data flowing diagonally from right to left (top to bottom), left to right (bottom to top) and right to left (bottom to top).
As shown in FIG. 25, the array 100 can include an additional set of local vertical buses and an additional set of local horizontal busses. However, instead of these busses being purely vertical and horizontal, as in the case of the local busses discussed above, this second set of local busses runs diagonally. Thus, as shown in FIG. 25, one set of these busses attaches to the cell's East side and one attaches the cell's South side. In this architecture, every cell 102 is capable of driving each of the busses to which it is attached. In this arrangement, each cell 102 in the array 100 can connect more easily to nearby cells 102 in a diagonal direction, a very useful feature in compute-intensive algorithms and in random logic.
Each programmable function of the CLA 100 is controlled by one or more transistor pass gates, each of which has its pass-or-block state determined by the state of a memory bit, either directly or through a decoder. All of these registers are collectively referred to as SRAM Configuration Data Storage. The advantage of an SRAM (Static Random Access Memory), as opposed to a ROM (Read Only Memory), in this application, is that the configuration data can be changed a virtually unlimited number of times by simply rewriting the data in the SRAM.
The functional diagram for an embodiment of the logic cell 102 is shown in FIG. 26. It consists of five 4:1 muxes, (shown in pass-gate form), cell function logic, and 4 high impedance local bus connectors (also shown in pass-gate form) drivers. Three of the 4:1 muxes determine the A, B, and L inputs to be used by the cell function logic. If no input to a mux is selected, then the output of the mux is forced to a logical "1" state. The cell function logic implements the function to be applied to the A, B and L inputs and supplies the result to the A and B output muxes. The four pass gates connecting the cell to the local busses allow the cell 102 to drive its corresponding local busses or receivers signals from the busses.
The application of the illustrated technology uses 16 bits of SRAM for each cell's configuration memory address space to define the functionality of the FIG. 26 logic cell 102. Fourteen bits are used for input and output multiplex control. The remaining two bits are used to determine the cell's use of its associated local busses. These two bits (BUS0, BUS1), combined with the number of local busses enabled for a given cell, determine the function of the local busses within the cell, as shown in Table I below. If BUS0 is a "1", then either 1 or 2 of the local busses must be selected. Otherwise, any number of local busses may be selected, within the dictates of Table I.
TABLE I______________________________________ Local bus L's en- function TRI-STATEBUS0 BUS1 abled within cell Li Control______________________________________0 0 0 not used "1" "0"(disabled)0 0 1-4 output "1" "0"(enabled0 1 0 not used "1" "0"0 1 1-4 output "1" Bin1 0 1 input enabled L "0"1 0 2 x/y turn "1" "0"1 1 1 mux select enabled L "0"1 1 2 x/y turn "1" "0"______________________________________
The function of the cell's control/configuration bits is described in Table II below.
TABLE II__________________________________________________________________________SIGNALS # OF BITS DESCRIPTION__________________________________________________________________________CAN, CAS 4 A Input mux selects (zero or one enabled)CAE, CAWCBN, CBS 4 B Input mux selects (zero or one enabled)CBE, CBWCLN, CLS 4 L enables (any number, per Table I)CLE, CLWBUS0, BUS1 2 Determines local bus function within cellCFUN0, CFUN1 2 A and B output function select__________________________________________________________________________
Thus, there are sixteen primary functional configurations of the CLA cell 102, based on the sixteen possible combinations at signals CFUN1, CFUN2, BUS0 and BUS1. FIG. 27 shows the functional diagrams of these sixteen configurations.
Other applications of this technology may use more (or less) than 16 SRAM configuration bits per cell, e.g. to switch the connections of additional busses.
FIG. 28 shows a possible modification to the FIG. 26 logic cell 102 that allows the high impedance control signal to be input over the local bus through the L mux. Additionally, both the local bus input and the B input of the cell can be used for control of the high impedance state. This allows the user the flexibility of using either of the inputs for high impedance control, thereby saving cells used for wiring. As shown in FIG. 28, the high impedance control signal is provided by the output of OR gate 104. The L-mux and B-mux outputs, with the high impedance enable signal, are inputs to the OR gate 104. This facilitates using either the local bus inputs (through the L-mux) or the B inputs (through the B-mux) as the high impedance control signal.
FIG. 29 shows an alternative embodiment of logic cell 102. The alternate cell utilizes six-state output muxes, giving the user the flexibility of obtaining the outputs of the XOR, Flip-Flop, NAND and AND functions on either the A output or B output of the cell. Therefore, the user does not have to use an extra cell as a cross-wire for routing to switch the A output to the B output and vice versa.
The alternate cell shown in FIG. 29 requires one extra configuration bit to provide the extra control required for both the A output mux and the B output mux. This extra bit is accommodated by decoding the control signals for all of the input muxes, as shown in FIG. 29. If cell space is a limitation, then only one input mux must be changed to decoded control (3 lines) signals, with the other two input muxes using undecoded control signals (4 lines).
FIG. 30 shows an embodiment of a high-performance, high impedance output buffer circuit 106, with reduced groundbounce, that is utilizable in conjunction with the CLA array 100. The output buffer circuit 106 compensates output buffer slew-rate for process and temperature variation to reduce groundbounce with minimal performance impact.
The output buffer 106 is designed to reduce groundbounce by staging the turn on of the upper transistors (P1, P2, P3, . . . Px) and lower output transistors (N1, N2, N3, . . . Nx).
The delays between stages are created by transmission gates (TP1, TP2, TP3, TN1, TN2, TN3) in series with capacitors connected at the gates of the output transistors. These transmission gates tend to compensate the output buffer's slew rate for variations in processing and temperature. Under conditions that would normally cause the output transistors to have highest current carrying capability and, thus, fastest slew rate and greatest groundbounce, the transmission gates will have lowest impedance and thus allow the capacitors to which they are connected to have maximum effect. Under conditions that would normally cause the output transistors to have lowest current-carrying capability and, thus, slowest slew rate, the transmission gates will have highest impedance and thus tend to isolate their corresponding output transistors from the capacitors to which they are connected. The benefit of this is that, for a given level of groundbounce under fast conditions, the maximum delay of the output buffer under slow conditions can be less than that possible using conventional, non-compensating techniques.
FIG. 32 shows an embodiment of a power-up sensing circuit 108 utilizable with the CLA array 100. The purpose of circuit 108 is to create a reset signal for the internal logic of the CLA array 100 when the power supply ramps, independent of the ramp rate.
The power-up circuit 108 detects power applied to the CLA device by monitoring the VCC signal. After VCC reaches the level of two n-channel Vts, the PWRERRN signal goes low and stays low until VCC reaches the level of two n-channel and two p-channel Vts. The PWRERRN signal can thus be used as a reset signal for the CLA device to ensure that the device is in a known state after power up. When the PWRERRN signal goes high, the VCC level necessary to keep PWRERRN high changes to 2 n-channel and 1 p-channel Vts. This hysteresis quality, illustrated in FIG. 33, means that power supply spikes down to 2 n-channel and 1 p-channel Vt can be tolerated without resetting the chip.
Referring to FIG. 32, the power-up sensing circuit 108 works as follows. N-channel transistors 110, 112, 114 and 116 make up a comparator, with the gates of transistors 112 and 116 being the comparator inputs. N-channel transistors 118 and 120 have very large gate widths, while P-channel transistor 122 is very small. This will result in the gate of transistor 112 being clamped at (2*Vth,n) above ground for Vcc>(2*Vtn,n). Both P-channel transistor 124 and P-channel transistor 126 are very large and N-channel transistor 128 transistor is very small. This would make the input to the transistor 116 gate (2*Vth,p) less than Vcc, for Vcc>(2*Vtn,P). As Vcc ramps up, while the Vcc to GND voltage is less than (2*Vth,p+2*Vth,n) the transistor 112 gate will be at a higher potential than the transistor 116 gate. This will result in the comparator output (m) providing a logic "1" level to the input of inverter 130 input causing the power up signal to be at a logic "0" level. Once the Vcc to GND potential exceeds (2*Vth,n+2*Vth,p) the transistor 112 gate will be lower than the transistor 116 gate. This will cause the (m) node to be at a logic "0" level, and the power up output to be at a logic "1" level. This indicates that the power is at a sufficient level to support proper device operation. Hysteresis is provided by P-channel transistor 132. When the gate of transistor 132 is high, transistor 132 is disabled, and the circuit operates as described above. After node (m) goes low, the gate of transistor 132 will be pulled to ground by inverter 134. Thus, transistor 132 will effectively short the source of transistor 126 to its drain, thereby lowering the Vcc to GND voltage needed to cause node (m) to be at a logic "1" level to (2*Vtn,P). Therefore, the Vcc to GND differential will have to fall to (1*Vth,p) plus (2*Vth,n) before the power up signal provided by inverter 136 will go low.
In accordance with another aspect of the CLA device 100 architecture, I/O cell pins are provided that are connected directly to the array's express busses in addition to the edge core cells.
As stated above, the architecture of the CLA device 100 comprises a regular array of logic cells 102. I/O pins in I/O cells are attached uniformly around the periphery of the array. An I/O cell is connected to two adjacent edge core cells 102 of the array.
FIG. 34 shows an example of pin Pw23 in an I/O cell connected to two core cells 102 on the west edge of the array 100. The input buffer Cin of the Pw23 I/O cell is connected to an A input of an edge core cell via wire Aw12. The output buffer Cout is connected to an A output of an adjacent edge core cell via wire Aw13. Placing of the output buffer Cout in the high impedance state can be controlled by configuration (always enabled or disabled) or by signals on a horizontal or vertical buss, Ls3 or Lw1 respectively.
Express busses running horizontally and vertically are connected to A or B inputs and outputs of edge core cells (e.g. express busses Es1, En1, Es2, En2, Es3 and En3 in FIG. 34).
In a modified architecture, a new type of I/O cell is added. These new express bus I/O cells connect directly to the express busses instead of being connected to a core cell. FIG. 35 shows an example of an express bus I/O cell Pw12 adjacent to I/O cell Pw23.
The express bus I/O cells make only minor modifications in the architecture of the CLA device 100. As in the regular I/O cells, high impedance is controlled at configuration or by the horizontal and vertical local busses Lw1 and Ls2, respectively. Unlike the regular I/O cell, however, input buffer Cin and output buffer Cout are connected directly to express busses En1 and Es2, respectively, and the express bus links that previously went to the core cells are disconnected from the express busses; for example, express bus Es2 is not connected to A output A12 and express bus En1 is not connected to A input Aw11.
The addition of the express bus I/O cells allows direct access to express busses, thus improving access to interior regions of the array 100 and improving its cross-point switch capabilities.
FIG. 36 shows a block diagram of the configuration logic for the CLA array 100.
The device pins required for configuration of the CLA array 100 are as follows:
The dedicated pins are:
/Con Configuration Request Pin (Open collector I/O). This pin is pulled low along with /Cs by the user to initiate configuration. Once the device has begun configuration, it will drive /Con low until configuration is complete. The device will also pull /Con low during the power-up and reset sequences. The chip will auto-configure in modes 4 and 5 (as shown in Table III).
/Cs Chip Select (Input). Must be pulled low with /Con to initiate configuration or reset.
Cclk Configuration Clock (Input/output). This signal is the byte clock in Address modes, and the bit clock in bit-sequential modes. In the byte-sequential mode, this pin is used as an active low write strobe. In direct-Address mode, this is an active low data strobe. Cclk is not used during configuration reset. The device drives Cclk during configuration in modes 4 and 5 with a frequency between 1 and 1.5 MHz. In all other modes, Cclk is an input, with a maximum frequency of 16 MHz. Note that cascaded programming will not work in byte-sequential or Address modes with as Cclk of over 1 MHz.
The Mode pins M2, M1, M0 (input) are used to select the configuration mode, as described in Table III.
TABLE III______________________________________M2 M1 M0 Description of Modes______________________________________0 0 0 Configuration Reset0 0 1 Address, Count up, external CCLK0 1 0 Address, Count down, external CCLK0 1 1 Bit-Sequential, external CCLK1 0 0 Bit-Sequential, internal CCLK1 0 1 Address, Count up, internal CCLK1 1 0 Byte-Sequential, external CCLK as write strobe1 1 1 Direct Addressing, external CCLK as data strobe______________________________________
The dual-purpose pins are:
D0 Data pin (Input/Output). This pin is used as serial data input pin, and as the LSB in byte-sequential, direct addressing and Address modes. Used as an I/O only in direct address mode.
D1-7 Data pins (Input/Output). These pins are used as data input pins in byte-sequential and Address modes and as I/O only in direct address mode.
A0-16 Address pins (Input/Output). 17 bits of address are used as outputs during Address modes for accessing external memory. 13 bits are also used as internal address inputs for the configuration RAM in direct address mode.
/Cen Chip enable (Output). This signal is driven low by the device during configuration in byte-sequential and Address modes. It can be disabled by setting configuration register bit B2. It is used for the Output Enable (OE) and Chip Enable (CE) of parallel EPROMs.
/Check Enables Check configuration (Input). This pin enables checking of the configuration RAM against data on input pins. If this pin is enabled, then writing configuration data is disabled. This pin is disabled during the first configuration after power-up or reset, and whenever configuration register bit B3 is set. In direct address mode, this pin selects whether data is being written to or read from the configuration RAM.
/Err Error (Output). This output is driven low if there is a configuration error, a configuration RAM addressing error, or an incorrect preamble or postamble at the end of a block of configuration data. It also signals the result of the configuration check, selected when /Check is low. This output is disabled when configuration register bit B3 is set.
Dout Data out (Output). This pin provides the data output to another CLA device during cascaded programming. It can be disabled by setting configuration register bit B2.
Clkout Clock out (Output). This pin provides the clock output to another CLAY during cascaded programming. It can be disabled by setting configuration register bit B2.
Testclk Test clock (Input). This pin overrides the internal oscillator after a certain reserved configuration bit is set to logical "1". This feature is used for internal testing purposes.
The CLA array 100 can be in either an operational state or in a configuration state. After initial configuration, the device moves into the operational state. It can be pulled back into the configuration state by assertion of the "/Con" and "/Cs" inputs.
The configuration file, in a cascaded programming environment, is shown in Table IV below. The first CLA device in the cascade receives the Preamble. This is followed by the contents of the configuration register, an optional external memory address, and the number of windows in the first CLA device that need to be programmed. The start/stop addresses for each window and the configuration data follow. The configuration data (including header) for the cascaded devices are appended to the file. If the configuration register specifies that the device needs to load an external memory address, then this address is loaded every time it encounters that field. When the master has finished configuring itself, it looks for a preamble or postamble. If it finds a postamble, then configuration is complete. If it receives a preamble, then it passes on the data and clock to configure the next CLA device in the cascade.
TABLE IV______________________________________Preamble (1 byte)Config reg contents for first device (1 byte)External Memory Address (3 bytes)Number of windows to be programmed (1 byte)Reserved Byte (1 byte)Start address of window number 1 (2 bytes)End address of window number 1 (2 bytes)Bytes of data for window number 1 (1 byte each)Start address of window number n (2 bytes)End address of window number n (2 bytes)Bytes of data for window number n (1 byte each)Preamble (1 byte)Config reg contents for cascaded device (1 byte)External Memory Address (for first device) (3 bytes)Reserved Byte (1 byte)Number of windows to be programmed (1 byte)Postamble (1 byte)______________________________________
The first CLA device loads itself until it exhausts the number of windows it has to configure. Any data after this and within the configuration file is used for cascaded devices. At the end of configuration, the external memory address counter in the first device is either reset or stored at the current value depending on the state of bit 0 in the configuration register. The preamble is "10110010" and the postamble is "01001101". Serial data is transmitted LSB first.
The clock description for each mode is shown in Table V below.
TABLE V______________________________________M2 M1 M0 Clkout CSM CCLK______________________________________0 0 0 NA NA NA0 0 1 osc cclk input0 1 1 cclk cclk input1 0 0 cclk cclk osc/81 0 1 osc cclk osc/81 1 0 osc /wr /wr1 1 1 NA NA /DS______________________________________
Osc is the internal oscillator which runs between 8 and 12 MHz.
/WR is the Cclk input used as a write strobe.
/DS is the Cclk input used as a data strobe.
In modes 1, 2, and 6, data is output on the Dout pin along with the clock on the clkout pin. The configuration scheme allows the user to provide a Cclk at up to 16 MHz for these modes. However, for cascaded programming and other applications where Clkout and Dout are required, the speed of Cclk must be less than 1 MHz in these modes.
To specify the desired application function, the user must load the internal SRAM which the CLA device uses to store configuration information. The user does not need to generate the SRAM bit pattern; this is done for the user by the Configurable Logic Array Software System.
The user must also determine the method by which the configuration RAM is loaded. Many factors, including board area, configuration speed, and the number of designs concurrently implemented in a device can influence the user's final choice.
The CLA provides seven configuration modes:
Mode 0: Configuration Reset
Mode 1: Address Count-up, External CCLK
Mode 2: Address Count-down, External CCLK
Mode 3: Bit-sequential, External CCLK
Mode 4: Bit-sequential, Internal CCLK
Mode 5: Address Count-up, Internal CCLK
Mode 6: Byte-sequential, External CCLK
Mode 7: Direct Addressing, External CCLK
Upon power-up, the CLA goes through a boot or initialization sequence. This sequence initializes all core cells, repeaters, I/O logic, clock distribution logic, and open collector controls, as well as the configuration register and external memory address counter (discussed below).
Core cells become flip-flops with A N and B N inputs.
All bus drivers are switched off.
All repeaters are open and all bus segments are high impedance.
I/0s are set as TTL inputs only, with the pull-up on.
Column clocks are set to "0".
All open collector controls are set for full CMOS drive.
Each of the bits in the configuration register is reset.
During the initialization sequence, the CLA device 100 drives the /CON pin low. Since power-up initialization uses an internal clock for timing, no external clock source is required. Once initialization is complete, /CON, which is an open collector output, is released; it must be pulled high by an external pull-up resistor.
After power-up initialization is complete, the CLA device 100 is ready to accept the user's configuration. After /CON has been released for a minimum period of time, the user can initiate the configuration cycle by driving /CS and /CON low (in some modes this can take place automatically). The configuration mode is determined by the values on the M0, M1, and M2 pins, as described above. Once the first bytes of the configuration have been loaded, the CLA device 100 takes over driving /CON low, the values on the M0, M1, and M2 pins are ignored, and /CS can be released high. The CLA device 100 will release /CON only after the complete configuration file has been read. It will remain in the configuration state until both /CON and /CS are released.
The CCLK pin should be driven with the configuration clock (in External CCLK Modes) and the M0, M1, and M2 pins held constant throughout the reboot and configuration sequences.
The user can reconfigure the CLA device 100 at any time by asserting /CON and /CS, as outlined above. The CLA device must be allowed to move into the operational state (/CON and /CS high) between configurations. Note that those pins not required for configuration remain operational throughout a configuration sequence allowing partial reconfiguration of an operational device.
Details of each configuration mode are described below.
The configuration file which is stored in an external memory device is used to load the user's configuration into the internal configuration SRAM within the CLA, as shown in FIG. 38. This file has a similar format, shown in Table VI, regardless of the configuration mode (sequential, or Address).
TABLE VI______________________________________Configuration File Formats______________________________________Single CLA Cascaded CLAsPreamble PreambleHeader Header[Window 1] [Window 1][Window 2] [Window 2][Window 3] [Window 3][Window n] [Window n]Postamble Preamble Header 2 [Window 1] [Window 2] [Window 3] [Window n] Preamble Preamble Header n [Window 1] [Window 2] [Window 3] [Window n] Postamble______________________________________
The preamble is a fixed data byte used to synchronize the serial bit stream in sequential modes, and to signal the start of the configuration file in all modes.
The header is a five byte field which includes configuration register data, the external memory address for Address modes, and a counter for the number of CLA data windows to be programmed.
The configuration register includes five bits used to control various configuration sequence parameters. Information regarding these five bits follows. ##STR1## B0 This bit determines whether the external memory address in Address modes is reset after each configuration sequence (default), or if it retains its last value. This allows the user to store multiple designs as sequential configuration files. Otherwise, the subsequent configuration sequences will load the configuration file from the same initial address (00000 in modes 1 and 5, 1FFFF in mode 2).
B1 This bit determines whether the external memory address in the header field(s) will be ignored (default) or loaded into the CLA's external memory address counter. This allows the user to store configuration files as a continuous stream or as a pointer-based linked list.
B2 This bit disables the /CEN, DATAOUT, and CLKOUT functions of these multiplexed configuration pins. This is useful if a minimum pin count configuration circuit is desired.
B3 This bit disables the /ERR and /CHECK pins. This is useful both for design security and minimum pin-count configurations.
B4 This bit prevents configuration data from being written into the CLA during subsequent configuration sequences. The only way to reset this bit is by rebooting the device.
The external memory address is used to set the external memory address counter of the CLA device 100 in the Address modes. This counter increments on every configuration clock in order to drive the address of an external memory device to generate a parallel data stream. The counter counts up in Modes 1 and 5, and down in Mode 2. The new programmed value will be output after each header has been read, according to the configuration bit settings. Note that the external address is for use by external memory. It has no relationship with the internal configuration SRAM within the CLA device 100. Configuration data is read into the CLA device 100 in a stream format.
Another header byte loads the number of windows counter. Configuration data windows make it possible to configure or reconfigure one or more sub-sections of the device. It is possible to load the entire CLA array using a single window. Multiple windows allow the user to jump over sections of the CLA array, thus saving configuration time and memory for lightly used arrays.
Data windows also support the creation of dynamic CLA designs, as small sections of the array can be reconfigured regularly as part of the design's functionality. The optimum set of configuration data windows are generated automatically by the CLA's development system. Only the section of the array selected by the user for reconfiguration will be programmed. There can be a maximum of 255 windows per CLA device 100. If 0 windows are specified, then the array's configuration will not be modified. This is useful if multiple CLA devices 100 are being configured simultaneously.
Each configuration data window consists of an internal array start address, an internal array end address, and the sequential data required to fill the segment of the array defined by the two addresses. Internally, the array is represented as a circular address space. The configuration data stream sequence is divided such that cell types are grouped together in the following order:
Core Cell Configuration Data
Bus Repeater Cell Data
I/O and Clock Cell Data
Open Collector Control Data
If a single CLA device 100 is being configured, then the configuration data windows are followed by a postamble. This is a fixed data byte which signals the end of the configuration file. If multiple CLA devices 100 are being cascaded, however, another preamble byte will appear at this point in the configuration file. This preamble will be followed by another header and a new set of configuration data windows. Theoretically, any number of CLA devices 100 can be programmed in this fashion. In actual practice, however, it is recommended that not more than 8 CLA devices 100 be linked in this cascaded fashion, due to potential clock skew problems.
Configuration reset is not a true configuration mode. It is used to start the boot sequence. Enabling this mode is equivalent to turning power to the device off and on again, except that the state of the core's user-accessible flip-flops is saved. This mode is enabled by asserting /CS, /CON, M0, M1, and M2 low for a minimum period of time and then returning them to the desired mode. Once the reboot process is started, it overrides any other configuration sequence that may be running and cannot be stopped.
The remaining configuration modes load all or some of the CLA device's internal configuration SRAM.
Bit-sequential, internal CCLK mode 4 is the simplest of configuration modes, as it requires the fewest pins and the fewest external components. For a single CLA device, only one dual-function pin, DO, is needed for data received from a serial EPROM. The other dual-function pins, /CEN, /ERR, /CHECK, DATAOUT, and CLKOUT, are all optional. Assuming the /CS and mode pins (M0, M1 and M2) are fixed, the only active pins are /CON, CCLK, and DO. Because most serial EPROMs come in 8-pin DIP packages, little board space is required for this configuration mode, as shown in FIG. 38.
During the power-up boot sequence, /CON is asserted low by the CLA device. Once initialization is complete, /CON is released long enough to reset a serial EPROM. If the mode pins are set to mode 4 before release of /CON, the CLA will then begin autoconfiguration. It reasserts /CON low and an internal oscillator toggles CCLK. This causes the serial EPROM to generate a stream of data which configures the CLA device 100. One bit of configuration data is loaded from the DO pin on each rising edge of CCLK until configuration is complete. The CLA device 100 will then release /CON indicating that the device 100 is ready for use.
Configuration time will vary depending on the speed of the internal oscillator, but the maximum configuration time for a complete array is about 80 milliseconds.
Bit-sequential, External CCLK (Mode 3) is very much like Mode 4, above, with two exceptions: the user must supply a configuration clock to the CCLK pin and the user most drive /CON low to start configuration. Mode 3 will not automatically generate a /CON signal after the power-up boot sequence. During configuration, only one dual-function pin, DO, is required. The pins /CEN, /ERR, CHECK, DATAOUT, and CLKOUT are optional. The only active pins are /CON, CCLK, and DO, as shown in FIG. 39.
Mode 3 can be used for the cascaded configuration of multiple CLA devices 100, as shown in FIG. 40. The first device 100 in a chain can use any configuration mode. If the first device 100 receives a configuration file containing another preamble instead of a postamble, then the remaining configuration data will be ignored by the first device 100 and passed on through its DATAOUT and CLKOUT pins to the next device 100. The DATAOUT pin of an upstream device 100 goes to DO of the downstream device, and the upstream CLKOUT pin connects to the downstream CCLK. In Mode 3, the CLKOUT signal is derived directly from the CCLK Input. The /CON pins of each device 100 in the cascade can be tied together to create a single "configuration complete" signal.
It is also possible for an external processor to configure multiple Mode 3 CLA devices 100 in parallel by assigning a unique bit of its data path to the DO of each device 100, and tying the CCLK inputs of the devices 100 together as a write strobe, as shown in FIG. 41.
One advantage that the Mode 3 has over Mode 4 is that, depending on the accuracy of the user-supplied clock, the time required to configure the device 100 can be determined precisely. Also, because the user can supply a faster maximum clock rate than the typical internally-generated clock range, Mode 3 can be a faster configuration method. As long as data set-up and hold requirements are satisfied, the CCLK pulses can have arbitrary periods. Such a clock is required when using asynchronous communication ports or UARTs to configure the device 100 instead of a serial EPROM. It is necessary, however, to allow sufficient preceding and trailing clock pulses with respect to /CON going low CCLK is to be stopped entirely between configurations.
Count-up Address, Internal CCLK (Mode 5) mode requires the same number of parts as Mode 4, but uses more dual-function I/O pins during the configuration sequence. Because serial EPROMs are not currently available in sizes large enough of all multiple-device designs, the increased memory of a parallel EPROM is sometimes necessary. With the standard parallel EPROM, this configuration mode uses the CO-D7 data pins, the A0-A16 address pins, /CEN, and the fixed function pins, as shown in FIG. 42.
/CHECK, DATAOUT, and CLKOUT pins are optional in this mode.
Mode 5 supports auto-configuration. If the mode pins are set appropriately before the release of /CON during the power-up boot sequence. After a brief period, the CLA device reasserts /CON low, and the internal oscillator begins to toggle CCLK. This causes the CLA device 100 to generate addresses, beginning at 0X00000 to read the configuration file from the parallel EPROM. The external memory address is incremented and one byte of configuration data is loaded from the D0-D7 pins on each rising edge of CCLK until configuration is complete. The CLA device 100 will then release /CON, indicating that the device 100 is ready for use.
Thirteen address bits are required to fully program a single CLA device 100; the extra addresses allow multiple device configuration and reconfiguration, as well as the ability to share a larger memory space with other components of a system. If cascading is necessary, the parallel input data is automatically converted to a serial data output stream on the DATAOUT and CLKOUT pins. Configuration time will vary depending on the speed of the internal oscillator, but the maximum configuration time per array in this mode is about 10 milliseconds.
The Count-up Address, External CCLK (Mode 1) mode is very much like Mode 5, above, with two exceptions: the user must supply as configuration clock to the CCLK pin and the user must always drive /CON low to start configuration. Mode 1 will not automatically generate a /CON signal after the power-up boot sequence. This configuration mode uses the D0-D7 data pins, the A0=A16 address pins /CEN and the fixed function pins, as shown in FIG. 43.
/CHECK, DATAOUT, and CLKOUT pins remain operational in this mode.
In Mode 2, the user can supply the maximum clock rate in order to complete configuration of a single device in under 1 millisecond. The use of cascading however, limits the parallel data rate to 800 KHz, since the internal clock is used to drive the CLKOUT pin. As in Mode 3, the CCLK signal can be synchronous or asynchronous.
The Count-Down Address, External CCLK (Mode 2) is identical to Mode 1, above, except that the DMA address counter starts at 1FFFF instead of 00000, and counts down instead of up. The two modes are included because a typical microprocessor uses the highest or lowest address to load its own reboot address vector. If the CLA device 100 is sharing a large EPROM with a microprocessor, it must start from the opposite end of the EPROM address map so that it does not interfere with the microprocessor, and vice versa.
The Byte-sequential, External CCLK (Mode 6) mode is similar to Mode 3, except that data is loaded in 8-bit words to decrease load time. This mode uses fewer dual-function pins than the does the Address mode because the CLA device 100 does not generate an address instead, the next byte in the data stream is assumed to be present on the rising edge of CCLK. During configuration, D0-D7 are the only dual-function pins required, as shown in FIG. 44. The pins /ERR, /CHECK, DATAOUT, and CLKOUT are optional. The CCLK requirements are the same as for Mode 1.
Intended to be used as the parallel port of a microprocessor, this mode may be best for a smart system in which the user intends to reconfigure the CLA device 100 as a regular part of system operation. Multiple CLA devices 100 can be configured by tying all the data busses together, as well as the /CON pins. The /CS pin can then be used to select individual devices for configuration. Alternatively, multiple CLA devices 100 can be configured in parallel by assigning each byte of a 32-bit processor's data path to a unique CLA device 100, and tying the CCLK inputs of the CLA devices 100 together as a common write strobe, as shown in FIG. 31. It is also possible to program the first device 100 in Mode 6, and cascade all downstream devices 100 in Mode 3 as outlined previously.
It should be understood that various alternatives to the embodiment of the invention described herein may be employed in practicing the invention. For example, although the inventive concepts are described above in the context of reconfigurable logic, these concepts are also applicable to one-time programmable logic. It is intended that the following claims define the scope of the invention and that methods and apparatus within the scope of these claims and their equivalents be covered thereby.
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The present invention provides a configurable logic array that includes a plurality of individually configurable logic cells arranged in a matrix that includes a plurality of horizontal rows of logic cells and a plurality of vertical columns of logic cells. The array further includes at least one horizontally aligned local bus running between adjacent rows of logic cells, the logic cells in the adjacent rows being connectable thereto, and at least one vertically aligned local bus running between adjacent columns of logic cells, the logic cells in the adjacent columns being connectable thereto. The array further includes a dynamic tristate bus driver associated with each logic cell and connectable to the local busses associated with the corresponding logic cell and means for controlling the dynamic tri-state driver through one or more combinations of inputs to the logic cell.
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TECHNICAL FIELD
This invention relates in general to radio communication systems and more specifically to a method for determining when a radio leaves a radio talk group.
BACKGROUND
During a talk group call that is taking place in a trunked radio system, if a radio such as a key radio (e.g., a radio with highest priority or a radio critical to the call, etc.) is pulled away from the call by a dispatcher interrupt, going out of service, the radio switching talk groups in the middle of the conversation, etc., the initiator of the call does not have knowledge of this fact in present trunked systems. As a result, key or priority radios may miss part of the conversation without the originator of the talk group call knowing.
Another situation not currently addressed by current trunked radio systems is if a key radio is the initiator of a talk group call, and any of the radios in the talk group are pulled away from the call, the initiator of the call is not notified that the radio pulled away from the call is no longer participating in the talk group call. As a result, if the key initiator radio is communicating to all members of the talk group, the radio that is pulled away from the call will miss part of the conversation without the key initiator radio's knowledge. For example, when a talk group call is initiated by a priority radio, the user expects all parties in the talk group to be informed of the emergency at hand. If specific instructions are given, and one of the radios in the talk group leaves or is pulled away from the call, the user will miss the instructions. Therefore, the emergency situation may not be properly responded to since one or more radios in the talk group did not receive the emergency instructions and the priority or key initiator radio failed to be advised that some of the radios in the talk group were not in the group when the instructions were provided. A need thus exists for a method for initiator radios and/or key radios in a radio talk group to be informed if other key radios in the talk group are pulled away or leave the talk group during the talk group call.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a trunked system in accordance with the invention.
FIG. 2 is a flowchart showing the method at the radio end of determining when a radio from an established radio talk group leaves the talk group in accordance with the invention.
FIG. 3 is a flowchart showing the method from the fixed-end side of how the fixed-end provides a radio user with the information that a member of the radio talk group has left the group in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, a block diagram of a trunked communication system 100 is shown. The radios or subscriber units 108 which are part of system 100 communicate over control channel 102 with a control resource such as a system central controller 104 in order to receive status and control information from the central controller 104. The system central controller104 acts as the system coordinator and is responsible for assigning radios to different repeaters 106 (channels) so that they may communicate amongsteach other. The central controller 104 is also responsible for knowing where each of the radios are located (i.e. what voice channel) and for controlling other features typically found in a modern trunked communication system (e.g., handling phone patches, coordinating groups ofradios in emergency situations, etc.).
The typical central controller 104 includes a main processing unit such as a computer with appropriate control software which controls the operation of controller 104. Also normally included as part of controller 104 is a video display and keyboard in order to allow the central control operator to communicate with the system. The signals which are sent from the central controller 104 to the subscriber units 108 over the control channel 102 are typically called outbound signaling words ("OSW's"). The control signals going from radios 108 to the central controller 104 are called inbound signaling words (ISW's). OSW's inform radios 108 when to change channels automatically so as to communicate with other members in the same radio talk group over an assigned voice channel 106 which has been assigned by the system central controller 104.
When requesting a channel 106 for a talk group call, the radio unit 108 sends in a single word group request (if affiliated) with its individual radio identification number. The central controller 104 generates a grant OSW for the talk group affiliated with the radio unit that transmitted thechannel request by referencing a radio ID to talk group affiliation database residing in the central controller 104. If there is no talk groupaffiliation in the central controller database (e.g., due to corrupt data, etc.), the central 104 requests a dual word ISW from the radio unit which identifies the unit ID and the desired talk group. If the radio unit changes talk groups, or systems, it immediately begins to receive calls for the new talk group or system and preferably performs an auto affiliation sequence after being on the selected talk group for about 2 seconds. This typically includes transmitting an ISW that includes the unit's ID and new talk group information to controller 104. Controller 104then updates its affiliation database accordingly.
If PTT (push to talk) is asserted before auto affiliation, the radio unit 108 sends in a dual word ISW identifying the unit's radio ID number and the new desired talk group affiliation. The central controller 104 will store the talk group information in the affiliation table and then if a voice channel 106 is available, it will generate a grant OSW for that talkgroup. The grant OSW is initially sent out as a dual word grant to identifythe transmitting unit and the talk group number. The requesting radio 108 sees its individual and talk group IDs in the grant OSW and goes to the voice channel 106 as a transmitting radio. Any other subscriber units 108 which are currently operating in the same talk group also see the talk group ID in the grant OSW and move to the same voice channel 106 as receivers. After the dual OSW grant is sent out 4 times, subsequent assignment update OSWs are transmitted by the central controller 104 as single word OSWs with simply the talk group ID and the voice channel it isassigned to the particular talk group.
An example of a typical trunked conversation will begin by one radio 108 ingroup "A" pressing PTT which automatically sends an ISW over the control channel 102 to the central controller 104 requesting a voice channel 106 grant. Once the request comes in, central controller 104 decides which voice channel 106 to assign and transmits an OSW via control channel 102 back to the radios 108. The OSW will inform all radios 108 in group "A" tomove to repeater No. 2 for example, at which point all the radios in group "A" will move to that repeater to begin their conversation. Some trunked radio communication systems do not use a central control channel, but embed the control information within the voice channels such as by sendingthe control information using low-speed data which does not affect the voice communication.
Referring now to FIG. 2, a flowchart showing the steps taken by one of the radios 108 in accordance with the preferred embodiment of the invention isshown. In step 202, the radio (for example a radio in talk group "A") transmits a talk group request to central controller 102. In step 204, thecentral controller grants the talk group call transmitting a talk group grant OSW informing the radios in talk group "A" which channel 106 to use for the talk group conversation. The radio commences the talk group call in step 206. If a radio in the talk group that is presently active, in this case talk group "A", decides to leave the talk group (e.g., radio user switches his talk group switch mode selector, radio user goes out of service, one of the radios in the talk group has to leave the talk group due to a priority interrupt transmission, etc.), the radio that leaves thetalk group performs an auto affiliation routine after switching to the new group (e.g., talk group "B") after a predetermined period of time has elapsed (e.g., after a few seconds). This information comes in from the radio as an ISW which includes the radio identification number and the newtalk group information. The central controller 104 upon receiving the information at step 208 from the radio updates its group affiliation data base which stores information on all the radios on the system and their current talk group affiliations. An auto affiliation routine is also performed by the radios when they leave service, leave a talk group due toa priority interrupt, etc.
In step 210, if a member of the ongoing talk group call leaves the talk group and subsequently notifies the central controller of its new talk group affiliation, the central controller generates an OSW which is sent to a key radio(s) in the talk group (or any other select unit or units in the talk group) which informs the key radio(s) that a particular radio hasleft the talk group. This information can be displayed at the radio and an audible alert such as a tone can be generated to alert the user of the departure. In an optional feature of the present invention, once the talk group call has ended in step 212, the key radio(s) receive an OSW that allmembers of the talk group were present during the call in step 214. This can be accomplished by central controller 104 making sure that any radios affiliated with the particular talk group did not leave the talk group between the call was started and when it ended. In step 215, the notification that all members of the talk group were present during the call is displayed at the radio and a tone can be generated to alert the user.
In FIG. 3, the steps taken by the central controller 104 in accordance withthe invention are shown. In step 302, the central controller 104 receives atalk group call request from a radio 108 in the form of a channel request ISW. In step 304, if a channel 106 is available, the request is granted and the radios in the talk group are informed to which channel 106 to automatically switch to. In step 306, the central controller 104 monitors its affiliation data base to determine if any members of the current talk group are removed or leave the call and later send a new current affiliation to the central controller 104. If a talk group member leaves the talk group during the call, in step 308, central controller 104 transmits an information OSW to a key radio or radios in the talk group informing them that a radio was removed from the talk group. This information can also include information as to which radio in the group left. For example, the radio receiving the information can display the ID number of the radio which left the group. This can be accomplished by transmitting a one or more OSW's which include the above noted information. In the preferred embodiment, the information is sent to the radio that initiated the talk group call or to a designated key radio (e.g., supervisor radio user, etc.) in the talk group. In the case of the initiator radio the central controller 104 knows this by the ISW information transmitted by the radio. In the case the information is to besent to a key radio, or radios, the information of which radios are to be designated a key can be pre-loaded into the central controller's database.
In step 310, it is determined if the talk group call has ended. In step 312, if all members of the talk group were present for the call, the initiator of the call or another key radio(s) in the talk group can be optionally notified of the fact that all radios were affiliated to the talk group during the duration of the call. The notification can be as simple as a confirmation tone, or a message being displayed at the radio.
Although the preferred embodiment of this invention has been discussed in relation to a trunked system having a central controller and a control channel in which to transmit and receive ISW's and OSW's, the present invention is not so limited. The invention can also be used in other trunked system which transmit control/data information on the same voice channel, on systems not having a dedicated control resource, but which usesophisticated ("smart") repeaters which act as control resources, and many other radio communication systems.
In summary, the present invention provides a method for initiator radios and/or key radios to be informed if other radios are pulled away from their talk group during the time the talk group call is taking place. Whenthe initiator radio is done transmitting, the fixed end can inform the radio of the identification of the radio(s) that were pulled away from thecall. If the system is a full duplex system, notification that a radio is no longer part of the call can occur while the initiator radio is transmitting. The invention allows the radio transmitting to decide whether to continue the call, issue a priority interrupt, re-initiate the call at a later time, etc. The added information provided by the present invention provides for added security that all radios that are to receive the talk group call information are in fact in position to receive the call.
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A method for determining when a radio leaves a radio talk group includes the step of notifying a radio(s), such as the initiator of the call (step 308), that one or more members of the talk group left the talk group. This information allows for the initiator of the call or another radio to re-transmit the call at a later date, or to attempt to get the missing radios back into the talk group prior to transmitting another call.
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FIELD OF THE INVENTION
The present invention relates to the field of digital video, and in particular to digital video broadcasting.
BACKGROUND ART
Scrambling techniques are commonly used in video applications such as payment-on-demand cable TV. A common technique for scrambling analogue video signals is to randomise the position of the horizontal synchronisation pulse. Frequently, an incoming video signal will contain sections of scrambled video interleaved with sections of unscrambled video and it is necessary to distinguish between them in the processing circuits—see for example U.S. Pat. No. 4,926,477.
As regards digital broadcasting (DVB) various standards have been set, and in particular a standard has been set, known as the Common scrambling specifications devised by the European project for digital video broadcasting, concerning the scrambling and descrambling of data (the DVB algorithm). Essential characteristics of the DVB algorithm are shown in FIG. 1. A packet 2 of data having a header field HEADER followed by n consecutive blocks (of 8 bytes) of scrambled data SB(n) is applied to a stream cipher 4 , of a form defined by the common scrambling specifications. The scrambled data is deciphered on a block by block basis with the first block SB( 1 ) being used for initialisation, and each subsequent block being subject to the stream cipher CB and then passed as an intermediate block IB(n) to a block cipher unit 6 , also of a form defined by the common scrambling specification. Each block is subject to a block deciphering operation BD and descrambled blocks DB(n) are output for assembly into a descrambled packet 8 .
A more specific implementation of the descrambler of FIG. 1 is shown in FIG. 2, wherein scrambled data is applied to a stream cipher unit 10 and a first input of an exclusive OR gate 12 . The output of cipher unit 10 is applied to a second input of gate 12 . The output of gate 12 is applied to an 8 byte register 14 (herein referred to as Reg 1 ), which provides an 8 byte delay. A parallel output of Reg 1 is coupled to a block cipher unit 16 . A serial output of Reg 1 is coupled via a two way switch 18 to an 8 byte register 20 (providing a further 8 byte delay—referred to herein as Reg 2 ) and to a first input of an exclusive OR gate 22 . The output of block cipher unit 16 is connected as a parallel input to Reg 2 and a serial output of Reg 2 is applied to a second input of exclusive OR gate 22 . The output of gate 22 provides descrambled data. It will be understood that the presence of the two registers Reg 1 , Reg 2 in the data path stream creates substantial 16 byte delay. The notation in FIG. 2 is as follows:
k indexes scrambled bytes through the stream
p end of a scrambled field
n number of complete 8 bytes blocks in a scrambled field
r the residue that is left in a scrambled field after the last complete 8 byte block of that scrambled field
For compressed video signals, compressed according to the MPEG standards, the application of the DVB descrambler algorithm to MPEG transport data streams requires that the fields of scrambled data contained in the received transport stream be extracted from the stream, descrambled according to the DVB descrambler algorithm, then reinserted into their original place in the received transport stream.
Where the transport stream contains interleaved sections of scrambled video and unscrambled video (plain text) a problem therefore arises in that the descrambling of the scrambled sections naturally introduces a time delay and it is not therefore possible to reinsert the descrambled sections to their original place in the transport steam without further modification of the receiving system.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a simple and inexpensive means of descrambling scrambled data in a transport stream containing sections of both scrambled and unscrambled data.
In accordance with the present invention, there is provided apparatus for processing a stream of digital video broadcast data containing interleaved sections of scrambled data and unscrambled data, the apparatus including a common data flow path provided both for sections of scrambled data and sections of unscrambled data, one or more data flow path loops extending from and back to said common data flow path and containing cipher means to enable the descrambling of scrambled data, and a control means capable of assuming a plurality of control states for selectively controlling the passage of data through the data flow paths to enable passage of unscrambled data sections in said common data flow path and descrambling of scrambled data sections in said data flow loops, while maintaining the relative positions of the data sections in this data stream.
In accordance with the invention, since a single main data flow path is provided, with control of the main data flowpath and the data flow path loops, the passage of unscrambled sections and scrambled sections of data can be regulated to avoid problems of reinsertion of descrambled data and resynchronisation to a single data stream.
The present invention provides in a specific aspect apparatus for processing digital video broadcast data comprising interleaved sections of scrambled and unscrambled data, the apparatus comprising:
a data input terminal coupled to a first input of an exclusive OR gate means, a stream cipher means having an input connected to said data input terminal and an output connected to a second input of the exclusive OR gate means;
a first shift register means having an input coupled to receive the output of the exclusive OR gate means, and having first and second outputs, a second shift register means having a first input coupled to the first output of the first shift register means, and having a second input and an output, a block cipher means coupled between the second output of the first shift register means and the second input of the second shift register means; and
a control means responsive to whether data at said data input terminal is scrambled data or unscrambled data for selectively enabling said stream cipher means, block cipher means and first and second shift register means (a) to pass an unscrambled data directly through said first and second shift register means and (b) to pass scrambled data through said stream and block cipher means.
In accordance with the invention, since a single data flow path is provided a more secure, reliable and inexpensive system is provided. Whilst other arrangements may be envisaged for example splitting the data into completely separate data flow paths for scrambled and unscrambled data with appropriate delays in the flow paths to maintain correct timing relationships, this would result in a more expensive system.
The single data stream path in accordance with the invention is preferably arranged that it cannot pass both a scrambled byte of data and a non-scrambled data and that further the two shift register means do not contain gaps between successive fields of data. These two conditions mean that scrambled and non-scrambled fields follow each other without either a gap or an overlap, in data (but not necessarily in time intervals), and since the non-scrambled data uses the same shift register means, providing a 16 byte time delay as is used by the scrambled data, the problem of inserting non-scrambled data into the descrambled data stream does not arise and is automatically solved.
The control means preferably comprises a control state machine, preferably occupying a number of predefined states in which it issues appropriate control signals to control the data stream. As preferred a key state machine is provided for controlling the issuing of keys to the cipher means for the descrambling process. A packet counter is preferably provided to count the number of bytes of the current signal packet of the incoming data stream up to a maximum of 184 bytes as permitted by MPEG-2. A first block counter is provided to count the number of bytes of a new scrambled field modulo 8 ; this counter controls said first shift register means. As preferred a second block counter is provided to count the bytes of a second block of data of a new scrambled field modulo 8 . Two block counters are needed since there may be less than 8 bytes of unscrambled data between two successive scrambled fields.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention will now be described with reference to the accompanying drawings wherein:
FIG. 1 is a diagram illustrating the concept of descrambling, according to the ETSI Common scrambling specifications;
FIG. 2 is a more detailed implementation of a descrambling mechanism according to the ETSI Common scrambling specifications;
FIG. 3 is a block diagram of a preferred embodiment of descrambling apparatus according to the present invention;
FIGS. 4 and 5 are wave form diagrams for apparatus of FIG. 3;
FIG. 6 is a more detailed block diagram of the preferred embodiment of descrambling apparatus according to the present invention;
FIGS. 7 and 8 are timing diagrams showing operation of counters and flags in the apparatus of FIG. 3;
FIGS. 9 and 10 are diagrams indicating the operation of the control state machine in terms of transitions between states ( 9 ) and actions taken in the various states ( 10 ); and
FIG. 11 is a schematic view of an integrated circuit chip incorporating the circuit of FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 3, the descrambling apparatus according to the present invention includes a demultiplexing function 30 and a descrambler function 32 , both indicated in dotted lines. Function 30 includes a packet identification processor 34 . Function 32 includes a key control and key generator unit 36 , a control state machine 38 , and a descrambler unit 40 . Machine 38 includes counters 42 , 44 , 46 as will be described below.
Referring to FIGS. 4 and 5 the format of transport packets are shown as preceded by a synchronisation byte SB and include 188 bytes of data which may be scrambled data, plain data or a mixture of the two. Where scrambled data is provided, preceding instruction bytes IB may also be provided. The format of an instruction byte IB is shown in FIG. 4 as comprising bits 0 to 3 as a key index and bits 4 and 5 as SC control bits. Packet identification unit 34 provides the incoming packets, on pid_i_data to machine 38 , and produces the wave forms shown in FIG. 4, pid_i_decidb, pid_i_pacst and pid_i_sr, which provide waveform steps in response to instruction bytes, synchronisation bytes and scrambled data sections respectively to machine 38 .
As indicated in FIG. 5, descrambler unit 40 provides descrambled data assembled in packets dsc_o_data, together with a signal, dc_o_pacst in response to synchronisation bytes at the start of packets. Timing and validation signals clock, data_val, data, busyb and captured data are provided as indicated.
The control state machine 38 includes a counter 42 , pack_counter for counting the bytes in a packet, a counter 44 for counting blocks of 8 bytes, first_block_count and a second counter 46 for counting bytes of blocks, block_count. The two block counters count the number of bytes of a new scrambled field modulo 8 to generate blocks. When the counters reach 8 they wrap round to 1. A zero value means the byte currently is unscrambled. Two block counters are needed since there may be less than 8 bytes of unscrambled data between two successive scrambled fields. The counters produce various flags as indicated in FIGS. 7 and 8 for controlling operation of the descrambler as referred to below.
Referring now to FIG. 6, this shows a more detailed diagram of unit 40 of FIG. 3, an input stream ib(m) (in FIG. 6, m indexes the incoming bytes, k indexes scrambled bytes and j to q refer to unscrambled bytes) is input on a data flow path ( 1 ) to an exclusive OR gate 60 . The input stream is also applied on a data path ( 6 ) to a stream cipher unit 62 , whose output is coupled by a data flow path ( 7 ) to a second input of exclusive OR gate 60 . The output of exclusive OR gate 60 is coupled on data flow path ( 2 ) to a serial input of first shift register Reg 1 . Reg 1 is an 8 byte shift register and provides a parallel output on a data flow path ( 8 ) and a serial output on a data flow path ( 3 ). Data flow path ( 3 ) is coupled to the serial input of 8 byte shift register Reg 2 Data flow path ( 8 ) is coupled to a block cipher unit 64 , and the output of block cipher unit 64 is coupled on a data flow path ( 9 ) to the parallel input of Reg 2 . The serial output of Reg 2 is coupled via a data flow path ( 4 ) to an input of an exclusive OR gate 66 , the output of which provides a descrambled output on data flow path ( 5 ). A further data flow path ( 10 ) is connected from the output of Reg 1 to the second input of gate 66 , in order to complete the DVB descrambling algorithm.
In use, scrambled data, m=k, is directed through the two signal path loops ( 6 , 7 ), ( 8 , 9 ) including ciphers 62 , 64 , and along signal path 10 to provide descrambled data. The two shift registers Reg 1 and Reg 2 , supplying data to and receiving data from block cipher 64 eight bytes at a time, introduce a 16 byte delay. Sections of non-scrambled data, j<=m<=q are directed along the common data flow path 1 , 2 , 3 , 4 , 5 . Since the common signal flow path includes the two byte serial shift registers Reg 1 and Reg 2 , there is automatically provided the 16 byte time delay compensation to maintain timing with scrambled data sections, without the need for external delay elements.
The data flow paths 1 , 2 , 3 , 4 and 5 are specified as indicated by the values of m in FIG. 6 to achieve two aims. Firstly that they never simultaneously pass both a scrambled byte and a non-scrambled byte, and secondly that they never result in Reg 1 or Reg 2 containing gaps between successive fields of data. These two conditions mean the scrambled and non-scrambled fields follow each other without either a gap or an overlap, and since the non-scrambled data uses the same circuitry to provide the 16 byte time delay as is used by the scrambled data, the problem of inserting the non-scrambled data back into the descrambled data stream does not arise and is therefore automatically solved.
Referring now back to FIG. 3 together with the wave form diagrams of FIGS. 4 to 8 and the control operation diagrams of FIGS. 9 and 10, the function of the unit shown in FIGS. 3 and 6 are as follows:
packet counter 42 : this counts the number of bytes since the last packet start. This counter is used to determine when the end of a packet is reached (188 bytes).
first block counter 44 : this counts the bytes from the beginning of a new scrambled field modulo 8 . This means that when the count reaches 8 it wraps around to 1. From this it is possible to determine when Reg 1 is full with a complete scrambled block from a new scrambled field. The counter is defined from 0 to 8 with the 0 having the meaning that the byte currently in the first stage of Reg 1 is unscrambled. Therefore unscrambled fields are not counted by this counter.
second block counter 46 : this counts the bytes from the beginning of the second block of a new scrambled field modulo 8 . From this it is possible to determine when Reg 1 is full with the next block of scrambled data from the stream cipher.
Two block counters are needed since there may be less than 8 bytes of unscrambled data between two successive scrambled fields. In such a case Reg 1 will not fill with the unscrambled data before the next scrambled field, i.e. Reg 1 will contain both the end of the last scrambled field and the beginning of the next scrambled field. The control state machine needs to know when the last block is ready for emptying from the block cipher and when the first block has reached the end of Reg 1 , so two counters are needed.
From these counters a series of flags are produced as follows as shown in FIGS. 7 and 8 :
first_block_flag: Indicates the block in Reg 1 is the first block of a scrambled field
last_block_flag: Indicates the block in the block cipher is the last block of a scrambled field.
r 1 _full_flag: Indicates that Reg 1 is full with 8 new bytes (one block) of data.
It is set when block count is 7.
r 1 _sc_full_flag: Indicates that Reg 1 is full with 8 new scrambled bytes of data. It is set when first block counter is 7.
pack_end_flag: Indicates that 188 bytes have been loaded since the last packet start.
Control State Machine 38 : The state machine is held in signal ‘current state’ with the value of the state after the next clock being held in Register ‘next state’. This state machine has 6 states—IDLE, GEN, UNSCR, BCLOAD, FBCLOAD, LBCLOAD as indicated in FIGS. 9 and 10. Referring to FIGS. 9 and 10, these states are as follows:
IDLE
Default state after reset. The internal controls in the descrambler are such that a new byte can be accepted. If a new byte is available and it is scrambled then the next state is GEN. If a new byte is available and it is un-scrambled then the next state is UNSCR. Otherwise the next State is IDLE.
GEN
The processing state for scrambled data. The stream cipher requires two clock cycles to process each byte. By default this will occur by advancing IDLE to GEN then back to IDLE. This is the normal flow for a scrambled data byte except in the following cases: if Reg 1 is full and the block cipher contains the last block of a scrambled field then the next state is LBCLOAD; if Reg 1 is full a block from a scrambled field and it is neither the first nor last block of that field then the next state is BCLOAD, if none of these cases are true then the next state is IDLE.
UNSCR
The processing state for unscrambled data. In reality unscrambled data only needs one cycle to process but providing a special state has two advantages. Firstly the cycle behaviour is the same for scrambled and unscrambled bytes. This inevitably reduces the special case requirements in the code thus increasing its reliability. Secondly the latency of the descrambler is the same for scrambled and unscrambled data which can simplify external interfacing requirements in some systems. In this state if Reg 1 is full and the last block of a scrambled field is in the block cipher then the next state is LBCLOAD, and if Reg 1 is full with the first block of a scrambled field then the next state is FBCLOAD; Otherwise the next state is IDLE.
BCLOAD
The processing state for loading and unloading the block cipher. This state is entered from GEN when Reg 1 contains a new scrambled block that is neither the first block nor the scrambled residue of a scrambled field. This state waits until two conditions are true: firstly we have completed the shifting in of data; secondly the block cipher is currently idle i.e. it has finished its decipherment of the previous block. When these are true: Reg 2 is loaded with the contents of the block cipher; the block cipher is loaded with the contents of Reg 1 and the block cipher is started; Reg 2 is set to mode ‘Shift As Scrambled’ (SAS); the next state is IDLE.
FBCLOAD
The processing state for loading the block cipher with the first block of a scrambled field. This state is entered from GEN when Reg 1 contains a new scrambled block that is also the first block of a new scrambled field. In this case the block cipher does not contain a block from the current field, Any last block from the previous field will have been emptied into Reg 2 by a LBCLOAD state. To correctly operate this scheme it is necessary to have at least one byte of unscrambled data between successive scrambled fields. This state waits for the same two conditions to be true as BCLOAD then performs the following: the block cipher is loaded with the contents of Reg 1 and the block cipher is started; Reg 2 is set to mode ‘Empty As Residue’ (EAR); the block cipher key Register ‘bc key’ is loaded with the latest ‘common key’; the next state is IDLE.
LBCLOAD
The processing state for handling any possible scrambled residue for a scrambled field. This state is entered from the IDLE state when Reg 1 is detected as having 8 new bytes that have not yet been processed and not all of those bytes are from the current scrambled field. Scrambled residue does not pass through the block cipher, but is instead serially passed into Reg 2 . There will be the previous block of data in the block cipher. This state waits until two conditions are true: firstly we have completed the shifting in of data; secondly the block cipher is currently idle i.e. it has finished its decipherment of the previous block. When these are true; Reg 2 is loaded with the contents of the block cipher; Reg 2 is set to mode ‘Shift As Reside’ (SAR); the next state is IDLE.
Key State Machine 36 : The descrambling process requires the use of a common key, there being a possible large number of such keys. An instruction byte IB (FIG. 4) passed in the data stream contains the key index information necessary to determine which of those keys is to be used. When the instruction byte appears in the data stream then the key state machine takes control of the input interface and performs the key look up operation.
The key state machine is held in signal ‘key state’ and the next state of the machine is held in state ‘next key state’. The default state is IDLE. If the current state is IDLE and an instruction byte arrives (this is indicated by the PID-processor 34 ) then the next state progression is KEY 1 followed by KEY 2 followed by IDLE. During KEY 1 and KEY 2 the signal ‘look up key’ is asserted ‘1’ causing a look up of the key addressed by two Register values. These are ‘sc bits’ and ‘key index’ which are constructed from the instruction byte. The key file returns the key value on the bus COMMON_KEY. This is registered inside the key file in descrambler 40 and control state machine 38 .
Control State Machine 38
As regards the specific construction of the control state machine, it will be understood that it is practice within the art to define a machine construction in terms of a software routine written in a hardware programming language, VHDL, and for a computer directly to translate such routines into a set of layout diagrams and chip masks for a chip consisting of hard-wired logic gates, the chip being indicated schematically in FIG. 11 . There is not normally generated anything which corresponds to a traditional functional block diagram.
Accordingly the construction of the control state machine is defined by the following routine:
Process: next_state_proc
This process calculates the next state of the control state machine. It also flags when to start the block cipher, when to load Reg 2 and which mode to set for Reg 2 .
next_state_proc: process
(current_state, new_byte_flag, captured, bc_busy,
first_block_flag, r 1 _sc_full_flag, int_r 1 _shift,
r 1 _full_flag, reg 2 _active_mode, last_block_flag,
int_bc_key, common_key, pack_end_flag, if_empty)
begin
a_bc_key<=int_bc_key;
bc_start<=NO;
reg 2 _load 13 flag<=NO;
a_reg 2 _active_mode<=reg 2 _active_mode;
exit_state<=NO;
case (current_state) is
when IDLE=>
if (new_byte_flag=YES and captured.sc=SCRAMBLED) then
next_state<=GEN;
elsif (new_byte_flag=YES and captured.sc=SCRAMBLED) then
next_state<=UNSCR;
elsif (pack_end_flag=YES) then
next_state<=UNSCR;
else
next_state<=IDLE;
end if;
when GEN=>
if (if_empty=NO) then
next_state<=current_state;
elsif (r 1 _full_flag=YES and last_block_flag=YES) then
next_state<=LBCLOAD;
exit_state<=YES;
elsif (r 1 _sc_full_flag=YES) then
if (first_block_flag=YES) then
next_state<=FBCLOAD;
a_bc_key<=common_key;
exit_state<=YES;
else
next_state<=BCLOAD;
exit_state<=YES;
end if;
else
next_state<-IDLE;
exit_state<-YES;
end if;
when USCR=>
if (if_empty=NO) then
next_state<=current_state;
elsif (r 1 _full_flag=YES and last_block_flag=YES) then
next_state<=LBCLOAD;
exit_state<=YES;
elsif (r 1 _sc_full_flag=YES and first_block_flag=YES) then
next_state<=FBCLOAD;
a_bc_key<=common_key;
exit_state<=YES;
else
next_state<=IDLE;
exit_state<=YES;
end if;
when LBCLOAD=>
if (int_r 1 _shift=YES or bc_busy=YES) then
next_state<=current_state;
else
next_state<=IDLE;
reg 2 _load_flag<=YES;
a_reg 2 _active_mode<=SAR;
end if;
when FBCLOAD=>
if (int_r 1 _shift=YES or bc_busy=YES) then
next_state<=current_state;
else
next_state<=IDLE
bc_start<=YES;
a_reg 2 _active_mode<=EAR;
end if:
when BCLOAD=>
if (int_r 1 _shift=YES or bc_busy=YES) then
next_state<=current_state;
else
next_state<=IDLE;
bc_start<=YES;
reg 2 _load_flag<=YES;
a_reg 2 _active_mode<=SAS;
end if;
when others=>
next_state<=IDLE;
end case;
end process next_state_proc;
It will be understood that control state machine 38 will be essentially the same construction, even if expressed differently using different nomenclature, changes in algorithm producing an equivalent result, and expressed in a different programming language, all of which changes will be apparent to the person skilled in the art. It is to be understood that the claims appended hereto are intended to cover all such variations.
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In order to descramble sections of scrambled data interleaved with sections of unscrambled data in a transport stream of broadcast video data, while leaving the sections with the original timing relationship in the transport stream, a common data flow path ( 1-5 ) is provided both for sections of scrambled data and sections of unscrambled data and signal path loops ( 6,7; 8,9 ) including cipher means ( 62,64 ) to enable the descrambling of scrambled data, and a control state machine for controlling the flow of data through said common data flow path and said signal path loops to enable passage of unscrambled data sections and descrambling of scrambled data sections, while maintaining the desired relative positions of the data sections.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method and apparatus for separating air into nitrogen and oxygen-rich products by cryogenic distillation in which the air, after having been compressed and purified, is cooled to a temperature suitable for its distillation through indirect heat exchange with the nitrogen and oxygen-rich products within heat exchangers. More particularly, the present invention relates to such a method and apparatus in which a liquid oxygen stream is pumped and then vaporized in a separate heat exchanger through indirect heat exchange with part of the air that has been further compressed in a booster compressor.
BACKGROUND OF THE INVENTION
[0002] It is well known in the art to separate air into nitrogen and oxygen-rich products and also potentially an argon-rich product by cryogenic distillation. In accordance with such method, the air is compressed and purified and then cooled to a temperature suitable for its distillation within a heat exchanger against return streams that comprise the nitrogen and oxygen-rich products.
[0003] The separation of the air into the oxygen and nitrogen-rich products takes place within an air separation unit having higher and lower pressure columns that are operatively associated with one another in a heat transfer relationship, typically by a condenser-reboiler located at the bottom of the lower pressure column. The incoming air is rectified within the higher pressure column to produce a crude liquid oxygen column bottoms and a nitrogen column overhead that is condensed by the condenser-reboiler to reflux the higher pressure column. A stream of the nitrogen-rich liquid is also introduced into the top of the low pressure column to reflux the lower pressure column. A stream of the crude liquid oxygen is also introduced into the lower pressure column for further refinement and to produce an oxygen-rich liquid column bottoms in the lower pressure column that is vaporized by the condenser-reboiler. A waste nitrogen stream is withdrawn below the top of the lower pressure column together with a nitrogen-rich vapor column overhead that are introduced into a heat exchanger to cool the incoming air.
[0004] It is known to produce a high pressure oxygen product by pumping a liquid oxygen stream that is composed by the oxygen-rich liquid column bottoms and then vaporizing it in a heat exchanger against a stream of the compressed and purified air that has been further compressed by a booster compressor. The boosted pressure stream of air either liquefies or is converted into a dense phase fluid against vaporizing the pressurized liquid oxygen stream to produce the high pressure oxygen product. Additionally, it is also known that a nitrogen product composed of the nitrogen-rich liquid produced in the higher pressure column can also be pumped and vaporized in a like manner.
[0005] As mentioned above, an argon product can also be separated by withdrawing an argon-rich vapor stream from the lower pressure column and rectifying it in an argon column. The resulting liquid column bottoms is returned to the lower pressure column. The argon column is refluxed by condensing argon-rich column overhead in a condenser through indirect heat exchange with all or part of the crude-liquid oxygen stream before its introduction into the lower pressure column.
[0006] Although the above process and apparatus can utilize a single, main heat exchanger for cooling the incoming air streams through indirect heat exchange with the return streams that contain the oxygen-rich and nitrogen-rich products as well as the pressurized, pumped oxygen stream, it is also known to separately vaporize the pressurized oxygen product within a separate high pressure heat exchanger. Such process and apparatus are shown in Linde Reports on Science and Technology, “The Production of High-Pressure Oxygen”, Springmann (1980). In this paper it is also illustrated to utilize the waste nitrogen stream after having been used in subcooling duty as a feed to both the higher pressure heat exchanger that is used in vaporizing the pressurized and pumped liquid oxygen and also as a feed to the other heat exchanger that operates at a lower pressure to cool the main air stream to a temperature suitable for its rectification. This waste nitrogen feed to the heat exchangers is necessary for thermal balancing purposes. By “thermal balancing” what is meant is that the waste nitrogen streams decrease the difference between warm end temperatures of the streams exiting the lower pressure heat exchanger and the higher pressure heat exchanger to inhibit warm end losses of refrigeration by such heat exchangers and also to decrease the temperature difference of the boosted-pressure air stream and the main air stream at the cold end of the high pressure heat exchanger and the low pressure heat exchanger. In this way, the temperature difference between the boosted-pressure air stream and the pumped liquid oxygen stream at the cold end of the higher pressure heat exchanger can be optimized. It is advantageous to decrease the temperature difference at the cold end of the higher pressure heat exchanger in that the boosted pressure air liquefies within such heat exchanger and then thereafter, must be expanded for its introduction into at least the lower pressure column but also, potentially, the higher pressure column. If the temperature of this stream is too warm, vapor will evolve from the boosted pressure air during the expansion to effect the requisite distillation of the air to produce the desired products.
[0007] Brazed aluminum heat exchangers are used from both the higher and lower pressure heat exchangers. Such heat exchangers have a layered construction in which each of the streams, for example the incoming air stream, the nitrogen-rich stream and etc. pass through separate layers that are arranged in a pattern to efficiently conduct indirect heat exchange between the streams. The layered construction is produced in such heat exchangers by a series of parallel parting plates and peripheral side bars to seal the layers along their edges. Manifolds are provided to feed the streams into the layers. An arrangement of fins is provided in each of the layers that increase the area available for the heat exchange.
[0008] As can be appreciated, a high pressure heat exchanger for pumped liquid oxygen service in which typically the oxygen is to be supplied at 450 psia require air at a pressure of 1100 psia to vaporize the oxygen. Heat exchangers designed to handle such high pressures are more expensive than heat exchangers designed for lower pressure duty. For example, in case of brazed aluminum plate-fin heat exchangers, such heat exchangers require the use of reduced cross-sectional areas, have a very limited selection of heat transfer fins and require thicker design elements such as parting sheets and side bars as compared with a heat exchanger that operates at a lower pressure. All of this increases the cost of such heat exchangers that are designed to operate at high operational pressures such as is the case where a pressurized, pumped liquid oxygen stream is to be vaporized. Thicker materials and other known considerations would increase the costs of other types of heat exchangers such as like spiral wound, printed circuit and stainless steel plate-fin heat exchangers.
[0009] A spiral-wound heat exchanger is in general a tubular heat exchanger, wherein copper or aluminum tubes are wound round a central mandrel. The tubes and mandrel are enclosed in a pressure vessel shell. Each tube starts and ends in one of several tubesheets which are connected through the pressure vessel shell to headers. There will be one inlet and one outlet header for each stream in the heat exchanger.
[0010] If the operating pressure is high, these exchangers must utilize thicker tube walls to contain the pressure, which increases the quantity of material required. Hence spiral wound heat exchangers are more expensive if required to operate at higher pressure. Diffusion-bonded heat exchangers are constructed from flat metal plates into which fluid flow channels are either chemically etched or pressed.
[0011] Plates are then stacked and diffusion-bonded together by pressing metal surfaces together at temperatures below the melting point, to form a block. The blocks are then welded together to form the complete heat exchange core. Headers and nozzles are welded to the core in order to direct the fluids to the appropriate sets of passages. Design pressures up to 600 bara can be accommodated.
[0012] Higher design pressures are achieved in a printed circuit heat exchanger at the expense of smaller channels with thicker walls. To achieve the same pressure drop and heat transfer duty more material will be required—hence the heat exchanger is more expensive.
[0013] As will be discussed among other advantages of the present invention, a method and apparatus is provided for separating air in which fabrication costs of the higher pressure heat exchanger can be reduced by decreasing its size.
SUMMARY OF THE INVENTION
[0014] In one aspect, the present invention relates to a method of separating air. In accordance with the method, a first compressed and purified air stream and a second compressed and purified air stream are produced. The second compressed and purified air stream has a higher pressure than the first compressed and purified air stream. The first compressed and purified air stream and the second compressed and purified air stream are cooled in a lower pressure heat exchanger and a higher pressure heat exchanger, respectively, through indirect heat exchange with return streams generated in an air separation unit, thereby to produce a main feed air stream and a high pressure air stream that is either in a liquid or dense phase fluid state. In this regard, the term, “return streams” as used herein and in the claims means the oxygen-rich and nitrogen-rich streams that are separated from the air by rectification within the air separation unit. Additionally, the term “heat exchanger” means as used herein and in the claims either a single unit or a series of such units in parallel.
[0015] The main feed air stream is introduced into a higher pressure column of the air separation unit. The high pressure air stream is expanded and introduced at least in part into at least one of the lower pressure column or the higher pressure column of the air separation unit. The return streams comprise at least part of a pumped liquid oxygen stream composed of a liquid oxygen column bottoms of the lower pressure column that is introduced into the higher pressure heat exchanger and vaporized. Additionally, return streams also comprise first and second subsidiary waste nitrogen streams that are formed from a waste nitrogen stream removed from the lower pressure column. The first and second subsidiary waste nitrogen streams are introduced into the higher pressure heat exchanger and the lower pressure heat exchanger, respectively, for thermal balance purposes. As used herein and in the claims, the term “thermal balance purposes” means the minimization of the temperature of the streams entering and exiting the warm end of the lower pressure heat exchanger and the temperature differences of the main feed air stream and the high pressure air stream being discharged from the cold end of the higher pressure heat exchanger and the lower pressure heat exchanger, respectively. In this way, the temperature difference between the boosted-pressure air stream and the pumped liquid oxygen stream at the cold end of the higher pressure heat exchanger can be optimized. As indicated above, divergence of temperatures at the warm end of the lower pressure heat exchanger will produce warm end losses of refrigeration and such divergence in temperature at the cold end of the higher pressure heat exchanger will result in the liquid air evolving into an undesirable high vapor fraction upon its expansion that will upset the intended distillation to be carried out in the air separation unit.
[0016] The higher and lower pressure heat exchangers are configured such that the first subsidiary waste nitrogen stream undergoes a higher pressure drop in the higher pressure heat exchanger than the second subsidiary waste nitrogen stream in the lower pressure heat exchanger. This is accomplished by passing the first subsidiary waste nitrogen stream through a smaller cross-sectional flow area than would otherwise be required to produce a pressure drop in the first subsidiary waste nitrogen stream equal to that of the second subsidiary waste nitrogen stream in the lower pressure heat exchanger.
[0017] If for example, the higher pressure heat exchanger were made of plate-fin construction and used a higher cross-sectional flow area for the first subsidiary waste nitrogen stream, thicker parting sheets and side bars would otherwise be required with the result in increased fabrication costs over the heat exchanger being contemplated by the present invention. By passing the first subsidiary waste nitrogen stream through a smaller cross-sectional area its velocity will increase resulting in the higher pressure drop. However, small cross-sectional flow area will also reduce the number of layers of a plate-fin heat exchanger that are required for heat exchange of the first subsidiary waste nitrogen stream within the higher pressure heat exchanger. Since less layers are used, in case of a plate-fin heat exchanger, the height of the higher pressure heat exchanger can be reduced to reduce its fabrication costs.
[0018] An air stream can be compressed, cooled and purified. The air stream is purified in a purification unit having an adsorbent to adsorb higher boiling impurities in the air stream. The first compressed and purified air stream can be formed from a first part of the air stream after having been compressed, cooled and purified. The second compressed and purified air stream can be formed by further compressing and cooling a second part of the air stream after having been compressed, cooled and purified. The adsorbent in the purification unit is regenerated with a second of the first and second waste nitrogen streams having passed through the lower pressure heat exchanger. Thus, since the second of the waste nitrogen streams is at a higher pressure, it is capable of serving such regeneration duties. Thus, nothing is lost by allowing the first subsidiary waste nitrogen stream to undergo the higher pressure drop in the higher pressure heat exchanger.
[0019] A third part of the air stream after having been compressed, cooled and purified can be further compressed and then partially cooled within the lower pressure heat exchanger. Thereafter, it can be turboexpanded within a turboexpander to generate a refrigeration stream and therefore refrigeration for the process. The refrigeration stream can be introduced into the lower pressure column. Alternatively, a third part of the air stream after having been compressed, cooled and purified can be further compressed and cooled and then partially cooled within the higher pressure heat exchanger. Thereafter it can be turboexpanded within a turboexpander to generate a refrigeration stream and then introduced into the lower pressure column.
[0020] In any embodiment of the present invention, a crude liquid oxygen stream composed of liquid column bottoms of the higher pressure column and a nitrogen-rich liquid stream composed of liquefied nitrogen column overhead of the higher pressure column can be subcooled through indirect heat exchanger with the waste nitrogen stream and a nitrogen-rich vapor stream composed of column overhead of the lower pressure column. At least part of the crude liquid oxygen stream and at least part of the nitrogen-rich liquid stream are expanded and introduced into the lower pressure column. The nitrogen-rich vapor stream is introduced into the lower pressure heat exchanger as one of the return streams. Where refrigeration is generated in the lower pressure heat exchanger, a crude liquid oxygen stream composed of liquid column bottoms of the higher pressure column and nitrogen-rich liquid stream composed of liquefied nitrogen column overhead of the higher pressure column can be subcooled within the lower pressure heat exchanger. At least part of the liquid oxygen stream and at least part of the nitrogen-rich liquid stream are expanded and introduced in the lower pressure column. The nitrogen-rich vapor stream is introduced into the lower pressure heat exchanger as one of the return streams. In such embodiment, the nitrogen-rich liquid stream can be a first nitrogen-rich liquid stream and a second nitrogen-rich liquid stream composed of the liquefied nitrogen column overhead of the higher pressure column can be pumped and vaporized within the higher pressure heat exchanger.
[0021] In another aspect, the present invention provides an air separation apparatus. In accordance with this aspect of the invention, a main air compressor, a first after-cooler and a purification unit can be provided to compress, cool and purify an air stream. This produces a first compressed and purified air stream from a first part of the air stream after having been compressed, cooled and purified. A booster compressor, provided in flow communication with the purification unit, can further compress a second part of the air stream after having been compressed, cooled and purified and a second after-cooler can be connected to the booster compressor to cool the second part of the air stream. This forms a second compressed and purified air stream having a higher pressure than the first compressed and purified air stream. A higher pressure heat exchanger and a lower pressure heat exchanger are provided. The higher pressure heat exchanger is connected to the second after-cooler. The lower pressure heat exchanger is in flow communication with the purification unit. Each of the higher pressure heat exchanger and the lower pressure heat exchanger are of brazed aluminum construction.
[0022] The higher pressure heat exchanger and the lower pressure heat exchanger can be configured to cool the first compressed and purified air stream and the second compressed and purified air stream, respectively, through indirect heat exchange with return streams generated in an air separation unit, thereby to produce a main feed air stream and a high pressure air stream that is either in a liquid or a dense phase fluid state. The air separation unit comprises a higher pressure column connected to the lower pressure heat exchanger to receive the main feed air stream and a lower pressure column connected to the higher pressure heat exchanger by an expansion device to receive at least part of the high pressure air stream.
[0023] A pump can be provided to pressurize a liquid oxygen stream composed of a liquid oxygen column bottoms of the lower pressure column. The pump is connected to the higher pressure heat exchanger so that the liquid oxygen stream after having been pumped is introduced into the higher pressure heat exchanger and vaporized. The higher pressure heat exchanger and the lower pressure heat exchanger are also in flow communication with the lower pressure column to receive first and second subsidiary waste nitrogen streams, respectively. The first and second subsidiary nitrogen streams are formed from a waste nitrogen stream removed from the lower pressure column, for thermal balance purposes. The higher pressure heat exchanger is configured such that a smaller cross-sectional flow area for the first subsidiary waste nitrogen stream exists within the higher pressure heat exchanger than would otherwise be required to produce a pressure drop in the first subsidiary waste nitrogen stream equal to that of the second subsidiary waste nitrogen stream in the lower pressure heat exchanger. Again, as outlined above, this allows the higher pressure heat exchanger to be fabricated in a less expensive manner.
[0024] The purification unit can be provided with an adsorbent to adsorb higher boiling impurities in the air stream. The purification unit is connected to the lower pressure heat exchanger so as to receive the second of the first and second waste nitrogen streams after having passed through the lower pressure heat exchanger to regenerate the adsorbent.
[0025] A further booster compressor can also be provided in flow communication with a purification unit to further compress a third part of the air stream and a third after-cooler is connected to the further booster compressor. The lower pressure heat exchanger is connected to the further booster compressor and is configured to partially cool the third part of the air stream after having been further compressed. The turboexpander is connected between the lower pressure heat exchanger and the lower pressure column so as to turboexpand the third part of the air stream. This forms a refrigeration stream that is introduced into the lower pressure column. Alternatively, the higher pressure heat exchanger can be connected to the third after-cooler and can be configured to partially cool the third part of the air stream after having been further compressed. The turboexpander can then be connected between the higher pressure heat exchanger and the lower pressure column so as to turboexpand a third part of the air stream, thereby to form a refrigeration stream that is introduced into the lower pressure column.
[0026] In any embodiment of the present invention, a subcooler can be connected to the higher pressure column and the lower pressure column to subcool a crude liquid oxygen stream composed of liquid column bottoms of the higher pressure column and a nitrogen-rich liquid stream composed of liquefied nitrogen column overhead of the higher pressure column through indirect heat exchange with the waste nitrogen stream and a nitrogen-rich vapor stream composed of column overhead of the lower pressure column. The lower pressure column is also connected to the subcooler to receive at least part of the crude liquid oxygen stream and at least part of the nitrogen-rich liquid stream. Expansion valves located between the lower pressure column and the subcooler expand the at least part of the crude liquid oxygen stream and the at least part of the nitrogen-rich liquid stream. The lower pressure heat exchanger is connected to the subcooler to receive the nitrogen-rich vapor stream as one of the return streams.
[0027] Alternatively, the lower pressure heat exchanger can be connected to the higher pressure column and is configured to subcool the crude liquid oxygen stream composed of liquid column bottoms of the higher pressure column and the nitrogen-rich liquid stream composed of liquefied nitrogen column overhead of the higher pressure column. In such case, the lower pressure column is connected to the lower pressure heat exchanger so that part of the crude liquid oxygen stream and at least part of the nitrogen-rich liquid stream are introduced into the lower pressure column.
[0028] A nitrogen-rich liquid stream can be a first nitrogen-rich liquid stream. A pump can be connected between the higher pressure column and the higher pressure heat exchanger to pressurize a second nitrogen-rich liquid stream composed of liquefied nitrogen column overhead of the higher pressure column. The second nitrogen-rich liquid stream is vaporized within the higher pressure heat exchanger.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] While the specification concludes with claims distinctly pointing out the subject matter that Applicants regard as their invention, it is believed that the invention will be better understood when taken in connection with the accompanying drawings in which:
[0030] FIG. 1 is a schematic process flow diagram of an apparatus utilizing and carrying out a method in accordance with the present invention;
[0031] FIG. 2 is a schematic, fragmentary view of an alternative embodiment of the apparatus illustrated in FIG. 1 that is modified by incorporating a subcooling unit into a lower pressure heat exchanger in accordance with the present invention;
[0032] FIG. 3 is a schematic, fragmentary view of an alternative embodiment of the apparatus illustrated in FIG. 1 that also incorporates the alternative of FIG. 2 and that provides for production of a high pressure nitrogen product; and
[0033] FIG. 4 is a schematic, fragmentary view of an alternative embodiment of the apparatus illustrated in FIG. 1 illustrating an alternative arrangement for providing refrigeration.
[0034] The portions of FIGS. 2 , 3 and 4 that are not shown in the illustrations are the same as shown in FIG. 1 .
DETAILED DESCRIPTION
[0035] With reference to FIG. 1 , an apparatus 1 in accordance with the present invention is illustrated.
[0036] An air stream 10 is compressed in a main air compressor 12 . After removal of the heat of compression by a first after-cooler 14 , air stream 10 is purified within a purification unit 16 . Purification unit 16 , as well known to those skilled in the art can contain beds of adsorbent, for example alumina or carbon molecular sieve-type adsorbent to adsorb the higher boiling impurities contained within the air and therefore air stream 10 . For example such higher boiling impurities as well known would include water vapor and carbon dioxide that could tend to freeze and accumulate at the low rectification temperatures contemplated by apparatus 1 . In addition, hydrocarbons can also be adsorbed that could collect within oxygen-rich liquids and thereby present a safety hazard. A first compressed and purified air stream 18 is produced from a first part of air stream 10 after having been compressed, cooled and purified. A booster compressor 20 is in flow communication with purification unit 16 to compress a second part of the air stream after having been compressed, cooled and purified and a second after-cooler 22 is provided that is connected to booster compressor 20 to remove the heat of compression from the second part of air stream 10 . This forms a second compressed and purified air stream 24 having a higher pressure than the first compressed and purified air stream 18 .
[0037] It is to be noted that main air compressor 10 and booster compressor 20 are shown as single units. However, as is known in the art, two or more compressors can be installed in parallel to form either the main air compressor 10 or the booster compressor 20 . Such compressor can be of equal size, however, unequal sizes in which capacity is split can be used, for example a split of 70/30 or 60/40.
[0038] A higher pressure heat exchanger 26 is connected to second after-cooler 24 and a lower pressure heat exchanger 28 is in flow communication with purification unit 16 to receive the first compressed and purified air stream 18 . Both the higher pressure heat exchanger 26 and the lower pressure heat exchanger 28 are preferably of brazed aluminum construction and consist of layers of parting sheets separated by side bars to produce flow passages for the streams to be heated and cooled. Each of the flow passages are provided with fins as well known in the art to enhance the surface area for heat transfer within said heat exchangers. In this regard, the higher pressure heat exchanger 26 is configured to cool the second compressed and purified air stream 24 to produce a high pressure air stream 30 and the lower pressure heat exchanger 28 is configured to cool a first compressed and purified air stream to produce a main feed air stream 32 . The high pressure air stream 30 is either in a liquid or dense phase state. As can be appreciated, other types of heat exchangers could be used, for example, such as spiral wound, printed circuit and stainless steel plate-fin heat exchangers. Moreover, although each of the higher pressure heat exchanger 26 and the lower pressure heat exchanger 28 are illustrated as single units, in practice, each could consist of several heat exchangers linked together in parallel.
[0039] The lower pressure heat exchanger will have a larger cross-sectional area for flow and a large total volume than the higher pressure heat exchanger 26 . Typically the average density of the higher pressure heat exchanger 26 will be greater than the lower pressure heat exchanger 28 where density is the empty weight divided by volume. A typical density is about 1000 kg/m 3 . A typical working pressure of the higher pressure heat exchanger is about 1200 psig and greater.
[0040] An air separation unit 34 is provided that has a higher pressure column 36 operatively associated with a lower pressure column 38 in a heat transfer relationship by means of a condenser-reboiler 40 . Optionally, as illustrated, air separation unit 34 also includes an argon column 42 that is connected to low pressure column 38 for producing an argon product. It is understood however that argon column 42 is optional and the present invention has applicability to an air separation unit consisting solely of the higher pressure column 36 and the lower pressure column 38 . It is understood that each of the higher pressure column 36 , lower pressure column 38 and argon column 42 contain liquid-vapor mass transfer elements such as sieve trays or packing, either random or structured. Such elements as well known in the art enhance liquid-vapor contact of liquid and vapor phases of the mixture to be separated in each of such columns for rectification purposes.
[0041] High pressure air stream 30 is expanded to a pressure suitable for its introduction into higher pressure column 36 by way of a liquid turboexpander 44 . Energy from liquid turboexpander 44 can be recovered. Alternatively, an expansion valve can be used. After having been expanded, high pressure air stream 30 is divided into a first subsidiary expanded stream 46 and a second subsidiary expanded stream 48 . It is understood that typically first and second subsidiary expanded air stream 46 and 48 are two phase streams. Second subsidiary expanded stream 48 is expanded by an expansion valve 50 to pressure suitable for its introduction into lower pressure column 38 . Thus, both first and second subsidiary expanded streams 46 and 48 are introduced into intermediate locations of higher and lower pressure columns 36 and 38 , respectively at points thereof that would match the composition of the mixture being separated in the columns. It is understood, however, that embodiments of the present invention are possible in which the higher pressure air stream 30 is introduced into either the higher pressure column 36 or the lower pressure column 38 .
[0042] The rectification of the air within higher pressure column 36 produces a crude liquid oxygen column bottoms and a nitrogen-rich vapor column overhead. A nitrogen-rich vapor column overhead stream 52 is condensed in condenser-reboiler 40 against vaporizing an oxygen-rich column bottoms that is produced by the rectification occurring in the lower pressure column. In this regard, such rectification also produces, within lower pressure column 38 , a nitrogen-rich vapor column overhead. The resultant condensation produces a nitrogen-rich liquid stream 54 . First part 56 of nitrogen-rich liquid stream 54 is returned to higher pressure column 36 as reflux. A second part 58 is subcooled within a subcooling unit 60 , expanded within an expansion valve 62 to a pressure suitable for its introduction to lower pressure column 38 and then introduced into lower pressure column 38 as reflux. A crude liquid oxygen stream 64 is also subcooled within subcooling unit 60 , expanded in an expansion valve 64 and a first part 66 thereof is introduced into lower pressure column 38 for further refinement. Additionally, a first part 63 of the nitrogen-rich liquid stream is introduced into lower pressure column 38 . As illustrated, a second part 68 of the nitrogen-rich liquid stream after having been subcooled can be taken as a product stream. Also, a second part 70 of crude liquid oxygen stream 64 is expanded in an expansion valve 72 and then partially vaporized within an argon condenser 74 contained within a shell 76 . Liquid and vapor fractions of second part 70 of crude liquid oxygen stream 64 designated by reference numerals 74 and 76 , respectively are reintroduced into the lower pressure column 38 .
[0043] At a suitable point within lower pressure column 38 , an argon-rich stream 78 is withdrawn and rectified within an argon column 42 to produce an argon-rich vapor stream 80 that is condensed within argon condenser 74 to produce an argon-rich liquid stream 82 . A first part 84 of argon-rich stream 82 can be taken as an argon product stream and a second part 86 thereof can be returned to argon column 42 as reflux.
[0044] A nitrogen vapor product stream 88 can be removed from the top of lower pressure column 38 and a waste nitrogen stream 90 can be removed below the top of low pressure column 38 in order to maintain the purity of nitrogen product stream 88 . Nitrogen product stream 88 and crude nitrogen stream 90 then partially warmed within subcooling units 60 in order to subcool crude liquid oxygen stream 64 and nitrogen-rich liquid stream 58 . Additionally, a liquid oxygen stream 92 composed of the oxygen-rich liquid column bottoms of lower pressure column 38 can be removed therefrom. The first part 94 of liquid oxygen stream 92 can be pressurized by a pump 96 to produce a pumped liquid oxygen stream 98 and a second part 100 of liquid oxygen stream 92 can optionally be taken as a product. Pumped liquid oxygen stream 98 , nitrogen product stream 88 and in a manner to be discussed, crude waste nitrogen stream 90 constitutes return streams of the air separation unit 34 that are used to cool the incoming air within higher pressure heat exchanger 26 and lower pressure heat exchanger 28 . Pumped liquid oxygen stream 98 is vaporized within higher pressure heat exchanger 26 to produce a high pressure oxygen product stream 102 . Nitrogen product stream 88 after having been partially warmed within subcooling unit 60 is introduced into lower pressure heat exchanger 28 and then optionally compressed with a compressor 104 to produce a nitrogen vapor product stream 106 .
[0045] After partially warming with subcooling unit 60 , waste nitrogen stream 90 is divided into a first subsidiary waste nitrogen stream 108 and a second subsidiary waste nitrogen stream 110 . First subsidiary waste nitrogen stream 108 and second subsidiary waste nitrogen stream 110 are introduced into higher and lower pressure heat exchangers 26 and 28 , respectively, for thermal balancing purposes such as have been described above. Advantageously, second subsidiary waste nitrogen stream 110 , after having traversed lower pressure heat exchanger 28 , can be divided into first and second portions 112 and 114 . Portion 112 can be utilized to regenerate the adsorbent within purification unit 16 in a manner known in the art and second subsidiary waste nitrogen stream 108 is fully warmed and discharged as a waste nitrogen stream 116 . As described above, thermal balancing is required in order to minimize the temperature difference between the return streams and the air streams within lower pressure heat exchanger 28 at the warm end thereof, namely, second subsidiary waste nitrogen stream 110 , product nitrogen stream 88 and incoming first compressed and purified air stream 18 to eliminate warm end refrigeration losses at lower pressure heat exchanger 28 . Low pressure air stream 32 and high pressure air stream 30 will be similar temperatures such that the temperature difference between pumped liquid oxygen stream 98 and high pressure air stream 30 must is optimized. If the temperature of high pressure air stream 30 is too high, upon expansion thereof within liquid turboexpander 40 or an expansion valve, too much vapor will evolve and will not produce the desired distillation.
[0046] As also mentioned above, higher pressure heat exchanger 26 and lower pressure heat exchanger 28 are preferably of brazed aluminum design. Higher pressure heat exchanger 26 , given its high pressure environment, will require thicker parting sheets and side bars and high fabrication costs. In order to decrease the fabrication costs, yet perform the thermal balancing function, cross-sectional flow area for first subsidiary waste nitrogen stream 108 is sized such that first subsidiary waste nitrogen stream 108 undergoes a higher pressure drop and therefore, the warm waste nitrogen stream 116 is at a lower pressure than first and second parts 112 and 114 of fully warmed second subsidiary waste nitrogen stream 110 . The cross-sectional flow area is selected such that the pressure drop within the higher pressure heat exchanger 26 of first subsidiary waste nitrogen stream 108 is greater than that would otherwise have been required to produce the pressure drop of second subsidiary waste nitrogen stream 110 within lower pressure heat exchanger 28 . Given the fact that first part 112 of fully warmed second subsidiary waste nitrogen stream 110 has not undergone a great pressure drop, it can be utilized to regenerate the absorbent within prepurification unit 16 .
[0047] As described above and as well known in the art, plate-fin heat exchangers have a layered construction in which each of the streams, for example the incoming air stream, the nitrogen-rich stream and etc. pass through separate layers that are arranged in a pattern to efficiently conduct indirect heat exchange between the streams. The layered construction is produced in such heat exchangers by a series of parallel parting plates and peripheral side bars to seal the layers along their edges. Manifolds are provided to feed the streams into the layers. An arrangement of fins is provided in each of the layers that increase the area available for the heat exchange. In the preferred embodiment, the cross-sectional flow area of the higher pressure heat exchanger 26 is reduced by manipulating the number of layers therewithin. As a result, higher pressure heat exchanger 26 is of lower height than it otherwise would have been had the pressure drop within first subsidiary waste nitrogen stream 108 and second subsidiary waste nitrogen stream 110 been equal. Nonetheless, the higher velocity of stream 108 through high pressure heat exchanger 26 enables the necessary heat transfer to be accomplished due to dramatically improved heat transfer coefficients. Similarly, for a spiral wound heat exchanger the increased velocity will result in the necessary heat transfer being accomplished with a smaller number of tubes for the first subsidiary waste nitrogen stream. The whole unit will therefore be smaller and require less material.
[0048] A printed circuit-type heat exchanger is similar to a plate-fin heat exchanger in that it is constructed from a number of layers. A higher velocity of the first subsidiary nitrogen stream will result in a higher pressure drop for the same heat transfer, but at the expense of fewer layers and therefore a cheaper heat exchanger.
[0049] As well known in the art, any cryogenic rectification plant must be refrigerated in order to overcome warm end heat exchange losses. In air separation plant 1 , a third part 118 of the compressed and purified air stream 10 after having been compressed, cooled and purified is then further compressed within a booster compressor 120 and then cooled within a third after-cooler 122 . After partially cooling within lower pressure heat exchanger 28 , the resultant partially cooled stream 124 can be introduced into a turboexpander 126 to produce a refrigeration stream 128 as an exhaust. Refrigeration stream 128 is introduced into lower pressure column 38 .
[0050] With reference to FIG. 2 a higher pressure heat exchanger 28 ′ is illustrated that is an alternative embodiment to higher pressure heat exchanger 28 shown in FIG. 1 . In higher pressure heat exchanger 28 ′, the subcooling unit 60 has been eliminated and incorporated into the higher pressure heat exchanger 28 ′. The resultant method and apparatus is much the same as that described with respect to air separation plant 1 . However, the main air stream 32 is withdrawn at an intermediate location of higher pressure heat exchanger 28 ′ given the lower cold end temperatures that result from the elimination of the subcooling unit 60 .
[0051] With reference to FIG. 3 , an alternative embodiment of the air separation plant shown in FIG. 1 and as modified in FIG. 2 is to produce a high pressure nitrogen product stream by pumping a first part 68 ′ of the nitrogen-rich liquid stream within a pump 130 and then vaporizing the pumped nitrogen stream to produce a high pressure nitrogen vapor stream 132 within higher pressure heat exchanger 26 ′ that is provided with passages for such purpose. As can be appreciated, the air separation column of FIG. 3 would in all other respects be similar to the air separation plant shown in FIG. 2 . Moreover, a product nitrogen stream 68 could be taken as illustrated in FIGS. 1 and 2 .
[0052] With reference to FIG. 4 , a third part 136 of air stream 10 after having been compressed, cooled and purified can be compressed in a booster compressor 138 and cooled within a third after-cooler 140 to remove the heat of compression and is then partly cooled within a higher pressure heat exchanger 26 ′ having passages provided for such purpose. The resulting partially cooled stream 142 can be expanded within a turboexpander 144 to produce a refrigerant stream 146 from the exhaust thereof. Refrigerant stream 146 can be introduced into the lower pressure column 38 . In all other respects, the embodiment shown in FIG. 4 can be the same as that illustrated in FIG. 1 . The following table summarizes a calculated example for a process in accordance with the present invention that is conducted with the apparatus shown in FIG. 3 .
[0000]
Stream
Temper-
Pressure,
Percent
No.
Flow
ature, K
psia
Composition
vapor
*10
5036
285.9
87.6
Air
100
18
2875
285.9
87.6
Air
100
24
1623
308.2
1600
Air
100
32
2875
102.1
84.2
Air
100
30
1623
99.1
1597
Air
0
46
454
96.7
83.7
Air
0
**48
1169
81.5
19.1
Air
15.8
124
538
183.8
161.0
Air
100
128
538
108.9
19.5
Air
100
68
21.7
80.8
80.9
99.9995% N 2 + Ar
0
84
34.2
88.5
16.8
99.9997% Ar
0
100
29.4
93.7
20.9
99.6% O 2
0
102
1000
304.1
1266
99.6% O 2
100
110
2293
79.8
18.5
98.6% N 2
100
***110
2293
286.9
16.5
98.6% N 2
100
108
416
79.8
18.5
98.6% N 2
100
116
416
304.1
15.5
98.6% N 2
100
****88
1000
286.9
16.2
99.9995% N 2 + Ar
100
132
241
304.1
175
99.9995% N 2 + Ar
100
*10: Air stream 10 after having been compressed in main air compressor 12 and purified within purification unit 16.
**48: Second subsidiary expanded stream 48 after passage through valve 50.
***110: Second subsidiary waste nitrogen stream 110 after passage through lower pressure heat exchanger 28
****88: Nitrogen vapor product stream after passage through lower pressure heat exchanger 28.
[0053] While the present invention has been described with reference to preferred embodiments, as will occur to those skilled in the art, numerous changes and additions and omissions can be made without departing from the spirit and the scope of the present invention that set forth in the presently pending claims.
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A compressed air stream is cooled to a temperature suitable for its rectification within a lower pressure heat exchanger and a boosted pressure air stream is liquefied or converted to a dense phase fluid within a higher pressure heat exchanger in order to vaporize pumped liquid products. Thermal balancing within the plant is effectuated with the use of waste nitrogen streams that are introduced into the higher and lower pressure heat exchangers. The heat exchangers are configured such that the flow area for the subsidiary waste nitrogen stream within the higher pressure heat exchanger is less than that would otherwise be required so that the subsidiary waste nitrogen streams were subjected to equal pressure drops in the higher and lower pressure heat exchangers. This allows the higher pressure heat exchanger be fabricated with a reduced height and therefore a decrease in fabrication costs.
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FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a combing machine having a pair of detachment rolls, and a nipper head which, during a nip, effects a forward stroke towards the pair of detachment rolls as well as a return stroke.
In combing machines which operate in accordance with the Nasmith principle, the web is completely separated and then brought together again during a nip, i.e. during a complete stroke cycle of the nipper. Although the separating by an extensive drawing between defined clamping points does not raise any problem, the bringing together of the web, referred to as "piecing", encounters difficulties.
Piecing is a very important quality feature. Good piecing of the web (top) is characterized by a parallel, stretched position of the fibers, connected with uniform distribution of the fibers in longitudinal and transverse directions.
Good piecing requires an undisturbed application of the starting end of the following fiber structure (i.e. of the fiber tuft) onto the trailing end of the top.
On the one hand, with increasing frequency of stroke of the nipper or with an increasing number of nips, undisturbed piecing becomes more and more difficult. On the other hand, a high number of nips is desired since the production of combed sliver can thus be directly increased. Every spinning mill is confronted by the task of finding a suitable compromise between productivity and quality upon combing.
For reasons of economy, therefore, the highest possible number of nips without disturbing reductions in quality is desirable.
SUMMARY OF THE INVENTION
It is an object of the present invention is to increase the number of nips while at the same time retaining good quality of piecing.
In accordance with the invention, in a path of the strokes of the nipper head, there are present active means for forcing a fiber tuft into a given relative position with respect to the nipper head at least at the end of the forward stroke movement.
BRIEF DESCRIPTION OF THE DRAWINGS
With the above and other objects and other advantages in view, the present invention will become more clearly understood in connection with the detailed description of preferred embodiments, when considered with the accompanying drawings of which:
FIG. 1 is a cross section through a combing machine, the fiber tuft being combed out by the comb cylinder;
FIG. 2 is a similar, but simplified, showing of FIG. 1, shortly before the start of the piecing process;
FIG. 3 shows a detail from FIG. 2 on a larger scale, partially in section;
FIG. 4 is an identical showing as FIG. 3, of a second embodiment; and
FIG. 5 shows three variants of the blast nozzle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the construction, in principle, of a combing machine such as described in detail in U.S. Pat. No. 3,479,699 (Swiss patent 485 873). In the machine stand 1, a nipper head 3 is swingably fastened by a clamp 8 on a nipper shaft 2, a combing cylinder 4 having a needle segment 5 being associated with the nipper head 3. The nipper head 3 cooperates with detachment rolls 6. The wadding 7 to be combed is fed continuously to the nipper head from a lap roll (not shown), which rests on a pair of continuously driven shafts, also not shown. The front end of the wadding 7, the so-called fiber tuft 10, is connected (called piecing) to the top 11 which is held between the detachment rolls 6--following a pilgrimstep-like rearward movement of the top--moved away, and detached from the following wadding 7. The comber waste (noils) combed out from the fiber tuft 10 is removed from the needle segment 5 by a brush roller 12 rotating in opposite direction with high circumferential speed. The nipper head 3 has a lower nipper 13 pivoted to the nipper shaft 2 and an upper nipper 14 swingably mounted.
The on said lower nipper 13. The lower nipper 13 consists essentially of a lower-nipper arm 15 and a lower-nipper plate 16 fastened to it. The upper nipper 14 is swingably mounted having an upper nipper plate 21 (knife) on the lateral swivel pins 17 of the lower-nipper arm 15. In the lower nipper 13 there is supported a feed roller 18 for the wadding 7 which converts the continuous advance of the wadding into a discontinuous advance. The intermittent drive of the feed roller 18 is effected in the rhythm of the movement of the nipper head by means of a pawl drive, not shown, but described in detail in U.S. Pat. No. 3,479,699 (Swiss Patent 485/873)
In the lower nipper plate 16 which is in the form of a hollow body there is an air chamber 26 which is connected, for instance, by an elastically expandable hose 27, continuously to a source of compressed air (not shown) also during the stroke movements. In the clamping surface of the lower nipper plate 16 which cooperates with the upper nipper plate 21, there debouches a slot nozzle 28 (FIG. 5a) which extends substantially over the width thereof or a series of slot openings or holes (FIG. 5b, c) through which the blast air can emerge from the air chamber 26 in the direction against the detachment rolls 6 below the fiber tuft 10. When the nipper head 3 is closed, the upper nipper plate 21 rests against the slot nozzle opening and closes it.
The upper nipper 14 consists, in principle, of an upper nipper arm 20 which is pivoted to the swivel pin 17 and of the upper nipper plate 21 fastened thereto, as well as of a lever firmly attached to the upper nipper arm 20. Furthermore, there is mounted on the upper nipper 14 an adjustable insertion comb 19 which retains those fibers of the fiber tuft 10 which do not have the length of the tearing distance ("ecartement") from being pulled into the detachment rolls 6. The upper nipper plate 21 is swingable in synchronism with the movement of the nipper head 3 towards and away from the lower nipper plate 16 in such a manner that the nipper head 3 is closed in the rear end position (shown in FIG. 1,) and clamps the fiber tuft 10 firmly between the lower nipper plate 16 and the upper nipper plate 21 (and closes the slot nozzle 28,) and is open in the front end position (in which the lower nipper plate 16 has arrived at a position in front of the clamping point of the detachment rolls 6 which is equal to the detachment length). The synchronization of the movement of the upper nipper 14 with the movement of the nipper head 3 is effected by means of a link 22 the ends of which are pivoted at one end on the machine stand 1 and at the other end on the lever 9 which is firmly attached to the upper nipper arm 20.
The detachment rolls 6 are formed of two pairs of detachment rolls 6', 6", each of which has a lower driven detachment roll 23 and an upper non-driven detachment roll 24. The detachment rolls 6 can also be formed by only one pair of detachment rolls 6". Their periodic forward and backward control effects (as already mentioned,) on the whole, a conveying of the top 11 in the direction indicated by the arrow 25 as well as a connection with the combed fiber tuft 10 fed by the nipper head 3.
The sector angle of the needle segment and the radius of the combing cylinder 4 are such that all needles of the needle segment 5 in the region of the rear end position (shown in FIG. 1) of the nipper head 3 comb once through the fiber tuft 10.
The drive of the comber is effected by means of a motor 31 which, via a reduction gearing 32, drives a timing shaft 33. Upon each revolution of the timing shaft 33 the machine effects one nip. A crank pin 34 which rotates with the timing shaft 33 is operatively connected by a crank rod 35 to a swivel pin 36 on a lever 36' which is firmly attached to the nipper shaft 2, the swinging movement of which during one revolution of the timing shaft 33 swings the nipper head 3 once from the rear end position into the front end position and back again.
Furthermore, the combing cylinder 4 and, via a known pilgrim-step transmission 37, the lower detachment rolls 23 are driven in synchronism by the timing shaft 33 in such a manner that their forward and return travel takes place during a nip in the same way as in the known combing machines. The circumferential speed of the brush roller 12 is greater than that of the oppositely rotating combing cylinder 4.
The manner of operation will be described below with reference to the drawing.
During a nip, the nipper head 3 swings around the nipper shaft 2 out of the rear end position (in which it comes very close to the circumference of the combing cylinder 4) into the front end position and back again, the leading edge of the lower nipper plate 16 moving over a circular arc 41. During the outward movement directed toward the detachment rolls 6, the leading edge of the lower nipper plate 16 moves away from the combing cylinder 4 and approaches it again during the return movement. During this return, the nipper head 3 closes before the needle segment 5 starts the combing-out of the fiber tuft 10 and opens again only when the needle segment 5 and the fiber tuft 10 have separated from each other. During the outward movement, the fiber tuft 10, with the nipper head open, is moved with its leading edge for piecing to the trailing end of the top 11.
In order that with high nip numbers the air resistance does not press the fiber tuft 10 (in combination with its moment of inertia) downward in front of the lower nipper plate 10, the air outlet from the slot nozzle 28 (or a corresponding number of nozzle holes) is freed with the opening of the nipper 3 (FIGS. 2 to 4). The stream of air emerging from the slot nozzle 28 acts on the bottom of the fiber tuft 10 and holds it stretched in front of the lower nipper 13 which is swinging towards the detachment rolls 6. Cross-section, direction and intensity of the stream of air must be such that upon the outward movement during a nip, a well-defined position results for the fiber tuft and, accordingly, an exact impingement and placing of the tip of the fiber tuft on the trailing end of the top 25.
Between the source of compressed air (not shown) and the air chamber 26, a reduction valve can be provided by which the pressure or the speed of the air emerging from the slot nozzle 28 can be optimally adjusted as a function of the stiffness of the fiber tuft and the operating speed of the machine.
As shown in FIG. 4, the direction of the blast of air, instead of being in the direction of movement of the fiber tuft 10, can be directed at an acute angle to the lower side thereof in order to achieve a substantially flat alignment. This variant can be suitable when operating with greater amounts of blast air and lower blast-air pressure.
It is of particular importance that, at the end of the forward stroke movement, the supporting and stabilizing of the fiber tuft 10 takes place, i.e. at that moment when it comes into contact with the top 11 and the piecing commences. At the end of the forward stroke movement, the speed of which has a substantially sinusoidal course, the nipper head 3 is slowed down to standstill, as a result of which the resistance of the air decreases and the mass inertia throws the free end of the fiber tuft 10 against the top 11. During the piecing, therefore, an exactly determined position of the fiber tuft 10, and a constantly high quality of the piecing, can therefore be brought about with comparatively small blast-air velocities and quantities.
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A combing machine having a pair of detachment rolls (6") and a nipper head (3) which, during a nip, carries out a forward stroke towards the pair of detachment rolls (6") and a return stroke. In the path of the stroke of the nipper head (3) active apparatus (26, 27, 28) is present in order to force a fiber tuft (10) into a given relative position with respect to the nipper head (3) at least at the end of the forward stroke movement.
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BACKGROUND OF THE INVENTION
The present invention relates to a novel triphenylmethane derivative which is useful as a medicament for treating osteoporosis.
Hitherto, phenolphthalin derivatives in which a carboxyl group is subjected to amidation are known. Chem. Abst., 53, 21801f (1959) discloses phenolphthalin derivatives in which carboxyl is modified to amide. Chem. Abst., 64, 19789g (1966) discloses those in which carboxyl is modified to anilide. Japanese Published Unexamined Patent Application No. 132,336/81 discloses phenolphthalin derivatives in which carboxyl is modified to methylamide.
J.C.S. Perkin I., 1978, 1211 and Archiv der Pharmazie 292, 690 (1952) describe phenolphthalin derivatives in which carboxyl is changed to amino.
In Arch. Pharm., 293, 733 (1960) are disclosed phenolphthalin derivatives represented by the following structural formula (P): ##STR2## in which R A , R B and R D are hydrogen, and R C is hydrogen, n-butyl or thioanilide; and phenolphthalin derivatives represented by the above formula in which R C is hydrogen, and R A , R B and R D represent acetyl. In Arch. Pharm., 292, 690 (1959) are disclosed phenolphthalin derivatives represented by the formula (P) in which both of R A and R B are hydrogen, and both of R C and R D are methyl or ethyl, or R C and R D are combined with nitrogen atom adjacent thereto together to form ##STR3##
It has however been not known that triphenylmethane derivatives are useful as a medicament for treating osteoporosis.
SUMMARY OF THE INVENTION
The present invention provides triphenylmethane derivatives represented by the following formula (I): ##STR4## wherein each of R 1 and R 2 independently represents hydrogen, lower alkyl, aralkyl, lower alkanoyl or lower alkoxymethyl; R 3 represents
--CONR 4 R 5 where each of R 4 and R 5 independently represents hydrogen, unsubstituted or substituted lower alkyl, cycloalkyl, allyl, unsubstituted or substituted aralkyl, styryl, or unsubstituted or substituted aryl, ##STR5## where Q 1 represents hydrogen or lower alkyl, m is an integer of 0 or 1, and n is an integer of 0-5, ##STR6## where n has the same meaning as previously defined, ##STR7## where m has the same meaning as previously defined, ##STR8## where Q 2 represents hydrogen, lower alkyl, or unsubstituted or substituted aralkyl, Q 1 , m and n have the same meaning as previously defined, ##STR9## where is single bond or double bond, Y 1 is hydrogen, Y 2 represents hydrogen, lower alkyl, unsubstituted or substituted aryl, pyridyl, piperidino or ##STR10## or Y 1 and Y 2 are combined together to form oxygen or --(CH 2 ) 5 --, p is an integer of 1-5, and Q 1 and m have the same meaning as previously defined, ##STR11## where X represents oxygen, sulfur or ##STR12## where Q 3 represents hydrogen, lower alkyl, unsubstituted or substituted aralkyl, unsubstituted or substituted aryl, pyridyl or lower alkoxycarbonyl, and p has the same meaning as previously defined, ##STR13## where Q 4 represents hydrogen, unsubstituted or substituted aryloxy, or halogen-substituted or unsubstituted pyridyloxy, and n has the same meaning as previously defined, ##STR14## where Q 5 represents hydrogen, lower alkyl, lower alkoxyl or aryl, and n has the same meaning as previously defined, ##STR15## where Q 5 and n have the same meanings as previously defined, ##STR16## where Q 5 and n have the same meanings as previously defined, or ##STR17## where R 1 and R 2 have the same meanings as previously defined (hereinafter, the foregoing definitions for R 4 and R 5 are referred to as "Group A"); or R 4 and R 5 are combined with nitrogen atom adjacent thereto to form a heterocyclic ring selected from the group consisting of ##STR18## where Q 1 , Y 1 , Y 2 and m have the same meanings as previously defined, ##STR19## where X has the same meaning as previously defined, ##STR20## (hereinafter the foregoing heterocyclic rings are referred to as "Group B"), provided that when R 4 is hydrogen, R 5 represents the other groups than hydrogen, methyl and phenyl, ##STR21## where R 6 represents hydrogen or lower alkyl, and each of R 4a and R 5a independently represents Group A or Group B, provided that when R 4a is hydrogen, R 5a represents the other groups than hydrogen and butyl, or both of R 4a and R 5a represent the other groups than methyl and ethyl, or R 4a and R 5a are combined with nitrogen atom adjacent thereto to form the other groups denoted by Group B than piperidino and morpholino, or ##STR22## where R 4b is Group A, and R 6 has the same meaning as previously defined; or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
In the definitions of the respective groups in the general formula (I), the lower alkyl and the alkyl moiety in the lower alkoxy, lower alkoxymethyl and lower alkoxycarbonyl means a straight or branched alkyl having 1 to 6 carbon atoms, for example, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, tert-butyl, pentyl, neopentyl, hexyl, etc. The cycloalkyl means cycloalkyls having 3 to 8 carbon atoms, for example, cyclopropyl, cyclopentyl, cyclohexyl, cyclooctyl, etc. The lower alkanoyl means a straight or branched alkanoyls having 1 to 5 carbon atoms, such as formyl, acetyl, propionyl, butyryl, isobutyryl, valeryl, pivaloyl, etc. The aralkyl means benzyl, benzhydryl, trityl, phenethyl, 1,2-diphenylethyl, etc. The aryl and aryl moiety in aryloxy mean phenyl, naphthyl, etc.
The number of the substituents for substituted alkyl is one to 3. The substituents are same or different, and include, for example, lower alkoxyl, mono- or di-alkyl-substituted amino or halogen.
The number of substituents for aryl and the aromatic moiety in the aralkyl is one to 3. The substituents are same or different, and include, for example, lower alkyl, trifluoromethyl, hydroxyl, lower alkoxyl, lower alkylthio, halogen, nitro, amino, lower alkanoyl, aroyl, morpholino, carboxyl, lower alkoxycarbonyl, etc. The lower alkyl and alkyl moiety in lower alkylthio and lower alkoxycarbonyl mean the same significance as defined for alkyl. The lower alkanoyl and aryl moiety in aroyl has the same meaning as previously defined. Halogen means fluorine, chlorine, bromine or iodine.
As the pharmaceutically acceptable salts of Compound (I), mention may be made of the acid addition salt such as hydrochloride, hydrobromide, hydroiodide, nitrate, sulfate, phosphate, formate, acetate, benzoate, maleate, fumarate, succinate, tartarate, citrate, oxalate, glyoxylate, asparate, methanesulfonate, ethanesulfonate, benzenesulfonate, and the like.
Processes for producing Compound (I) are described below.
Compound (Ia), which is Compound (I) in which R 1 and R 2 are other groups than hydrogen and R 3 is --CONR 4 R 5 can be prepared from phenolphthalin represented by the formula (II) in accordance with the following reaction steps: ##STR23## wherein R 1a represents other groups denoted by R 1 than hydrogen, R 2a represents other groups denoted by R 2 than hydrogen, R 1b represents other groups denoted by R 1 than hydrogen and lower alkanoyl, R 2b represents other groups denoted by R 2 than hydrogen and alkanoyl, R 7 has the same meanings as defined for R 1b and R 2b; Z represents halogen, such as chlorine, bromine and iodine; and R 4 and R 5 have the same meanings as previously defined.
Compounds (VI), in which R 1b and R 2b are lower alkyl or aralkyl is prepared by reacting Compound (II) with an alkylating agent or an aralkylating agent. As the alkylating agent, mention may be made of halogenated alkyls, such as methyl iodide, ethyl iodide, propyl iodide, isopropyl iodide, methyl bromide, ethyl bromide, propyl bromide and isopropyl bromide; dialkylsulfuric acids, such as dimethylsulfuric acid; and diazoalkanes, such as diazomethane. As the aralkylating agent, mention may be made of halogenated aralkyls, such as benzyl bromide and benzyl chloride. In the alkylation and aralkylation reactions, any solvent can be used as the reaction solvent, so long as it does not interfere with the reaction. As the solvent, mention may be made of halogenated hydrocarbons, such as dichloromethane, chloroform, dichloroethane and carbon tetrachloride; aromatic hydrocarbons such as benzene, toluene and xylene; ketones such as acetone and methyl ethyl ketone; alcohols such as methanol, ethanol and isopropanol; ethers such as diethyl ether, dioxane and tetrahydrofuran; amides such as formamide and dimethylformamide; acetonitrile; ethyl acetate; dimethyl sulfoxide and the like. The solvent can be used either alone or in combination. Usually, the reaction proceeds at a temperature of from 0 ° C. to the boiling point of the solvent used and terminates in 1 to 72 hours. If desired, the reaction may be carried out in the presence of an inorganic base, such as sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, cesium carbonate, sodium hydrogencarbonate and silver oxide, or an organic base such as triethylamine, N,N-diisopropylethylamine, N-methylmorpholine, pyridine and dimethylaminopyridine, so as to allow the reaction to proceed smoothly.
Compound (VI) in which R 1b and R 2b are lower alkoxymethyl is prepared by reacting Compound (II) with an alkoxymethylating agent. As the alkoxymethylating agents, mention may be made of methoxymethyl chloride, 2-methoxyethoxymethyl chloride and the like. The reaction is carried out in a similar manner as in the alkylation reaction described above.
Compound (III) in which R 1a and R 2a are lower alkyl, aralkyl or lower alkoxymethyl is prepared by hydrolyzing Compound (VI) with an acid or an alkali. As the acid, mention may be made of mineral acids such as hydrochloric acid and sulfuric acid; and organic acids such as formic acid, acetic acid and trifluoroacetic acid. As the alkali, mention may be made of sodium hydroxide, potassium hydroxide and the like. As the reaction solvent, water is used in addition to those mentioned hereinabove. Usually, the reaction proceeds at a temperature of from 0° C. to the boiling point of the reaction solvent used and terminates in 1 to 24 hours.
Compound (III) in which R 1a and R 2a are lower alkanoyl is prepared by reacting Compound (II) with an acylating agent. As the acylating agent, mention may be made of the reactive derivative of corresponding carboxylic acids, for example, acid anhydrides such as acetic anhydride and propionic anhydride; and acid halides such as acetyl chloride and acetyl bromide. The acylation reaction is carried out in a similar manner as in the alkylation reaction described hereinabove.
Compound (IV) is prepared by reacting Compound (III) with a halogenating agent. As the halogenating agent, mention may be made of thionyl chloride, phosphorus pentachloride, phosphorus trichloride, phosphorus tribromide and the like.
Then, Compound (Ia) is obtained by reacting Compound (IV) with an amine represented by the formula (V): ##STR24## in which R 4 and R 5 have the same meaning as previously defined.
Compound (V) is used in an amount of 0.1 to 10 equivalents, preferably 0.5 to 3 equivalents, based on Compound (IV). As the reaction solvent, there can be used water, in addition to those mentioned hereinabove. The reaction is carried out at a temperature of from -20° C. to the boiling point of the reaction solvent used and terminates in 30 minutes to 48 hours. If desired, the reaction is carried out in the presence of a base such as those described hereinabove.
Compound (Ic) which is Compound (I) in which R 1 and R 2 are lower alkyl, aralkyl or lower alkoxymethyl and R 3 is ##STR25## where R 61 is the other group denoted by R 6 than hydrogen, and R 5a has the same meaning as previously defined, is prepared form Compound (VI) in accordance with the following reaction steps: ##STR26## in which R 1b , R 2b , R 5a , R 6a and R 7 have the same meanings as previously defined.
Compound (VII) is prepared by reducing Compound (VI). As the reducing agent, mention may be made of lithium aluminum hydride, 9-borabicyclo[3.3.1]nonane, lithium triethyl borohydride, aluminum hydride, lithium trimethoxyaluminum hydride and the like.
Compound (VIII) is prepared by oxidizing Compound (VII). As the oxidizing agents usable therefor, mention may be made of Jones oxidation reagent Swern oxidation reagent and Corey-Kim oxidation reagent as well as pyridinium chlorochromate, pyridinium dichromate, manganese dioxide, silver oxide, ruthenium oxide and the like.
Compound (VIII) is obtained by directly reducing Compound (VI). As the, reducing agent usable therefor, mention may be made of diisobutylaluminum hydride and the like.
Compound (IX) is prepared by reacting Compound (VIII) with Compound (Va) represented by the formula (Va).
H.sub.2 N -R.sup.5a (Va)
where R 5a has the same meaning as previously defined.
Compound (Va) is used in an amount of 0.1 to 10 equivalents, preferably 0.5 to 3 equivalents, based on Compound (VIII). The reaction solvent includes water and those described hereinabove. The reaction is carried out at a temperature of -20° C. to the boiling point of the solvent used and terminates in 30 minutes to 48 hours. If desired, the reaction proceeds in the presence of a base such as those mentioned hereinabove.
Compound (Ic) is prepared by reacting Compound (IX) with Compound (X) represented by the following formula:
Li-R.sup.6a (X)
in which R 6a have the same meaning as previously defined.
Any reaction solvent is used alone or in combination, so long as it does not participate in the reaction. The reaction solvent includes, for example, hydrocarbons such as n-hexane, n-pentane, n-heptane and cyclohexane; ethers such as diethyl ether, tetrahydrofuran and dioxane; aromatic hydrocarbons such as toluene and benzene. Usually, the reaction is carried out at a temperature of -78° C. to the boiling point of the solvent used and terminates in 30 minutes to 24 hours.
Compound (Id), which is Compound (I) where R 1 and R 2 are lower alkyl, aralkyl or alkoxymethyl and R 3 is --CH 2 NHR 5a is prepared by reducing Compound (IX). As the reducing agents usable therefor, mention may be made of complexes of metal hydrides such as aluminum hydride, sodium borohydride and sodium cyanoborohydride. Compound (Id) is also prepared directly, from Compound (VIII), by subjecting Compound (VIII) to amination under a reducing condition.
Compound (Ie) or (If), which is Compound (I) where R 1 and R 2 are lower alkyl or lower alkanoyl and R 3 is ##STR27## is prepared in accordance with the following reaction steps from Compound (XI) which is prepared according to the process of J.C.S. Perkin I, 1978, 1211. ##STR28## in which R 1a , R 2a , R 4b , R 6a and Z have the same meanings as previously defined.
Compound (XII) is prepared by subjecting Compound (XI) to alkylation, aralkylation, alkoxymethylation or acylation in a similar manner as described hereinabove.
Compound (XIII) is prepared by reducing Compound (XII). The reduction reaction is carried out by any of the conventional methods for reducing nitro group to amino group. For example, the reaction is carried out by using a combination of a metal such as tin, iron, zinc, etc., and an acid such as an mineral acid (e.g., hydrochloric acid or sulfuric acid) or organic acids (e.g., acetic acid), or by using sulfides or hydrazines. It can also be carried out catalytically, using a catalyst, such as palladium-carbon and the like.
In case of using a catalyst, the reaction is effected by allowing Compound (XII) to adsorb 3 equivalents of hydrogen in water or a lower alcohol (e.g., methanol, ethanol, etc.) or a mixture thereof, at a temperature of 0° C. to the boiling point of the reaction solvent used. The reaction usually terminates in 30 minutes to 48 hours.
Compound (Ie) is prepared by reacting Compound (XIII) with Compound (XIV) represented by the following formula:
R.sup.4b COZ (XIV)
in which R 4b and Z have the same meanings as previously defined.
Compound (XIV) is readily prepared by the halogenation of a corresponding carboxylic acid, R 4b COOH. As the halogenating agent usable therefor, mention may be made of thionyl chloride, phosphorus pentachloride, phosphorus trichloride, phosphorus tribromide and the like. Compound (XIV) is used in an amount of from 0.1 to 10 equivalents, preferably from 0.5 to 3 equivalents based on Compound (XIII). As the reaction solvent, mention may be made of water as well as those solvents described hereinabove. The reaction is carried out at a temperature of -20° C. to the boiling point of the solvent and terminates in 30 minutes to 48 hours. If desired, the reaction is carried out in the presence of a base such as those as described hereinbefore.
Compound (If) is prepared by subjecting Compound (Ie) to alkylation in a similar manner as described hereinabove.
Compound (Ib), which is Compound (I) in which R 1 and R 2 are hydrogen is prepared by hydrolyzing Compound (Ia), (Ic), (Id), (Ie) or (If) where the corresponding R 1a or R 1b , and R 2a or R 2b are lower alkanoyl in the presence of a base. As the base, there can be used those described hereinabove. As the reaction solvent, water as well as alcohols such as methanol and ethanol can be used alone or in combination. The hydrolysis is carried out at a temperature of 0° C. to the boiling point of the reaction solvent used and terminates in 30 minutes to 24 hours.
Compound (Ib) is also prepared by treating, in an acidic solution, Compound (Ia), (Ic), (Id), (Ie) or (If) in which R 1a and R 2a are lower alkoxymethyl. The acid usable therefor includes, for example, mineral acids such as hydrochloric acid and sulfuric acid; organic acids such as acetic acid and trifluoroacetic acid, and the like. Usually, the treatment is carried out at a temperature of 0° C. to the boiling point of the reaction solvent used and terminates in 10 minutes to 24 hours.
Compound (Ib) is obtained by reducing Compound (Ia), (Ic), (Id), (Ie) or (If) in which R 1a and R 2a are aralkyl, with a hydrogenation catalyst such as palladium-carbon and the like, or by treating the compound with a hydrogen bromide-acetic acid solution and the like.
Compound (Ia), (Ic), (Id), (Ie) or (If) where R 1 and R 2 are lower alkyl is obtained by allowing Compound (Ib) to react with alkylating agent such as those as described hereinabove.
Compound (Ig), which is Compound (Ic) or (Id) where R 1b or R 2b is lower alkanoyl is synthesized by subjecting Compound (Ib) where R 3 is ##STR29## to a similar alkanoylation reaction as described hereinabove.
Compound (Ih) which is Compound (I) where R 3 is ##STR30## is prepared by reacting Compound (XVI) represented by the following formula: ##STR31## in which R 1 , R 2 , R 6 and Z have the same meanings as previously defined with Compound (Vb) represented by the following formula: ##STR32## in which R 4a and R 5a have the same meanings as previously defined.
Compound (XVI) is prepared by a known process [Arch. Pharm., 292, 690 (1959)] or by processes similar thereto. The reaction of Compound (XVI) with Compound (Vb) is carried out in a reaction solvent similar to those described hereinabove. Usually, it is carried out at a temperature of 0° C. to the boiling point of the reaction solvent and terminates in 1 to 72 hours. If desired, the reaction may be carried out in the presence of the same base as described hereinabove, so as to accelerate the reaction.
The intermediates and the desired products prepared in accordance with the above processes can be isolated and purified by any purification method conventionally employed in the synthetic organic chemistry, e.g., filtration, extraction, washing, drying, concentration, recrystallization, chromatographies and the like. It is also possible to use the intermediates as such in the subsequent reaction step, without subjecting them to any purification.
In the case where Compound (I) is obtained in a free form and its salt form is desired to obtain the free form may be converted into a salt form by a conventional method. In the case where Compound (I) is obtained in a salt form and the salt form is desired to obtain, the salt form as it is can be subjected to a purification step.
Compound (I) and pharmaceutically acceptable salts thereof may be present in the form of an adduct of water or various solvents. The adducts are also included in the scope of the present invention.
Typical examples of Compound (I) obtainable in accordance with the above-mentioned processes are shown in Table 1.
TABLE 1__________________________________________________________________________Compound No.(Example No.) R.sup.1 R.sup.2 R.sup.3__________________________________________________________________________ 1 (15) H H ##STR33##2 (1) CH.sub.3 CO CH.sub.3 CO ##STR34##3 (8) H H "4 (2) CH.sub.3 CO CH.sub.3 CO ##STR35##5 (9) H H " 6 (75) (CH.sub.3).sub.2 CH (CH.sub.3).sub.2 CH ##STR36##7 (3) CH.sub.3 CO CH.sub.3 CO ##STR37## 8 (10) H H " 9 (74) (CH.sub.3).sub.2 CH (CH.sub.3).sub.2 CH "10 (4) CH.sub.3 CO CH.sub.3 CO ##STR38##11 (11) H H "12 (5) CH.sub.3 CO CH.sub.3 CO ##STR39##13 (12) H H "14 (6) CH.sub.3 CO CH.sub.3 CO ##STR40##15 (13) H H ##STR41##16 (16) " " ##STR42##17 (17) " " ##STR43##18 (7) CH.sub.3 CO CH.sub.3 CO ##STR44##19 (14) H H ##STR45##20 (18) " " ##STR46##21 (19) " " ##STR47##22 (20) " " ##STR48##23 (21) " " ##STR49##24 (22) " " ##STR50##25 (23) " " ##STR51##26 (24) " " ##STR52##27 (25) H H ##STR53##28 (26) " " ##STR54##29 (27) " " ##STR55##30 (28) " " ##STR56##31 (29) " " ##STR57##32 (30) " " ##STR58##33 (31) " " ##STR59##34 (32) H H ##STR60##35 (33) " " ##STR61##36 (34) " " ##STR62##37 (35) " " ##STR63##38 (36) " " ##STR64##39 (37) " " ##STR65##40 (38) " " ##STR66##41 (39) " " ##STR67##42 (40) H H ##STR68##43 (41) " " ##STR69##44 (42) " " ##STR70##45 (43) " " ##STR71##46 (44) " " ##STR72##47 (45) " " CONHCH.sub.2 CHCH.sub.248 (46) " " ##STR73##49 (47) " " CONH(CH.sub.2).sub.2 CH.sub.350 (48) " " ##STR74##51 (49) " " ##STR75##52 (50) H H ##STR76##53 (51) " " ##STR77##54 (52) " " ##STR78##55 (53) " " ##STR79##56 (54) " " ##STR80##57 (55) " " ##STR81##58 (56) " " ##STR82##59 (57) " " CONH(CH.sub.2).sub.2 OC.sub.2 H.sub.560 (58) " " ##STR83##61 (59) " " CONHCH.sub.2 CF.sub.362 (60) H H ##STR84##63 (61) " " ##STR85##64 (62) " " ##STR86##65 (63) " " ##STR87##66 (64) " " ##STR88##67 (65) " " CONHC(CH.sub.3).sub.368 (66) " " ##STR89##69 (67) " " ##STR90##70 (68) " " ##STR91##71 (69) H H ##STR92##72 (70) " " ##STR93##73 (71) " " ##STR94##74 (72) " " ##STR95##75 (73) " " ##STR96##76 (76) CH.sub.3 OCH.sub.2 CH.sub.3 OCH.sub.2 ##STR97##77 (77) " " ##STR98##78 (78) " " ##STR99##79 (79) CH.sub.3 OCH.sub.2 CH.sub.3 OCH.sub.2 ##STR100##80 (80) " " ##STR101##81 (81) " " ##STR102##82 (82) ##STR103## ##STR104## ##STR105##83 (83) " " ##STR106##84 (84) H H ##STR107##85 (85) " " ##STR108##86 (86) H H ##STR109##87 (87) " " ##STR110##88 (88) ##STR111## ##STR112## ##STR113##89 (89) H H ##STR114##90 (90) " " ##STR115##91 (91) " " ##STR116##92 (92) " " ##STR117##93 (93) H H ##STR118##94 (94) " " ##STR119##95 (95) " " ##STR120##96 (96) " " ##STR121##97 (97) " " ##STR122##98 (98) " " ##STR123##99 (99) " " ##STR124##100 (100) CH.sub.3 CO CH.sub.3 CO ##STR125##101 (101) CH.sub.3 CO CH.sub.3 CO ##STR126##102 (102) " " ##STR127##103 (103) " " ##STR128##104 (104) " " ##STR129##105 (105) " " ##STR130##106 (106) " " ##STR131##107 (107) " " ##STR132##108 (108) " " ##STR133##109 (109) CH.sub.3 CO CH.sub.3 CO ##STR134##110 (110) " " ##STR135##111 (111) " " ##STR136##112 (112) " " NHCOC(CH.sub.3).sub.3113 (113) " " ##STR137##114 (114) " " ##STR138##115 (115) " " ##STR139##116 (116) " " ##STR140##117 (117) H H ##STR141##118 (118) H H ##STR142##119 (119) " " ##STR143##120 (120) " " ##STR144##121 (121) " " ##STR145##122 (122) " " ##STR146##123 (123) " " ##STR147##124 (124) " " ##STR148##125 (125) " " ##STR149##126 (126) H H ##STR150##127 (127) " " ##STR151##128 (128) " " ##STR152##129 (129) " " ##STR153##130 (130) " " ##STR154##131 (131) " " NHCOC(CH.sub.3).sub.3132 (132) " " ##STR155##133 (133) " " ##STR156##134 (134) H H ##STR157##135 (135) " " ##STR158##136 (136) " " ##STR159##137 (137) CH.sub. 3 OCH.sub.2 CH.sub.3 OCH.sub.2 ##STR160##138 (138) H H "__________________________________________________________________________
The bone absorption-inhibiting effects of the compounds of the present invention is proved by the following experiment.
Experiment
A calvaria of a 5 to 6 day-old dd mouse was aseptically cut off, washed with Dulbecco's modified phosphate buffered saline not containing calcium and magnesium (manufactured by Gibco Oriental Co.) and separated along the sutura of its center. One half of the calvaria so separated was cultured in 1.5 ml of Dulbecco's modified Eagle medium (manufactured by Gibco Oriental Co.) containing 15% of thermally inactivated (at 56° C. for 20 minutes) horse serum and 2.5% of fetal calf serum. The test compound was dissolved in dimethyl sulfoxide, and 10 μl (1×10-4 M) of the solution so prepared was added to the culture. Parathyroid hormone (PTH) was dissolved in 0.15 M sodium chloride solution (pH 3), and 3 μl (1×10 -8 M) of solution so prepared was added to the culture. The cultivation was carried out for 96 hours at 37° C. in an atmosphere consisting of 95% of air and 5% of carbon dioxide (the culture medium was once replaced with a fresh one after 48 hours from the beginning of the cultivation). The concentration of dissolved calcium (i.e., absorption of bone) from the PTH-intensified bone was determined by measuring the quantity of calcium accumulated in the culture collected in 96 hours of cultivation, whereby the concentration of total calcium contained in the culture was measured with Calcium C-Test Wako (manufactured by Wako Pure Chemicals Co., Ltd.), and the inhibition rate was calculated therefrom in accordance with the equation set forth below. Results obtained are shown in Table 2. ##EQU1## Cd: Total calcium concentration in culture treated with both test compound and PTH
Cp: Total calcium concentration in culture treated with PTH alone
Co: Total calcium concentration in culture treated with neither test compound nor PTH
TABLE 2______________________________________Compound No. Inhibition Rate (%)______________________________________ 5 105.5 8 133.9 9 93.613 86.419 124.221 159.223 172.324 167.925 130.626 141.727 125.528 144.029 203.076 167.977 174.578 127.479 136.880 38.281 127.484 141.7118 203.0119 212.0121 203.0______________________________________
Compound (I) and pharmaceutically acceptable salts thereof are formulated into any form of conventionally employed preparations, for example, tablets, capsules, syrups, injections, drippings, suppositories, etc., and administered either orally or non-orally, including, e.g., intramuscular injection, intravenous injection, intraarterial injection, dripping, and rectal administration of suppositories. Such preparations are produced by any of the conventional methods and may contain other ingredients, for example, excipients, lubricants, binders, disintegrators, suspending agents, isotonicities, emulsifying agents and the like.
As the carrier to be used in such preparations, mention may be made of water, distilled water for injection, physiological sodium chloride solution, glucose, fructose, sucrose, mannitol, lactose, starch, cellulose, methyl cellulose, carboxymethyl cellulose, hydroxypropyl cellulose, alginic acid, talc, sodium citrate, calcium carbonate, calcium hydrogenphosphate, magnesium stearate, urea, silicone resins, sorbitan fatty acid esters, glycerol fatty acid esters and the like.
Embodiments of the present invention are illustrated by the following examples and reference examples.
EXAMPLE 1
2-[Bis(4-acetoxyphenyl)methyl]-N-(2,4-dimethoxyphenyl)benzamide (Compound 2)
In 20 ml of methylene chloride were dissolved 1.08 g of 2,4-dimethoxyaniline and 4.5 ml of triethylamine. To this solution was dropwise added under ice cooling 20 ml of methylene chloride containing 3 g of 2-[bis(4-acetoxyphenyl)methyl]benzoyl chloride obtained in Reference Example 2. After stirring for 7 hours, water was added thereto. The organic layer was separated off, and the aqueous layer was extracted with chloroform. The chloroform layer was combined with the organic layer, and the combined organic layer was washed with 2N aqueous hydrochloric acid solution and dried over anhydrous magnesium sulfate. The resulting solution was concentrated under reduced pressure to give 2.6 g of the desired product (Compound 2) as an oily matter.
NMR (CDCl 3 ) δ (ppm): 8.25-8.18, 7.60-6.88, 6.60-6.45, 6.17, 3.78, 3.65, 2.25
In the following Examples 2 to 7, desired products were obtained in a similar manner as in Example 1, except that corresponding amines were used in place of 2,4-dimethoxyaniline.
EXAMPLE 2
1-{2-[Bis(4-acetoxyphenyl)methyl]benzoyl}piperidine (Compound 4)
NMR (CDCl 3 ) δ (ppm): 7.25-6.90, 5.93, 3.95-1.45
EXAMPLE 3
1-{2-[Bis(4-acetoxyphenyl)methyl]benzoyl}-4-(2-methoxyphenyl)piperazine (Compound 7)
NMR (CDCl 3 ) δ (ppm): 7.35-6.76, 6.01, 3.95-1.65
EXAMPLE 4
1-{2-[Bis(4-acetoxyphenyl)methyl]benzoyl}-4-(3-methoxyphenyl)piperazine (Compound 10)
NMR (CDCl 3 ) δ (ppm): 7.32-6.94, 6.50-6.39, 6.00, 3.95-1.60
EXAMPLE 5
1-{2-[Bis(4-acetoxyphenyl)methyl]benzoyl}-4-(4-methoxyphenyl)piperazine (Compound 12)
NMR (CDCl 3 ) δ (ppm): 7.25-6.83, 6.01, 3.88-3.76, 3.20-1.80
EXAMPLE 6
2-[Bis(4-acetoxyphenyl)methyl]-N-(3-morpholinopropyl)benzamide (Compound 14)
NMR (CDCl 3 ) δ (ppm): 7.28-6.89, 6.35, 3.63-3.04, 2.42-2.27, 2.67-2.30
EXAMPLE 7
2-[Bis(4-acetoxyphenyl)methyl]-N-(benzothiazol-2-yl)benzamide (Compound 18)
NMR (CDCl 3 ) δ (ppm): 7.48-6.80, 5.95, 2.27
EXAMPLE 8
2-[Bis(4-hydroxyphenyl)methyl]-N-(2,4-dimethoxyphenyl)benzamide (Compound 3)
In a mixture of 50 ml of saturated aqueous sodium hydrogencarbonate solution and 50 ml of methanol was suspended 2.6 g of Compound 2 prepared in Example 1, and the suspension was heated under reflux for 30 minutes. The resulting mixture was concentrated under reduced pressure, and water was added to the residue. The resulting mixture was extracted with ethyl acetate, and the extract was dried over anhydrous magnesium sulfate. After concentration under reduced pressure, the residue was recrystallized to afford 1.23 g of the desired product.
Melting point: 122.5-124.0° C.
IR (KBr) cm -1 : 1644, 1510, 1208
NMR (DMSO-d 6 ) δ (ppm): 8.60, 8.16, 7.54-7.09, 6.90-6.40, 5.88, 3.79, 3.64
In the following Examples 9 to 14, the desired products were obtained in a similar manner as in Example 8, except that corresponding acetyl derivatives were employed.
EXAMPLE 9
1-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}piperidine (Compound 5)
Melting point: 242.0-244.0° C.
IR (KBr) cm -1 : 1603, 1583, 1511
NMR (DMSO-d 6 ) δ (ppm): 9.14, 7.30-6.60, 5.51, 3.41-3.18, 1.41-1.31
EXAMPLE 10
1-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}-4-(2-methoxyphenyl)piperazine (Compound 8)
Melting point: 229.0-231.0° C.
IR (KBr) cm -1 : 1608, 1583, 1505
NMR (DMSO-d 6 +CDCl 3 ) δ (ppm): 8.83, 8.72, 7.21-6.62, 5.74, 3.81, 3.81-2.61
EXAMPLE 11
1-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}-4-(3-methoxyphenyl)piperazine (Compound 11)
Melting point: 229.0-234.0° C.
IR (KBr) cm -1 : 1605, 1597, 1509
NMR (DMSO-d 6 ) δ (ppm): 9.25, 9.19, 7.35-7.17, 7.07-6.65, 5.62, 3.74, 3.68-3.00, 2.65-2.50, 1.93
EXAMPLE 12
1-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}-4-(4-methoxyphenyl)piperazine (Compound 13)
Melting point: 208.0-210.0° C.
IR (KBr) cm -1 : 1646, 1610, 1511
NMR (DMSO-d 6 ) δ (ppm): 7.57-6.71, 5.92, 4.0-2.5, 3.82
EXAMPLE 13
2-[Bis(4-hydroxyphenyl)methyl]-N-(3-morpholinopropyl)benzamide (Compound 15)
Melting point: 120.0-121.5° C.
IR (KBr) cm -1 : 1643, 1511, 1237
NMR (DMSO-d 6 ) δ (ppm): 9.25, 8.11, 7.30-6.62, 5.91, 3.67-3.09, 2.27-2.17, 1.47
EXAMPLE 14
N-(Benzothiazol-2-yl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 19)
Melting point: 139.5-141.0° C.
IR (KBr) cm -1 : 1644, 1537, 1504
NMR (DMSO-d 6 ) δ (ppm): 9.20, 8.00-7.04, 6.84-6.61, 5.94
EXAMPLE 15
2-[Bis(4-hydroxyphenyl)methyl]-N-(3-methoxyphenyl)benzamide (Compound 1)
In 20 ml of methylene chloride were dissolved 0.62 g of m-anisidine and 5 ml of triethylamine. To this solution was added dropwise under ice cooling 20 ml of methylene chloride containing 2.64 g of 2-[bis(4-acetoxyphenyl)methyl]benzoyl chloride as obtained in Reference Example 2. After stirring for 30 minutes, water was added thereto. The organic layer was separated off, and the water layer was extracted with chloroform. The chloroform layer was combined with the organic layer, and the combined organic layer was washed with 2N aqueous hydrochloric acid solution and dried over anhydrous magnesium sulfate. The organic layer was concentrated under reduced pressure, and the residue was suspended in a mixture of 50 ml of saturated aqueous sodium hydrogencarbonate solution and 50 ml of methanol, and the resulting suspension was heated under reflux for 2 hours. The suspension was concentrated under reduced pressure, and water was added to the residue. The resulting mixture was extracted with ethyl acetate, and the extract was dried over anhydrous magnesium sulfate. The residue was concentrated under reduced pressure, and was recrystallized to afford 1.54 g of the desired product.
Melting point: 106-107° C.
IR (KBr) cm -1 : 1645, 1600, 1509
NMR (DMSO-d 6 ) δ (ppm): 10.18, 9.20, 7.40-7.04, 6.86-6.62, 5.87, 3.73
In the following Examples 16 to 73, desired products were obtained in a similar manner as in Example 15, except that corresponding amines were used in place of m-anisidine.
EXAMPLE 16
N-(1-Ethylpyrrolidin-2-yl)methyl]-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 16)
Melting point: 229.0-230.0° C.
IR (KBr) cm -1 : 1638, 1509, 1170
NMR (DMSO-d 6 ) δ (ppm): 9.19, 8.93, 7.33-6.97, 6.82-6.61, 5.92, 3.0-2.04, 1.61-1.37, 1.0
EXAMPLE 17
2-[Bis(4-hydroxyphenyl)methyl]-N-[3-(2-methylpiperidino)propyl]benzamide (Compound 17)
Melting point: 118.0-120.0° C.
IR (KBr) cm -1 : 1638, 1511, 1240
NMR (DMSO-d 6 ) δ (ppm): 9.19, 8.16, 7.33-6.62, 5.89, 3.14-2.15, 1.51-1.2, 0.94
EXAMPLE 18
2-[Bis(4-hydroxyphenyl)methyl]-N-(4-phenylthiazol-2-yl)benzamide (Compound 20)
Melting point: 291.0-292.5° C.
IR (KBr) cm -1 : 1678, 1651, 1537
NMR (DMSO-d 6 ) δ (ppm): 12.58, 9.21, 7.92-7.04, 6.84-6.62, 5.95
EXAMPLE 19
N-(Tricyclo[3.3.1.1 3 ,7 ]dec-1-yl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 21)
Melting point 167-169° C.
IR (KBr) cm -1 : 1631, 1514, 1269
NMR (DMSO-d 6 ) δ (ppm): 7.43, 7.29-7.18, 6.97, 6.85-6.63, 5.83, 1.97-1.92, 1.65-1.43
EXAMPLE 20
1-(2-Chlorophenyl)-4-{2-[bis(4-hydroxyphenyl)methyl]benzoyl}piperazine (Compound 22)
Melting point: >300° C.
IR (KBr) cm -1 : 1610, 1574, 1511
NMR (DMSO-d 6 ) δ (ppm): 9.28, 9.20, 7.39-7.18, 7.07-6.90, 6.85-6.65, 5.65, 3.91-3.86, 3.52-3.45, 3.23-3.00, 2.66-2.48, 1.81-1.06
EXAMPLE 21
N-(9-Fluorenyl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 23)
NMR (DMSO-d 6 ) δ (ppm): 9.20, 8.73, 7.80, 7.41-7.20, 6.97-6.67, 6.29, 6.10
EXAMPLE 22
N-(Tricyclo[3.3.1.1 3 ,7 ]dec-2-yl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 24)
NMR (DMSO-d 6 ) δ (ppm): 9.12, 7.81, 7.32-7.21, 6.97, 6.83-6.61, 5.84, 3.93, 1.88-1.36
EXAMPLE 23
N-Cyclooctyl-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 25)
NMR (DMSO-d 6 ) δ (ppm): 9.12, 7.89, 7.31-7.19, 6.96, 6.83-6.62, 5.89, 3.93, 1.88-1.36
EXAMPLE 24
N-(6-Ethoxybenzothiazol-2-yl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 26)
NMR (DMSO-d 6 ) δ (ppm): 12.50, 9.21, 7.63-7.33, 7.04, 6.84-6.61, 5.94, 4.08, 1.36
EXAMPLE 25
2-[Bis(4-hydroxyphenyl)methyl]-N-(1-indanyl)benzamide (Compound 27)
NMR (DMSO-d 6 ) δ (ppm): 9.18, 8.42, 7.35-6.04, 6.10, 5.38, 2.92-2.70, 2.31, 1.80
EXAMPLE 26
N-(2-Benzoylphenyl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 28)
NMR (DMSO-d 6 ) δ (ppm): 10.3, 9.13, 7.71-6.59, 5.75
EXAMPLE 27
2-[Bis(4-hydroxyphenyl)methyl]-N-diphenylmethylbenzamide (Compound 29)
NMR (DMSO-d 6 ) δ (ppm): 9.58, 9.15, 7.33-7.07, 6.85-6 57, 5.55, 5.13
EXAMPLE 28
1-Ethoxycarbonyl-4-{2-[bis(4-hydroxyphenyl)methyl]benzoyl}piperazine (Compound 30)
NMR (DMSO-d 6 ) δ (ppm): 9.23, 9.19, 7.32-7.15, 6.98, 6.82-6.65, 5.56, 4.02, 3.48-2.85, 2.50-2.34
EXAMPLE 29
2-[Bis(4-hydroxyphenyl)methyl]-N-{2-[bis(4-hydroxyphenyl)phenyl}benzamide (Compound 31)
NMR (DMSO-d 6 ) δ (ppm): 9.45, 9.15, 7.35-6.97, 6.89-6.63, 5.94, 5.72
EXAMPLE 30
N-{4-(1-Benzylpiperidyl)}-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 32)
NMR (DMSO-d 6 ) δ (ppm): 10.21, 9.19, 8.26, 7.56-7.23, 6.96, 6.82-6.63, 5.89, 4.24-3.84, 3.35-2.90, 2.00-1.60
EXAMPLE 31
N-[2-(4-tert-Butylphenoxy)pyridin-5-yl]-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 33)
Melting point: 121 -125° C.
IR (KBr) cm -1 : 3300, 1715, 1644, 1594, 1511, 1482, 377, 1257, 1170, 1107, 1014, 890, 814
NMR (DMSO-d 6 ) δ (ppm): 10.24, 9.15, 8.27, 8.01, 7.50-7.30, 7.10-6.95, 6.84, 6.64, 5.90, 1.30
EXAMPLE 32
N-[2-(4-Bromophenoxy)pyridin-5-yl]-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 34)
Melting point: 218 -223° C.
IR (KBr) cm -1 : 3300, 1712, 1650, 1598, 1538, 1512, 479, 1313, 1254, 1170, 1070, 1011, 889, 833, 784, 743
NMR (DMSO-d 6 ) δ (ppm): 10.27, 9.16, 8.29, 8.04, 7.57, 5 7.50-7.25, 7.15-7.00, 6.84, 6.64, 5.89
EXAMPLE 33
N-[2-(4-Chloro-3,5-dimethylphenoxy)pyridin-5-yl]-2-(bis-(4-hydroxyphenyl)methyl]benzamide (Compound 35)
Melting point: 125° C. (Decomposed)
IR (KBr) cm -1 : 3300, 1650, 1594, 1511, 1484, 1465, 379, 1303, 1236, 1170, 1148, 1104, 1026, 823,
NMR (DMSO-d 6 ) δ (ppm): 10.26, 9.16, 8.29, 8.03, 7.50-7.30, 7.10-7.00, 6.95, 6.84, 6.64, 5.90, 2.33
EXAMPLE 34
N-(Tricyclo[3.3.1.0 3 ,7 ]non-3-yl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 36)
Melting point: 219-224° C.
IR (KBr) cm -1 : 3200, 2938, 1659, 1627, 1598, 1512, 477, 1325, 1258, 1231, 1176, 825, 740
NMR (DMSO-d6) δ (ppm): 9.14, 7.90, 7.35-7.15, 6.95, 6.82, 6.65, 5.90, 2.36, 2.17, 2.05-1.70, 1.60-1.40
EXAMPLE 35
4-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}morpholine (Compound 37)
NMR (DMSO-d 6 ) δ (ppm): 9.25, 9.19, 7.35-7.14, 6.97, 6.81-6.65, 5.59, 3.58-3.19, 2.89, 2.57, 2.35-2.28
EXAMPLE 36
1-(3-Chlorophenyl)-4-[2-[bis(4-hydroxyphenyl)methylbenzoylpiperazine (Compound 38)
NMR (DMSO-d6) δ (ppm): 9.20, 7.36-7.15, 7.00, 5.59, 3.61, 3.05-3.01, 2.88-2.78, 2.55-2.48, 2.33-2.25
EXAMPLE 37
N,N-Dibutyl-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 39)
NMR (DMSO-d 6 ) δ (ppm): 9.26, 7.33-6.98, 6.86-6.57, 5.46, 3.45-3.12, 2.60-2.45, 1.45-0.60
EXAMPLE 38
N-(5-Chloro-2-methylphenyl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 40)
NMR (DMSO-d 6 ) δ (ppm): 9.21, 7.42-6.60, 6.00, 2.10
EXAMPLE 39
3-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}-3-azaspiro[5.5]undecan (Compound 41)
NMR (DMSO-d 6 ) δ (ppm): 7.31-6.61, 5.58, 3.50-3.28, 2.80-2.70, 2.46-2.25, 1.35-1.10
EXAMPLE 40
2-[Bis(4-hydroxyphenyl)methyl]-N-(3-thiomethylphenyl)benzamide (Compound 42)
NMR (DMSO-d6) δ (ppm): 9.20, 7.60, 7.45-7.21, 7.12, 6.98-6.62, 5.93, 2.44
EXAMPLE 41
1-Benzyl-4-{2-[bis(4-hydroxyphenyl)methyl]benzoyl}piperazine (Compound 43)
NMR (DMSO-d 6 ) δ (ppm): 7.23-6.79, 5.63, 3.60-3.30, 2.85-2.80, 2.50-1.95
EXAMPLE 42
N-(4-Fluorophenyl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 44)
Melting point: 122 -124° C.
IR (KBr) cm -1 : 3320, 1650, 1615, 1515
NMR (DMSO-d6) δ (ppm): 10.13, 7.80-6.90, 6.85-6.20, 5.86
EXAMPLE 43
N-(4-Butylphenyl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 45)
Melting point: 119 -121° C.
IR (KBr) cm -1 : 3300, 2920, 1600, 1520
NMR (DMSO-d 6 ) δ (ppm): 10.00, 9.03, 7.55-6.90, 6.85-6.45, 5.83, 2.65-2.35, 1.80-1.70
EXAMPLE 44
4-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}thiomorpholine (Compound 46)
Melting point: 259 -261° C.
IR (KBr) cm -1 : 3300, 1605, 1590, 1510
NMR (DMSO-d 6 ) δ (ppm): 9.30-9.00, 7.35-6.45, 5.48, 3.90-3.00, 2.90-2.40
EXAMPLE 45
N-Allyl-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 47)
Melting point: 179 -181° C.
IR (KBr) cm -1 : 3350, 3170, 1630, 1600, 1515
NMR (DMSO-d 6 ) δ (ppm): 9.03, 8.25-8.00, 7.35-7.05, 7.00-6.45, 5.95-5.40, 5.15-4.75, 3.85-3.55
EXAMPLE 46
N-Cyclopentyl-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 48)
Melting point 148 -150° C.
IR (KBr) cm -1 : 3150, 1635, 1515
NMR (DMSO-d6) δ (ppm): 9.05, 7.97-7.70, 7.35-6.40, 5.83, 4.15-3.85, 1.90-1.15
EXAMPLE 47
2-[Bis(4-hydroxyphenyl)methyl]-N-propylbenzamide (Compound 49)
Melting point: 202° C.
IR (KBr) cm -1 : 3330, 1630, 1615, 1515
NMR (DMSO-d6) δ (ppm): 9.07, 8.10-7.85, 7.50-7.10, 7.05-6.45, 5.90, 3.35-2.95, 1.55-0.65
EXAMPLE 48
N-Ethyl-2-[bis(4-hydroxyphenyl)methyl]-N-(3-methylphenyl)benzamide (Compound 50)
Melting point: 218 -220° C.
IR (KBr) cm -1 : 3280, 1615, 1580, 1515
NMR (DMSO-d 6 ) δ (ppm): 9.15, 7.45-6.15, 5.85, 3.90-3.70, 2.05, 1.25-0.90
EXAMPLE 49
N-(3-Trifluoromethylphenyl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 51)
Melting point: 198 -200° C.
IR (KBr) cm -1 : 3320, 1640, 1600, 1515, 1445
NMR (DMSO-d 6 ) δ (ppm): 10.40, 8.10-7.15, 7.10-6.40, 5.86
EXAMPLE 50
2-[Bis(4-hydroxyphenyl)methyl]-N-(2-isopropylphenyl)benzamide (Compound 52)
Melting point: 225 -227° C.
IR (KBr) cm -1 : 3330, 3150, 1640, 1510
NMR (DMSO-d6) δ (ppm): 9.55, 9.07, 7.50-6.50, 6.00, 3.20-2.80, 1.10
EXAMPLE 51
2-[Bis(4-hydroxyphenyl)methyl]-N-methyl-N-phenylbenzamide (Compound 53)
Melting point 246 -247° C.
IR (KBr) cm -1 : 3400, 3150, 1615, 1585, 1515, 1490
NMR (DMSO-d 6 ) δ (ppm): 9.10, 7.40-6.40, 5.70, 3.25
EXAMPLE 52
N-Cyclopropyl-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 54)
Melting point: 221 -226° C.
IR (KBr) cm -1 : 3380, 1895, 1725, 1632, 1610, 1594, 1510, 1503, 1479, 1445, 1361, 1309, 1227, 1172, 1105, 1045, 956, 814, 778, 754, 672, 625, 579, 562, 516
NMR (DMSO-d6) δ (ppm): 9.14, 8.05, 7.30, 7.22, 6.96, 6.80, 6.64, 5.88, 2.7-2.6, 0.60-0.53, 0.33-0.27
EXAMPLE 53
1-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}-4-methylpiperazine (Compound 55)
Melting point: 226 -231° C.
IR (KBr) cm -1 : 3150, 1737, 1605, 1587, 1512, 1466, 1439, 1365, 1269, 1250, 1171, 1137, 1099, 1046, 1022, 994, 848, 822, 777, 745, 650, 579, 562, 516
NMR (DMSO-d 6 ) δ (ppm): 9.24, 9.20, 7.31, 7.23, 7.14, 6.98, 6.79, 6.69, 6.67, 5.57, 3.51, 3.29, 3.0-2.8, 2.5-2.3, 2.3-2.1, 2.11
EXAMPLE 54
4-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}piperidone (Compound 56)
NMR (DMSO-d 6 ) δ (ppm): 9.23, 7.27, 6.82, 7.1-6.7, 6.67, 5.62, 3.9-3.6, 2.9-2.1
EXAMPLE 55
2-[Bis(4-hydroxyphenyl)methyl]-N-(N',N'-dimethyl-2-aminoethyl)benzamide hydrochloride (Compound 57)
Melting point: 215 -219° C.
IR (KBr) cm -1 : 3178, 1631, 1612, 1594, 1552, 1510, 1479, 1442, 1361, 1319, 1262, 1225, 1168, 1104, 1021, 987, 847, 818, 788, 745, 666, 582
NMR (DMSO-d6) δ (ppm): 10.45, 9.24, 8.35, 7.5-7.2, 6.95, 6.80, 6.67, 5.98, 3.43, 2.93, 2.72
EXAMPLE 56
1-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}-1,2,3,6-tetrahydropyridine (Compound 58)
Melting point: 227 -230° C.
IR (KBr) cm -1 : 3330, 1602, 1579, 1512, 1445, 1366, 1238, 1172, 1100, 1046, 818, 774, 749, 655, 635, 576, 561, 515
NMR (DMSO-d6) δ (ppm): 9.2, 9.1, 7.4,-7.2, 7.2-7.1, 7.00, 6.81, 6.67, 5.68, 5.49, 4.3-4.2, 3.7-3.6, 3.0-2.8, 2.4-2.2, 2.1-2.0, 2.0-1.8
EXAMPLE 57
N-(2-Ethoxyethyl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 59)
Melting point: 233 -235° C.
IR (KBr) cm -1 : 3320, 1990, 1610, 1590, 1560, 1504, 1481, 1443, 1367, 1347, 1315, 1259, 1221, 1170, 1120, 954, 864, 847, 818, 740, 715, 675, 624, 564, 508
NMR (DMSO-d 6 ) δ (ppm): 9.15, 8.00, 7.4-7.1, 7.24, 7.1-6.9, 6.82, 6.65, 5.90, 3.38, 3.32, 1.07
EXAMPLE 58
N-(exo-Bicyclo[2.2.1]hept-2-yl)-2-[bis(4-hydroxyphenyl)benzamide (Compound 60)
Melting point: 179 -181° C.
IR (KBr) cm -1 : 3370, 2946, 1630, 1610, 1592, 1512, 1445, 1241, 1173, 1104, 810, 750
NMR (DMSO-d 6 ) δ (ppm) 9.14, 7.80, 7.22, 7.3-7.1 7.0-6.8, 6.80, 6.65, 5.85, 3.6-3.4, 2.2-1.9, 1.6-0.8
EXAMPLE 59
N-(2,2,2-Trifluoroethyl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 61)
Melting point: 165 -166° C.
IR (KBr) cm -1 : 3525, 3345, 1892, 1650, 1612, 1598, 1540, 1511, 1446, 1392, 1314, 1253, 1175, 961, 826, 766, 665, 577, 562
NMR (DMSO-d 6 ) δ (ppm): 9.16, 8.83, 7.4-7.1, 7.1-6.9, 6.82, 6.65, 5.81, 4.1-3.7
EXAMPLE 60
2-[Bis(4-hydroxyphenyl)methyl]-N-(4-propylphenyl)benzamide (Compound 62)
Melting point: 218 -219° C.
IR (KBr) cm -1 : 3310, 1594, 1512, 1445, 1411, 1327, 1236, 1170, 1104, 835, 821, 744, 665, 562
NMR (DMSO-d 6 ) δ (ppm): 10.06, 9.14, 7.6-7.1, 7.1-6.9, 6.82, 6.63, 5.87, 2.47, 1.54, 0.85
EXAMPLE 61
2-[Bis(4-hydroxyphenyl)methyl]-N-(5-indanyl)benzamide (Compound 63)
Melting point: 220 -223° C.
IR (KBr) cm -1 : 3300, 2950, 2840, 1895, 1650, 1593, 1513, 1438, 1334, 1220, 1172, 1105, 1076, 1044, 1014, 946, 901, 865, 818, 746, 674, 625, 578, 561, 519
NMR (DMSO-d 6 ) δ (ppm): 10.04, 9.17, 7.6-7.2, 7.2-6.9, 6.83, 6.65, 5.88, 3.0-2.6, 2.3-1.8
EXAMPLE 62
2-[Bis(4-hydroxyphenyl)methyl]-N-(4-morpholinophenyl)benzamide (Compound 64)
Melting point: 151-155° C.
IR (KBr) cm -1 : 3300, 1615, 1596, 1514, 1447, 1413, 1382, 1321, 1233, 1172, 1110, 1047, 927, 902, 816, 740
NMR (DMSO-d 6 ) δ (ppm): 9.94, 9.16, 7.6-7.2, 7.2-6.9, 6.84, 6.65, 5.90, 3.8-3.6, 3.2-2.9
EXAMPLE 63
N-[2-(3-Chloro-5-pyridyloxy)pyridin-5-yl]-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 65)
Melting point: 122 -125° C. (decomposed at 122° C.)
IR (KBr) cm -1 : 3230, 1642, 1610, 1509, 1478, 1429, 1380, 1226, 1172, 1103, 1018, 933, 819
NMR (DMSO-d 6 ) δ (ppm): 10.33, 9.16, 8.48, 8.44, 8.31, 8.10, 7.87, 7.5-7.3, 7.15, 7.04, 6.83, 6.65, 5.89
EXAMPLE 64
1-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}-4-phenylpiperazine (Compound 66)
NMR (DMSO-d 6 ) δ (ppm): 9.21, 9.19, 7.36-7.15, 7.00, 6.84-6.63, 5.59, 3.64, 3.28, 3.18-2.95, 2.73, 2.54, 2.23
EXAMPLE 65
N-(tert-Butyl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 67)
Melting point: 264-266° C.
IR (KBr) cm -1 : 3400, 3330, 1630, 1620, 1595, 1550, 1510, 1460, 1260, 1240
NMR (DMSO-d 6 ) δ (ppm): 9.10, 7.40, 7.35-6.50, 5.85, 1.26
EXAMPLE 66
2-[Bis(4-hydroxyphenyl)methyl]-N-(2-methylphenyl)benzamide (Compound 68)
Melting point: 267 -269° C.
IR (KBr) cm -1 : 3330, 1660, 1620, 1600, 1590, 1535, 1520, 1460, 1320
NMR (DMSO-d 6 ) δ (ppm): 9.45, 9.05, 7.55-6.45, 5.95, 2.10
EXAMPLE 67
N-(4-Butoxyphenyl)-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 69)
Melting point: 110 -112° C.
IR (KBr) cm -1 : 3530, 3300, 2960, 1635, 1610, 1600, 1530, 1525, 1245
NMR (DMSO-d 6 ) δ (ppm): 9.95, 9.10, 7.65-7.20, 7.15-6.35, 5.90, 4.05-3.80, 1.90-0.90
EXAMPLE 68
2-[Bis(4-hydroxyphenyl)methyl]-N,N-diphenylbenzamide (Compound 70)
Melting point 262 -263° C.
IR (KBr) cm -1 : 3330, 3180, 1630, 1618, 1595, 1520, 1495, 1450, 1380, 1360, 1245, 1220
NMR (DMSO-d 6 ) δ (ppm): 9.13, 7.40-6.45, 5.90
EXAMPLE 69
3-{2-[Bis(4-hydroxyphenyl)methyl]benzoyl}-3-azabicyclo[3.2.2]nonane (Compound 71)
Melting point: 164 -166° C.
IR (KBr) cm -1 : 3350, 2930, 2860, 1610, 1590, 1520, 1460, 1230
NMR (DMSO-d 6 ) δ (ppm): 9.05, 7.30-6.40, 5.40, 4.25-3.90, 2.55-1.90, 1.85-1.10
EXAMPLE 70
2-[Bis(4-hydroxyphenyl)methyl]-N-(2-thenyl)benzamide (Compound 72)
Melting point: 109 -111° C.
IR (KBr) cm -1 : 3540, 3350, 1635, 1620, 1600, 1511, 1450
NMR (DMSO-d 6 ) δ (ppm): 9.05, 8.70, 7.45-6.40, 5.90, 4.48
EXAMPLE 71
N-[(Tricyclo[3.3.1.1 3 ,7 ]dec-1-yl)methyl]-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 73)
Melting point: 149 -151° C.
IR (KBr) cm -1 : 3350, 2900, 2850, 1640, 1620, 1530, 1520, 1450, 1230
NMR (DMSO-d 6 ) δ (ppm): 9.00, 7.85, 7.40-6.40, 5.92, 2.85, 2.00-1.10
EXAMPLE 72
2-[Bis(4-hydroxyphenyl)methyl]-N-(2-methylthiophenyl)benzamide (Compound 74)
Melting point: 119 -121° C.
IR (KBr) cm - 1: 3400, 3250, 1660, 1650, 1615, 1600, 1515, 1505, 1440, 1245
NMR (DMSO-d 6 ) δ (ppm): 9.50, 9.10, 7.65-6.35, 6.00, 2.47
EXAMPLE 73
N,N-Dicyclohexyl-2-[bis(4-hydroxyphenyl)methyl]benzamide (Compound 75)
Melting point: >300° C.
IR (KBr) cm -1 : 3260, 2930, 2850, 1610, 1590, 1520, 1440, 1370, 1240
NMR (DMSO-d 6 ) δ (ppm): 9.10, 7.40-6.35, 5.60, 2.90-2.20, 1.90-0.50
EXAMPLE 74
1-(2-Methoxyphenyl)-4-{2-[bis(4-isopropoxyphenyl)methyl]benzoyl}piperazine (Compound 9)
In 20 ml of dimethylformamide were dissolved 0.72 g of Compound 8 obtained by Example 10 and 3 g of cesium carbonate. To this solution was added 4 ml of isopropyl bromide, and the resulting mixture was stirred at 70° C. for 9 hours. The mixture was concentrated under reduced pressure, and water was added to the residue. The resulting mixture was extracted with chloroform, and the extract was washed with saturated aqueous sodium chloride and then dried over anhydrous sodium sulfate. The solvent was evaporated under reduced pressure, and the residue was recrystallized to obtain 0.75 g of the desired compound (Compound 9).
Melting point: 120.0 -121.0° C.
IR (KBr) cm -1 : 1632, 1504, 1241
NMR (CDCl 3 ) δ (ppm): 7.29-6.71, 5.88, 4.41, 3.81, 3.82-2.25, 1.32-1.21
EXAMPLE 75
1{2-[Bis(4-isopropoxyphenyl)methyl]benzoyl}piperidine (Compound 6)
The desired compound (Compound 6) was obtained in a similar manner as in Example 74, using Compound 5 obtained by Example 9.
Melting point 142.5 -143.5° C.
IR (KBr) cm 1620, 1505, 1433
NMR (CDCl 3 ) δ (ppm): 7.31-6.70, 5.79, 4.48, 1.30
EXAMPLE 76
N-(Tricyclo[3.3.1.1 3 ,7 ]dec-1-yl)-2-[bis(4-methoxymethoxyphenyl)methyl]benzylamine (Compound 76)
In a mixture of 50 ml of saturated aqueous sodium hydrogencarbonate and 50 ml of chloroform was suspended 0.94 g of 1-adamantanamine hydrochloride, and the suspension was then dissolved with stirring. Thereafter, the organic layer was separated, and the aqueous layer was extracted with chloroform. The chloroform layer was combined with the organic layer, dried over anhydrous magnesium sulfate. The solvent was evaporated under reduced pressure. The residue and 1.96 g of 2-[bis(4-methoxymethoxyphenyl)methyl]benzaldehyde obtained by Reference Example 7 were dissolved in 50 ml of ethanol, and the solution was stirred overnight. Then, 0.85 g of sodium borohydride was added thereto, and the mixture was stirred overnight. The reaction mixture was concentrated under reduced pressure, and water was added to the residue. The aqueous mixture was extracted with chloroform, and the organic layer was separated. The aqueous layer was again extracted with chloroform. The organic layer was combined and dried over anhydrous magnesium sulfate. The solvent was evaporated under reduced pressure, and the residue was purified by silica gel column chromatography to afford 2.1 g of the desired compound (Compound 76) as an oily matter.
IR (neat) cm -1 : 1609, 1507, 1232
NMR (CDCl 3 ) δ (ppm): 7.68, 7.26-6.79, 5.97, 5.14, 3.73, 3.46, 1.98-1.50
EXAMPLE 77
N-(Cyclooctyl)-2-[bis(4-methoxymethoxyphenyl)methyl]benzylamine (Compound 77)
In 50 ml of ethanol was dissolved 0.69 g of cyclooctylamine. To the solution was added 1.96 g of 2-[bis(4-methoxymethoxyphenyl)methyl]benzaldehyde obtained by Reference Example 7, and the mixture was stirred overnight. Then, 0.85 g of sodium borohydride was added thereto, and the reaction mixture was stirred for 2 hours. Thereafter, the solvent was evaporated under reduced pressure, and water was added to the residue. The aqueous mixture was extracted with chloroform, and the organic layer was separated. The aqueous layer was extracted with chloroform, and the organic layer was combined and dried over anhydrous magnesium sulfate. The solvent was evaporated under reduced pressure, and the residue was purified by silica gel chromatography to afford 2.25 g of the desired product (Compound 77) as an oily matter.
IR (neat) cm -1 : 1609, 1508, 1234
NMR (CDCl 3 ) δ (ppm): 7.30-6.87, 5.95, 5.14, 3.69, 3.46, 2.65, 1.70-1.40
In the following Examples 78 to 81, desired compounds were obtained in a similar manner as in Example 77, except that corresponding amines were used in place of cyclooctylamine.
EXAMPLE 78
N-(1-Indanyl)-2-[bis(4-methoxymethoxyphenyl)methyl]benzylamine (Compound 78)
IR (neat) cm -1 : 1609, 1510, 1246
NMR (CDCl 3 ) δ (ppm): 7.38-6.87, 6.00, 5.14, 4.17, 3.81, 3.47, 3.01-2.71, 2.45-2.32, 1.85-1.46
EXAMPLE 79
N-Cyclohexyl-2-[bis(4-methoxymethoxyphenyl)methyl]benzylamine (Compound 79)
IR (neat) cm -1 : 1609, 1508, 1234
NMR (CDCl 3 ) δ (ppm): 7.32-6.87, 5.93, 5.14, 3.72, 3.46, 2.31, 1.71-0.98
EXAMPLE 80
2-[Bis(4-methoxymethoxyphenyl)methyl]-N-[1,2-bis(4'-methoxyphenyl)ethhyl]benzylamine (Compound 80)
IR (neat) cm -1 : 1610, 1510, 1246
NMR (CDCl 3 ) δ (ppm): 7.20-6.73, 5.67, 5.12, 3.80, 3.73, 3.47, 2.83-2.64
EXAMPLE 81
N-[1-(1,2,3,4-Tetrahydronaphthyl)]-2-[bis(4-methoxymethoxyphenyl)methyl]benzylamine (Compound 81)
IR (neat) cm -1 : 1608, 1502, 1232
NMR (CDCl 3 ) δ (ppm): 7.24-6.80, 6.00, 5.13, 3.78, 3.47, 2.78-2.65, 1.85-1.75, 1.45-1.40
EXAMPLE 82
2-[Bis(4-benzyloxyphenyl)methyl]-N-(cyclooctyl)benzylamine (Compound 82)
In 50 ml of ethanol was dissolved 3 g of cyclooctylamine. To the solution was added 11.41 g of 2-[bis-(4-benzyloxyphenyl)methyl]benzaldehyde obtained by Reference Example 8, and the mixture was heated under reflux for 2 hours. Thereafter, 1.78 g of sodium borohydride was added thereto, and the mixture was heated under reflux for 2 hours. The solvent was evaporated under reduced pressure, and water was added to the residue. The aqueous mixture was extracted with ether, and the organic layer was separated. The aqueous layer was extracted with ether, and then the organic layers were combined and dried over anhydrous magnesium sulfate. The solvent was evaporated under reduced pressure, and the residue was recrystallized to afford 9.19 g of the desired product (Compound 82).
IR (KBr) cm -1 : 1606, 1504, 1226
NMR(DMSO-d 6 ) δ (ppm): 7.45-7.28, 7.18-7.14, 6.94, 6.88-6.79, 5.95, 5.05, 3.64, 2.49, 1.63-1.38
EXAMPLE 82
2-[Bis(4-benzyloxyphenyl)methyl]-N-[4-(1-benzylpiperidyl)]benzylamine dihydrochloride (Compound 83)
At first, 14.9 g of 2-[bis(4-benzyloxyphenyl)methyl]-N-[4-(1-benzylpiperidyl)]benzylamine was obtained in a similar manner as in Example 82, except that 4-amino- 1-benzylpiperidine was used in place of cyclooctylamine. To the compound was added ethyl acetate saturated with hydrogen chloride, and the mixture was stirred for 10 minutes. Precipitated crystals were collected by filtration and then subjected to recrystallization to afford 8.75 g of the desired compound (Compound 83).
IR (KBr) cm -1 : 1607, 1511, 1214
NMR(DMSO-d 6 ) δ (ppm): 7.64-7.29, 7.02-6.80, 5.95, 5.05, 4.24, 4.04, 3.41-3.26, 2.95, 2.22-2.11
EXAMPLE 84
N-[4-(1-Benzylpiperidyl)]-2-[bis(4-hydroxyphenyl)methyl]benzylamine (Compound 84)
In 50 ml of methanol was dissolved 0.95 g of 4-amino-1-benzylpiperidine. To the solution was added 1.95 g of 2-[bis(4-methoxymethoxyphenyl)methyl]benzaldehyde obtained by Reference Example 7, and the mixture was stirred overnight. Then, 0.85 g of sodium borohydride was added thereto, and the mixture was stirred overnight. The solvent was evaporated under reduced pressure, and water was added to the residue. The aqueous mixture was extracted with ethyl acetate, and the organic layer was separated. The aqueous layer was extracted with ethyl acetate, and the organic layers were combined and dried over anhydrous magnesium sulfate. The solvent was evaporated under reduced pressure, and 30 ml of 2N aqueous hydrochloric acid and 30 ml of methanol were added to the residue. The mixture was stirred for 7 hours at room temperature, and the mixture was neutralized with a saturated aqueous sodium hydrogencarbonate. Thereafter, water was added thereto, and precipitates were collected by filtration, recrystallized from a mixture of water and ethanol and then decolored with activated carbon to afford 1.65 g of the desired compound (Compound 84)
Melting point: 127.8-127.9° C.
IR (KBr) cm -1 : 1612, 1510, 1252
NMR (CDCl 3 ) δ (ppm): 9.2, 7.32-7.11, 6.82-6.64, 5.81, 3.61, 3.42-3.25, 2.7214 2.66, 2.50-2.31, 1.96-1.86, 1.68-1.62, 1.24-1.21
EXAMPLE 85
N-Cyclooctyl-2-[bis(4-hydroxyphenyl)methyl]benzylamine (Compound 85)
Two grams of 2-[bis(4-benzyloxyphenyl)methyl]-N-(cyclooctyl)benzylamine obtained by Example 82 was dissolved in 120 ml of a mixture of ice-cooled hydrogen bromide-acetic acid solution. The solution was stirred for 2 hours, and the mixture was added to a mixture of ice and a saturated aqueous sodium hydrogencarbonate, stirred and then neutralized with sodium hydrogencarbonate. Thereafter, it was extracted with ethyl acetate, washed with water and dried over anhydrous magnesium sulfate. The solvent was evaporated under reduced pressure, and the residue was subjected to recrystallization to afford 0.76 g of the desired compound (Compound 85).
IR (KBr) cm -1 : 1612, 1508, 1220
NMR(DMSO-d 6 ) δ (ppm): 9.25, 7.49-7.45, 7.30-7.27, 6.89-6.68, 5.68, 3.96, 1.96-1.41
EXAMPLE 86
N-(Tricyclo[3.3.1.1 3 ,7 ]dec-2-yl)-2-[bis(4-hydroxyphenyl)methyl]benzylamine hydrochloride (Compound 86)
At first, 4.2 g of N-(2-adamantyl)-2-[bis(4-methoxymethoxyphenyl)methyl]benzylamine was obtained in a similar manner as in Example 76, except that 2-adamantanamine hydrochloride was used in place of 1-adamantanamine hydrochloride. To the compound was added a mixture of isopropyl alcohol and ethyl acetate saturated with hydrogen chloride, and the mixture was stirred for 30 minutes. Thereafter, ether was added to the reaction mixture, and precipitates were collected by filtration and then dried to afford 1.24 g of the desired compound (Compound 86).
IR (KBr) cm -1 : 1725, 1613, 1511
NMR(DMSO-d 6 ) δ (ppm): 9.;30, 9.09, 7.72, 7.31, 6.85-6.68, 5.68, 4.07, 3.08, 2.16-2.04, 1.80-1.49
EXAMPLE 87
2-[Bis((hydroxyphenyl)methyl]-N-(diphenylmethyl)benzylamine hydrochloride (Compound 87)
At first, 4.88 g of 2-[bis(methoxymethoxyphenyl)methyl-N-(diphenylmethyl)benzylamine was obtained in a similar manner as in Example 77, except that aminodiphenylmethane was used in place of cyclooctylamine. The compound was then dissolved in ethyl acetate saturated with hydrochloric acid. The mixture was stirred for 10 minutes, and then ether was added to the mixture. Precipitates were collected by filtration and then dried to afford 1.3 g of the desired compound of hydrochloride (Compound 87).
IR (KBr) cm -1 : 1612, 1512, 1224
NMR (DMSO-d 6 ) δ (ppm): 10.21, 9.19, 7.73-7.29, 6.80-6.54, 5.62, 5.02, 4.76, 3.88, 3.50
EXAMPLE 88
1-[2-Bis(4-benzyloxyphenyl)methylphenyl]-N-(1-benzylpiperidin-4-yl)pentylamine dihydrochloride (Compound 88)
In 30 ml of toluene were dissolved 4 g of N-[2-bis(4-benzyloxyphenyl)methylbenzylidene]-(1-benzylpiperidin-4-yl)amine obtained by Reference Example 9 and the solution was cooled to 0° C. To the solution was dropwise added 5 ml of 1.4 M n-butyl lithium/hexane solution, and the mixture was stirred for 2 hours The reaction was terminated by the addition of saturated aqueous ammonium chloride. The reaction mixture was extracted with ethyl acetate, and the organic layer was dried over anhydrous magnesium sulfate. The solvent was evaporated under reduce pressure to afford crude product. The crude product was purified by silica gel column chromatography, and the purified product was converted into dihydrochloride by adding ethyl acetate saturated with hydrochloric acid. The solvent was evaporated under reduced pressure, and the residue was washed with either to afford 2.5 g of the desired compound (Compound 88).
Melting point: 147-150° C.
IR (KBr) cm -1 : 3400, 1606, 1580, 1505, 1453, 1379, 1225, 1175, 1110, 1012, 803, 738, 696
NMR (DMSO-d 6 ) δ (ppm): 8.1-6.7, 5.69, 5.01, 4.3-4.0, 3.30, 2.3-1.8, 1.3-0.6
EXAMPLE 89
1-(2-Chlorophenyl)-4-{2-[bis(4-hydroxyphenyl)methyl]benzyl}piperazine (Compound 89)
In 50 ml of tetrahydrofuran were dissolved 1.5 g of 1-(2-chlorophenyl)piperazine and 5 ml of triethylamine, and 3.4 g of 2-[bis(4-hydroxyphenyl)methyl]benzylbromide was added thereto. The mixture was heated under reflux for 3.5 hours, and then insoluble substances were filtered off. The filtrate was concentrated, and the residue was subjected to extraction with the addition of water and ethyl acetate. The organic layer was separated, and the aqueous layer was then extracted with ethyl acetate. The organic layers were combined and then dried over anhydrous magnesium sulfate. The solvent was evaporated off under reduced pressure, and the residue was purified by silica gel chromatography to afford 0.54 g of the desired compound (Compound 89).
Melting point: 149-151° C.
IR (KBr) cm -1 : 3375, 1610, 1510
NMR (DMSO-d 6 ) δ (ppm): 9.15, 7.39, 7.28-7.02, 6.88-6.66, 6.08, 3.41, 2.93, 2.50
In the following Examples 90 to 99, the desired compounds were obtained in a similar manner as in Example 89, except that a corresponding amine was used in place of 1-(2-chlorophenyl)piperazine.
EXAMPLE 90
1-{2-[Bis(4-hydroxyphenyl)methyl]benzyl}-4-(3-methoxyphenyl)piperazine (Compound 90)
Melting point: 128 -130° C.
IR (KBr) cm -1 : 3375, 1612, 1510
NMR (DMSO-d 6 ) δ (ppm): 9.16, 7.23-7.16, 6.92-6.65, 6.10, 3.76, 3.39, 2.93, 2.50
EXAMPLE 91
1-{2-[Bis(4-hydroxyphenyl)methyl]benzyl}-1,2,3,4-tetrahydroquinoline (Compound 91)
Melting point: 160 -163° C.
IR (KBr) cm -1 : 3375, 1600, 1510
NMR (DMSO-d 6 ) δ (ppm): 9.20, 7.13-7.06, 6.87-6.65, 6.39, 5.79, 5.57, 4.33, 3.24, 2.70, 1.89
EXAMPLE 92
1-{2-[Bis(4-hydroxyphenyl)methyl]benzyl}-4-(2-methoxyphenyl)piperazine (Compound 92)
Melting point: 175 -178° C.
IR (KBr) cm -1 : 3375, 1612, 1510
NMR (DMSO-d 6 ) δ (ppm): 9.15, 7.23-7.16, 6.92-6.65, 6.09, 3.79, 3.39, 2.93, 2.50
EXAMPLE 93
1-{2-[Bis(4-hydroxyphenyl)methyl]benzyl}-4-(2-oxo-3oxazolizyl)piperidine hydrochloride (Compound 93)
Melting point: 213 -216° C.
IR (KBr) cm -1 : 3225, 1709, 1511
NMR (DMSO-d 6 ) δ (ppm): 9.30, 7.88, 7.36-7.26, 6.95-6.68, 5.87, 4.27, 4.15, 3.82, 3.51-3.19, 2.20, 1.82
EXAMPLE 94
1-[2-(Trifluoromethyl)phenyl]-4-{2-[bis(4-hydroxyphenyl)methyl]benzyl}piperazine hydrochloride (Compound 94)
Melting point: 208 -210° C.
NMR (DMSO-d 6 ) δ (ppm): 11.35, 7.91, 7.48, 7.38-7.13, 6.91-6.68, 6.00, 4.76, 3.94, 3.89, 3.58-3.26
EXAMPLE 95
2-{2-[Bis(4-hydroxyphenyl)methyl]benzyl}-1,2,3,4-tetrahydroisoquinoline (Compound 95)
Melting point: 248 -250° C.
NMR (DMSO-d 6 ) δ (ppm): 9.30, 7.88, 7.36-7.26, 6.95-6.67, 5.94, 4.30-4.18, 3.09-2.73, 2.28-1.10
EXAMPLE 96
1-{2-[Bis(4-hydroxyphenyl)methyl]benzyl}-4-piperidinopiperidine hydrochloride (Compound 96)
Melting point: 290 -293° C.
IR (KBr) cm -1 : 3375, 1611, 1511
NMR (DMSO-d 6 ) δ (ppm): 9.31, 7.80, 7.36-7.23, 6.89-6.62, 5.90, 4.15, 3.37-2.90, 2.30-1.43
EXAMPLE 97
1-{2-[Bis(4-hydroxyphenyl)methyl]benzyl}-5,6,11,12-tetrahydrodibenz[b,f]azocine hydrochloride (Compound 97)
Melting point: 175 -177° C.
IR (KBr) cm -1 : 3210, 1612, 1511
NMR (DMSO-d 6 ) δ (ppm): 7.38-6.61, 5.80, 4.24-4.11, 3.16-3.10
EXAMPLE 98
1-(4-Acetylphenyl)-4-{2-[bis(4-hydroxyphenyl)methyl]benzyl}piperazine (Compound 98)
NMR (DMSO-d 6 ) δ (ppm): 9.17, 7.80, 7.26-6.81, 6.66, 6.07, 3.41, 3.37-3.30, 2.44
Example 99
1-{2-[Bis(4-hydroxyphenyl)methyl]benzyl}-4-(2-pyridyl)piperazine (Compound 99)
IR (KBr) cm -1 : 3215, 1608, 1511
NMR (DMSO-d 6 ) δ (ppm): 9.18, 8.10, 7.52, 7.20, 6.90-6.65, 6.08, 3.41-3.25, 2.51-2.41
EXAMPLE 100
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-3,4-dimethoxybenzamide (Compound 100)
In 50 ml of tetrahydrofuran were dissolved 1.26 g of 4,4'-diacetoxy-2"-aminotriphenylmethane obtained by Reference Example 11 and 0.4 ml of triethylamine, and the solution was cooled with ice. Subsequently, a solution of 0.6 g of 3,4-dimethoxybenzoyl chloride in 20 ml of tetrahydrofuran was added thereto under ice cooling, and the temperature of the mixture was raised gradually to room temperature. The mixture was stirred for 2 hours, and concentrated. The concentrate was subjected to extraction with water and ethyl acetate. The organic layer was separated, and the aqueous layer was extracted with ethyl acetate. The organic layers were combined, washed with water and then dried over anhydrous magnesium sulfate. The solvent was evaporated under reduced pressure, and the residue was recrystallized to afford 1.58 g of the desired compound (Compound 100).
NMR (CDCl 3 ) δ (ppm): 7.92-7.85, 7.41-6.55, 5.60, 3.92, 3.87, 2.30
EXAMPLE 101
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}cyclohexanecarboxamide (Compound 101)
In 30 ml of pyridine was dissolved 1.5 g of 4,4'-diacetoxy-2"-aminotriphenylmethane obtained by Reference Example 11, and then 0.59 g of cyclohexanecarbonyl chloride was added thereto under ice cooling. The temperature of the mixture was raised to room temperature, and the mixture was stirred for 2 hours, and then concentrated under reduced pressure. The residue was subjected to extraction with water and chloroform. The organic layer was separated, and the aqueous layer was extracted with chloroform. The organic layers were combined and then washed with 2N hydrochloric acid, saturated aqueous sodium hydrogencarbonate and saturated aqueous sodium chloride, in order. The layer was dried over anhydrous magnesium sulfate, and the solvent was evaporated under reduced pressure to afford 2.21 g of Compound 101.
NMR (CDCl 3 ) δ (ppm): 7.75-7.60, 7.25-6.50, 5.52, 2.45-2.35, 2.20, 2.00-1.05
In the following Example 102-116, the desired compound was obtained in a similar manner as in Example 101, except that a corresponding acid chloride was used in place of cyclohexanecarbonyl chloride.
EXAMPLE 102
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-4-nitrobenzamide (Compound 102)
NMR (CDCl ) δ (ppm): 8.25-8.05, 8.00-7.80, 7.55-6.55, 5.50, 2.30
EXAMPLE 103
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-4,7,7-trimethyl3-oxo-2-oxabicyclo[2.2.1]heptanecarboxamide (Compound 103)
NMR (CDCl 3 ) δ (ppm): 8.05-7.80, 7.40-6.50, 5.50, 2.60-1.60, 1.05, 0.70
EXAMPLE 104
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-2-methoxybenzamide (Compound 104)
NMR (CDCl 3 ) δ (ppm): 9.15, 8.20, 7.75, 7.50-6.55, 5.70, 3.45, 2.25
EXAMPLE 105
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-3-methoxybenzamide (Compound 105)
NMR (CDCl 3 ) δ (ppm): 8.00-7.80, 7.55-6.50, 5.60, 3.80, 2.30
EXAMPLE 106
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-1-naphthalenecarboxamide (Compound 106)
NMR (CDCl 3 ) δ (ppm): 8.40-8.15, 8.05-7.60, 7.60-6.55, 5.62, 2.25
EXAMPLE 107
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-3-pyridinecarboxamide (Compound 107)
NMR (CDCl 3 ) δ (ppm): 8.75-8.50, 7.85-7.45, 7.35-6.65, 5.60, 2.25
EXAMPLE 108
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}tricyclo[3.3.1.0 3 ,7 ]-nonane-3-carboxamide (Compound 108)
NMR (CDCl ) δ (ppm): 8.00, 7.40-6.60, 5.50, 2.25, 2.10-1.30
EXAMPLE 109
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-(3-methyltricyclo[3.3.1.1 3 ,7 ]dec-1-yl)acetamide (Compound 109)
NMR (CDCl 3 ) δ (ppm): 7.85, 7.30-6.55, 5.53, 2.27, 2.15-1.75, 1.65-1.05, 0.78
EXAMPLE 110
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}bicyclo[2.2.1]hept-2-yl-acetamide (Compound 110)
NMR (CDCl 3 ) δ (ppm): 7.75-7.60, 7.30-6.55, 5.55, 2.27, 2.10-1.85, 1.55-0.85
EXAMPLE 111
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}cinnamide (Compound 111)
NMR (CDCl 3 ) δ (ppm): 7.75-7.55, 7.45-6.55, 6.33, 6.16, 5.63, 2.23
EXAMPLE 112
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-2,2-dimethylpropaneamide (Compound 112)
NMR (CDCl 3 ) δ (ppm): 7.75, 7.30-6.60, 5.47, 2.25, 1.07
EXAMPLE 113
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-4-methoxycarbonylbenzamide (Compound 113)
NMR (CDCl 3 ) δ (ppm): 8.05-7.80, 7.45-7.15, 7.05, 6.85-6.70, 5.50, 3.91, 2.30
EXAMPLE 114
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-3-methoxy-4-nitrobenzamide (Compound 114)
NMR (CDCl 3 ) δ (ppm): 7.95-7.65, 7.55-7.40, 7.35-6.70, 6.50, 5.53, 3.93, 2.30
EXAMPLE 115
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-2-thiophenecarboxamide (Compound 115)
NMR (CDCl 3 ) δ (ppm): 7.85, 7.50-6.65, 5.60, 2.27
EXAMPLE 116
N-{2-[Bis(4-acetoxyphenyl)methyl]phenyl}-4-methoxybenzamide (Compound 116)
NMR (CDCl 3 ) δ (ppm): 7.90, 7.40-6.70, 5.55, 3.80, 2.27
EXAMPLE 117
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-4-nitrobenzamide (Compound 117)
In 30 ml of pyridine was dissolved 1.5 g of 4,4'-diacetoxy-2"-aminotriphenylmethane obtained by Reference Example 11, and then 0.74 g of p-nitrobenzoyl chloride was added thereto under ice cooling. The temperature of the mixture was raised to room temperature, and the mixture was stirred for 2 hours. The solvent was evaporated under reduced pressure. The residue was subjected to extraction with water and chloroform. The organic layer was separated, and the aqueous layer was extracted with chloroform. The organic layers were combined and then washed with 2N hydrochloric acid, saturated aqueous sodium hydrogencarbonate and saturated aqueous sodium chloride in order. The layer was dried over anhydrous magnesium sulfate, and the solvent was evaporated. The residue was dissolved in ethanol. To the solution was added 50 ml of saturated aqueous sodium hydrogencarbonate, and the mixture was heated under reflux for 2 hours. After the reaction was completed, the solvent was evaporated under reduced pressure. Precipitates were washed with water and then recrystallized to afford 1.02 g of the desired compound (Compound 117).
Melting point: 258 -259° C.
IR (KBr) cm -1 : 3495, 1680, 1605, 1520
NMR (DMSO-d 6 ) δ (ppm): 9.98, 9.17, 8.30, 7.95, 7.40, 7.30-7.18, 6.90-6.60, 5.72
In the following Examples 118 and 119, desired compounds were obtained in a similar manner as in Example 117, except that a corresponding acid halide was used in place of p-nitrobenzoyl chloride.
EXAMPLE 118
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}diphenylacetamide (Compound 118)
NMR (DMSO-d 6 ) δ (ppm): 9.58 9.16 7.33-7.08, 6.83, 6.68-6.56, 5.55, 5.13
EXAMPLE 119
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}tricylco[3.3.1.1 3 ,7 ]decane-1-carboxamide (Compound 119)
NMR (DMSO-d 6 ) δ (ppm): 9.20, 7.46, 7.18, 7.06, 6.83-6.66, 5.53, 1.96, 1.68-1.58
EXAMPLE 120
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}cyclohexanecarboxamide (Compound 120)
To 2.21 g of Compound 101 obtained by Example 101 was added 50 ml of ethanol and 50 ml of saturated aqueous sodium hydrogencarbonate, and the mixture was heated under reflux for 2 hours. After the reaction was completed, the solvent was evaporated under reduced pressure. Precipitated crystals were washed with water and then recrystallized to afford 1.05 g of the desired compound (Compound 120)
Melting point: 220 -223° C.
IR (KBr) cm -1 : 3310, 2930, 1660, 1515
NMR (DMSO-d 6 ) δ (ppm): 9.25, 8.89, 7.32, 7.20-7.00, 6.90-6.55, 5.67, 2.25-2.10, 1.75-1.55, 1.35-1.05
In the following Examples 121 to 135, desired compounds were obtained in a similar manner as in Example 120, except that Compound 100, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115 or 116 was used in place of Compound 101.
EXAMPLE 121
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-3,4-dimethoxybenzamide (Compound 121)
NMR (DMSO-d 6 ) δ (ppm): 9.40, 9.16, 7.43-7.13, 7.00, 6.87-6.63, 5.70, 3.82, 3.79
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-4,7,7-trimethyl-3-oxo-2-oxabicyclo[2.2.1]heptanecarboxamide (Compound 122)
Melting point: 229 -231° C.
IR (KBr) cm -1 : 3360, 1790, 1520
NMR (DMSO-d 6 ) δ (ppm): 9.20, 9.00, 7.47, 7.25-7.05, 6.90-6.60, 5.57, 2.40-2.28, 2.05-1.85, 1.80-1.70, 1.65-1.45, 1.01, 0.98, 0.72
EXAMPLE 123
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-2-methoxybenzamide (Compound 123)
Melting point: 258° C.
IR (KBr) cm -1 : 3320, 1640, 1515
NMR (DMSO-d 6 ) δ (ppm): 9.36, 9.23, 7.85-7.70, 7.50, 7.25, 7.20-7.05, 6.90-6.60, 5.57, 3.67
EXAMPLE 124
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-3-methoxybenzamide (Compound 124)
Melting point: 165 -168° C.
IR (KBr) cm -1 : 3395, 1665, 1585
NMR (DMSO-d 6 ) δ (ppm): 8.30, 7.45, 7.40-7.05, 6.87, 6.85-6.55, 3.79
EXAMPLE 125
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-1-naphthalenecarboxamide (Compound 125)
IR (KBr) cm -1 : 3300, 1650, 1620, 1505
NMR (DMSO-d 6 ) δ (ppm): 9.90, 9.18, 8.10-7.85, 7.65-7.15, 6.95-6.50, 5.89
EXAMPLE 126
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-3-pyridinecarboxamide hydrochloride (Compound 126)
Melting point: 176-178° C.
IR (KBr) cm -1 : 3090, 1675, 1520
NMR (CD30D) δ (ppm): 8.95, 8.65, 8.12, 7.45-7.20, 6.95-6.60, 5.70
EXAMPLE 127
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}tricyclo[3.3.1.0 3 ,7 ]nonane-3-carboxamide (Compound 127)
Melting point: 155 -157° C.
IR (KBr) cm -1 : 3200, 2940, 1660, 1510
NMR (DMSO-d 6 ) δ (ppm): 9.20, 8.15, 7.47, 7.19, 7.07, 6.90-6.55, 5.57, 2.21, 1.85-1.40
EXAMPLE 128
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-(3-methyltricyclo[3.3.1.1 3 ,7 ]dec-1-yl-acetamide (Compound 128)
Melting point: 111 -113° C. (
IR (KBr) cm -1 : 3360, 2900, 1515
NMR (DMSO-d 6 ) δ (ppm): 9.15, 8.90, 7.40, 7.12, 7.05, 6.90-6.60, 5.71, 2.05-1.90, 1.70-1.20, 0.75
EXAMPLE 129
N-{2-[Bis(4-hydroxyphenyl)methylphenyl}bicyclo[2.2.1]hept-2-ylacetamide (Compound 129)
Melting point: 125 -127° C.
IR (KBr) cm -1 : 3370, 2945, 1660, 1615, 1515
NMR (DMSO-d 6 ) δ (ppm): 9.40-8.80, 7.40, 7.15, 7.05, 6.90-6.55, 5.70, 2.20-1.65, 1.50-0.85
EXAMPLE 130
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}cinnamide (Compound 130)
Melting point: 256 -259° C.
IR (KBr) cm 3400, 1680, 1620, 1520
NMR (DMSO-d 6 ) δ (ppm): 9.40, 9.15, 7.65-7.35, 7.21, 7.13, 6.90-6.60, 5.76
EXAMPLE 131
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-2,2-dimethylpropaneamide (Compound 131)
Melting point: 259 -262° C.
IR (KBr) cm -1 : 3330, 1645, 1510
NMR (DMSO-d 6 ) δ (ppm): 9.18, 8.36, 7.36, 7.18, 7.08, 6.90-6.60, 5.65, 1.05
EXAMPLE 132
N-{2[Bis(4-hydroxyphenyl)methyl]phenyl}-4-carboxybenzamide (Compound 132)
Melting point: 280-182° C.
IR (KBr) cm -1 : 3400, 1695, 1535
NMR (DMSO-d 6 ) δ (ppm): 13.15, 9.72, 9.18, 8.05-7.70, 7.42, 7.30-7.10, 6.90-6.50, 5.72
EXAMPLE 133
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-3-methoxy-4-nitrobenzamide (Compound 133)
Melting point: 129-131° C.
IR (KBr) cm -1 : 3495, 1620, 1590, 1520
NMR (DMSO-d 6 ) δ (ppm): 9.90, 9.17, 7.92, 7.49-7.15, 6.90-6.55, 5.70, 3.97
EXAMPLE 134
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-2-thiophenecarboxamide (Compound 134)
Melting point: 240 -243° C.
IR (KBr) cm -1 : 3260, 1630, 1515
NMR (DMSO-d 6 ) δ (ppm): 9.55, 9.20, 7.90-7.00, 6.70, 5.70
EXAMPLE 135
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-4-methoxybenzamide (Compound 135)
Melting point: 154 -156° C.
IR (KBr) cm -1 : 3420, 1605, 1505, 1300
NMR (DMSO-d 6 ) δ (ppm): 9.37, 9.17, 7.70, 7.45, 7.30-7.10, 7.00, 6.90-6.60, 5.72, 3.82
EXAMPLE 136
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-4-aminobenzamide (Compound 136)
In 50 ml of methanol were suspended 1.48 g of Compound 117 obtained by Example 117 and 0.23 g of 10% palladium-carbon, and the suspension was stirred under hydrogen atmosphere at room temperature for 2 hours. After the reaction was completed, the reaction mixture was filtered by using a filter aid. The solvent was evaporated under reduced pressure to afford 0.53 g of the desired compound (Compound 136).
Melting point: 158 -161° C.
IR (KBr) cm -1 : 3400, 1605, 1505
NMR (DMSO-d 6 ) δ (ppm): 9.40-8.90, 8.85, 7.60-7.35, 7 30-7.05, 6.95-6.50, 5.75-5.50
EXAMPLE 137
N-{2-[Bis(4-methoxymethoxyphenyl)methyl]phenyl}-N-methylcyclohexanecarboxamide (Compound 137)
In 50 ml of pyridine were dissolved 2.38 g of 4,4'-dimethoxymethoxy-2"-aminotriphenylmethane obtained by Reference Example 13 and 0.92 g of cyclohexanecarbonyl chloride, and the solution was stirred under ice cooling for 1 hour. The solvent was evaporated under reduced pressure, and the residue was subjected to extraction with ethyl acetate and water. The organic layer was separated, and the aqueous layer was extracted with ethyl acetate. The organic layers were combined and washed with 2N hydrochloric acid, saturated aqueous sodium hydrogencarbonate and saturated sodium chloride, in order. The organic layer was dried over anhydrous magnesium sulfate, and the solvent was evaporated under reduced pressure.
The residue and 0.4 g of sodium hydride were dissolved under ice cooling in 50 ml of N,N-dimethylformamide, and then 0.62 ml of iodomethane was added thereto. The mixture was stirred for 1 hour, and the temperature of the reaction mixture was raised to room temperature and the mixture was stirred for 3.5 hours. Thereafter, the solvent was evaporated under reduced pressure, and the residue was subjected to extraction with water and ether. The organic layer was separated, and the aqueous layer was extracted with ether. The organic layers were combined, washed with saturated aqueous sodium chloride, and then dried over anhydrous magnesium sulfate. The solvent was evaporated under reduced pressure, and the residue was purified by silica gel column chromatography to afford 2.18 g of the desired compound (Compound 137)
NMR (DMSO-d 6 ) δ (ppm): 7.45-6.75, 5.50, 5.10, 3.45, 2.95, 2.20-0.80
EXAMPLE 138
N-{2-[Bis(4-hydroxyphenyl)methyl]phenyl}-
N-methylcyclohexanecarboxamide (Compound 138)
In 50 ml of ethyl acetate saturated with hydrogen chloride was dissolved 2.18 g of compound 137 obtained by Example 137, and the solution was stirred for 1 hour. Thereafter, the solvent was evaporated under reduced pressure, and the residue was recrystallized from methanol to afford 0.31 g of the desired compound (Compound 138).
Melting point: 250 -252° C.
IR (KBr) cm -1 : 3410, 3190, 2930, 1630, 1515
NMR (DMSO-d 6 ) δ (ppm): 9.20, 7.40-7.15, 7.05, 6.85-6.60, 5.32, 2.88, 1.85-0.60
Reference Example 1
2-[Bis(4-acetoxyphenyl)methyl]benzoic acid
In 125 ml of pyridine was dissolved 10.15 g of phenolphthalin, and 50 ml of acetic anhydride was added dropwise to the solution at room temperature. The mixture was stirred for 1 hour, and concentrated under reduced pressure, and water was added to the residue. The aqueous mixture was extracted with chloroform, and the chloroform layer was separated, washed with saturated aqueous sodium chloride and then dried over anhydrous magnesium chloride. The solvent was evaporated under reduced pressure to afford 15.78 g of the desired compound as a solid matter.
NMR (CDCl 3 ) δ (ppm): 7.92-7.82, 7.48-6.90, 6.57, 2.27
Reference Example 2
2-[Bis(4-acetoxyphenyl)methyl]benzoyl chloride
In 50 ml of methylene chloride was dissolved 7 g of 2-[bis(4-acetoxyphenyl)methyl]benzoic acid obtained by Reference Example 1, and then 10 ml of thionyl chloride was added dropwise to the solution at room temperature. The reaction mixture was stirred for 2 hours, and the reaction mixture was concentrated under reduced pressure to afford 11.33 g of the desired compound as an oily matter.
IR (neat) cm -1 : 1758, 1504, 1200
NMR (CDCl ) δ (ppm): 8.24-8.14, 7.53-7.02, 6.32, 2.27
Reference Example 3
Methoxymethyl 2-[bis(4-methoxymethoxyphenyl)methyl]benzoate
In 500 ml of dichloromethane were dissolved 50 g of phenolphthalin and 240 ml of N,N-diisopropylethylamine, and the solution was ice cooled. Subsequently, 59 ml of chloromethyl methyl ether was added dropwise to the solution, and the mixture was heated under reflux for 4 days. The mixture was cooled to room temperature, water was added thereto, and the organic layer was separated. The aqueous layer was extracted with chloroform, and the organic layers were combined, washed with an aqueous 10% citric acid solution and then dried over anhydrous magnesium sulfate. The solvent was evaporated under reduced pressure to afford 77.31 g of the desired compound as an oily matter.
NMR (CDCl 3 ) δ (ppm): 7.87-7.76, 7.45-6.88, 7.47, 5.24, 5.08, 3.41, 3.29
Reference Example 4
Benzyl 2-[bis(4-benzyloxyphenyl)methyl]benzoate
In 500 ml of methyl ethyl ketone were dissolved 50 g of phenolphthalin and 75 g of anhydrous potassium carbonate, and the solution was ice cooled. Subsequently, 58 ml of benzyl bromide was added dropwise to the solution, and the mixture was heated under reflux for 24 hours. The temperature of the mixture was brought back to room temperature, and concentrated. Thereafter, water was added to the residue, and the aqueous mixture was extracted with ethyl acetate. The organic layer was separated, and the aqueous layer was extracted with ethyl acetate. ]he organic layers were combined, washed with an aqueous 10% citric acid and then dried over anhydrous magnesium sulfate. The solvent was evaporated to give 114.61 g of the desired product.
NMR (CDCl 3 ) δ (ppm): 7.8 73, 7.40-7.20, 7.73-7.02, 7.43, 5.12-4.96
Reference Example 5
2-[Bis(4-methoxymethoxyphenyl)methyl]benzyl alcohol
In 500 ml of tetrahydrofuran was dissolved 74 g of methoxymethyl 2-[bis(4-methoxymethoxyphenyl)methyl]benzoate obtained by Reference Example 3. The solution was ice-cooled, 10 g of lithium aluminum hydride was added thereto, and the mixture was stirred for 10 minutes. The reaction mixture was stirred for additional 30 minutes at room temperature, and ice cooled, and then 10 ml of water, 10 ml of aqueous 15% sodium hydroxide and 30 ml of water were added thereto in order. The mixture was filtered by use of a filter aid and then concentrated under reduced pressure to afford 53.54 g of the desired compound as an oily matter.
NMR (CDCl 3 ) δ (ppm): 7.45-6.85, 5.77, 5.12, 4.60, 4.47
Reference Example 6
2-[Bis(4-benzyloxyphenyl)methyl]benzyl alcohol
The desired compound (69.03 g) was obtained from 114.61 g of benzyl 2-[bis(4-benzyloxyphenyl)methyl]benzoate obtained by Reference Example 4 in a similar manner as in Reference Example 5.
NMR (CDCl 3 ) δ (ppm): 7.40-7.10, 7.00-6.75, 5.73, 4.98, 4.61
Reference Example 7
2-[Bis(4-methoxymethoxyphenyl)methyl]benzaldehyde
In 400 ml of dichloromethane was dissolved 58.3 g of 2-[bis(4-methoxymethoxyphenyl)methyl]benzyl alcohol obtained by Reference Example 5, and the solution was ice cooled.
Subsequently, 110 g of pyridinium dichromate was added to the solution, and the mixture was stirred for 15 minutes. The mixture was then additionally stirred for one day at room temperature. To the reaction mixture was added 77 ml of isopropyl alcohol, and the mixture was stirred for 20 minutes. The mixture was diluted with ethyl acetate, filtered by using a filter aid and then concentrated under reduced pressure to afford 50.77 g of the desired compound as an oily matter.
NMR (CDCl 3 ) δ (ppm): 10.18, 8.51, 8.85-8.75, 8.38-6.92, 6.43, 5.10, 3.43
Reference Example 8
2-[Bis(4-benzyloxyphenyl)methyl]benzaldehyde
The desired compound (50.58 g) was obtained from 69 g of 2-[bis(4-benzyloxyphenyl)methyl]benzyl alcohol obtained by Reference Example 6 in a similar manner as in Reference Example 7.
NMR (CDCl 3 ) δ (ppm): 10.19, 9.98, 8.56, 7.9-7.78, 7.60-7 15, 7.00-6.78, 6.42, 4.99
Reference Example 9
N-[2-Bis(4-benzyloxyphenyl)methylbenzylidene]-(1-benzylpiperidin-4-yl)amine
In a mixture of 20 ml of ethanol and 20 ml of dioxane were dissolved 5 g of 2-[bis(4-benzyloxyphenyl)methyl]benzaldehyde obtained by Reference Example 8 and 2.1 ml of 4-amino-1-benzylpiperidine, and the solution was heated under reflux for 4.5 hours. The solvent was then evaporated under reduced pressure to afford 7.0 g of the desired compound.
NMR (CDCl 3 ) δ (ppm): 8.46, 7.77, 7.50-7.00, 6.86, 6.00, 4.98, 3.48, 3.20-2.70, 2.30-1.40
Reference Example 10
4,4'-Diacetoxy-2"-nitrotriphenylmethane
In 80 ml of pyridine was dissolved 12 g of 4,4'-dihydroxy-2"-nitrotriphenylmethane, and then 40 ml of acetic anhydride was added dropwise to the solution. The mixture was stirred for one day, and washed with 2N hydrochloric acid and then extracted with ethyl acetate. The extract was dried over anhydrous magnesium sulfate and then subjected to crystallization from a mixture of ether and hexane to afford 9.46 g of the desired compound.
NMR (CDCl 3 ) δ (ppm): 7.93-7.82, 7.52-7.04, 6.27, 2.31
Reference Example 11
4,4'-Diacetoxy-2"-aminotriphenylmethane
In a mixture of 180 ml of dioxane and 20 ml of ethanol was dissolved 7.68 g of 4,4'-diacetoxy-2"-nitrotriphenylmethane obtained by Reference Example 10. Thereafter, a mixture of 98 mg of 10% palladium-carbon and 10 ml of water was added thereto, and the mixture was stirred at room temperature for 8 hours, while being contacted with hydrogen. The reaction mixture was filtered by using a filter aid, and the filtrate was then concentrated to give 7.71 g of the desired compound.
NMR (CDCl 3 ) δ (ppm): 7.40-6.80, 6.75-6.6 3.10-2.50, 2.25
Reference Example 12
4,4'-Bis(methoxymethoxy)-2"-nitrotriphenylmethane
In 500 ml of methylene chloride was dissolved 93 g of 4,4'-dihydroxy-2"-nitrotriphenylmethane. To this solution were added 135 g of N,N-diisopropylethylamine and 77 ml of chloromethyl methyl ether, and the mixture was stirred at room temperature for 5.5 hours. Thereafter, the solvent was evaporated under reduced pressure, and the residue was subjected to extraction with water and ethyl acetate. The organic layer was separated, and the aqueous layer was extracted with ethyl acetate. The organic layers were combined, washed with saturated aqueous sodium chloride, and then purified by silica gel column chromatography to afford 19.5 g of the desired compound as an oily matter.
NMR (CDCl 3 ) δ (ppm): 7.80, 7.45-6.75, 6.13, 5.10, 3.45
Reference Example 13
4,4'-Bis(methoxymethoxy)-2"-aminotriphenylmethane
In a mixture of 40 ml of ethanol and 350 ml of dioxane was dissolved 19.5 g of 4,4'-bis(methoxymethoxy)-2"-nitrotriphenylmethane obtained by Reference Example 12. In the solution was suspended 0.25 g of 10% palladium-carbon, and the suspension was stirred under hydrogen atmosphere for 2 days. The reaction mixture was filtered by the using a filter aid. The solvent was then evaporated to afford 20.1 g of the desired compound.
NMR (CDCl 3 ) δ (ppm): 7.20-6.40, 5.30, 5.06, 3.40
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A triphenylmethane derivative represented by the following general formula: ##STR1## exhibits born absorption inhibiting effects and is useful as a medicament for treating osteoporosis.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of DE 10 2006 056 243.7, filed Nov. 27, 2006 and DE 10 2007 054 187.4, filed Nov. 14, 2007. The disclosures of the above applications are incorporated herein by reference.
FIELD
[0002] The invention relates to a contacting device for contacting an electrical test piece to be tested, in particular a test piece provided with tin-plated contacts, comprising at least two guide elements having openings through which contact elements pass essentially axially and which project from the test piece, on a side of the associated guide element facing the test piece, with a projecting length for contacting the test piece.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] A contacting device of the aforementioned type is known. Pin-shaped contact elements are positioned and held by being supported in openings in guide elements spaced at an axial distance from one another. The guide elements are designed as guide plates. The openings are preferably designed as boreholes, whereby guide lengths and borehole positions are fixed parameters. The pin-shaped contacts are also referred to as needles, one end of which is used to contact test points of the test piece, and the other end of which cooperates with a contacting device which is connected to an electrical test device. In this manner testing circuits may be connected in order to test the function, in particular the electrical function, of the test piece. In one specialized design the ends of the needle which contact the test piece may be provided without tips, i.e., so as to extend flatly, when in particular solder points of the test piece are to be contacted. The ends of the needles become soiled when the test piece is frequently contacted. The soilage is occasionally removed, preferably by abrasion, i.e., ground off, as the result of which a fraction of the length of the needles is always ground off as well. This relatively severe wear on the needles results in a corresponding shortening of the needles, requiring replacement of the needles when a minimum length is reached.
SUMMARY
[0005] The object of the invention is to significantly increase the service life of contact elements, in particular needles, in contacting devices.
[0006] This object is achieved according to the invention by the fact that the axial distance between the guide elements or the axial position of the guide element facing the test piece may be adjusted to fit the projecting length. As a result of these possibilities for axially displacing the guide elements relative to one another, or axially displacing the guide element facing the test piece, the needles after wearing down may once again acquire a sufficiently large projection to ensure good contacting. It is irrelevant whether the needles have a contact tip or have a flat-ground design. However, the flat design has the advantage that in the abrasive treatment performed to clean the needle tips the shape of the needle ends is preserved. When pointed needles are present, grinding also results in shortening of the tips. A further advantage of the subject matter of the invention is that the projection, i.e., the projecting length, of the needle ends may be kept relatively short, since according to the invention possibilities for adjustment exist, the short guide ensuring satisfactory guiding, which in turn provides good positioning and thus good contacting.
[0007] 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.
[0008] According to one refinement of the invention, the axial distance between the guide elements may be adjusted by means of at least one adjustment device. The adjustment device provides axial displacement of the guide element with the objective of adjusting or readjusting the projecting length of the contact elements.
[0009] The adjustment device may preferably be a continuous adjustment device and/or a stepped adjustment device. The continuous adjustment device allows stepless adjustment, whereas the stepped adjustment device allows the associated guide element to be displaced in specified increments.
[0010] Continuous adjustment is provided in particular when the adjustment device is preferentially designed as a threaded adjustment device. When at least one threaded system rotates the referenced adjustment device, the associated guide element is correspondingly displaced in the axial direction in a continuous manner.
[0011] It is advantageous when the adjustment device is a pneumatic, hydraulic, and/or piezoelectric adjustment device. Accordingly, the axial distance between the guide elements may be adjusted by means of the pneumatic adjustment device, i.e., by air pressure. Alternatively, a hydraulic adjustment device is possible in which the referenced adjustment takes place using a hydraulic medium. Since the adjustment paths are relatively small, the adjustment device may also be a piezoelectric adjustment device. Such a device changes the length of a piezoelectric path by impinging the path with a greater or smaller electrical voltage. By adjusting the electrical voltage, mechanical displacement may be achieved which in turn results in displacement of the associated guide element.
[0012] According to one refinement of the invention, the adjustment device is a wedged and/or stepped device which preferably is essentially radially displaceable. The guide element associated with the end regions of the contact elements is preferably supported on an additional axially spaced guide element. This support of the two guide elements is preferably provided by the adjustment device. If this adjustment device is adjustable in length, in particular in the form of a wedged and/or stepped device, it is obvious that, depending on the size of the wedge and/or the width of the step, the distance between the two guide elements may be adjusted, thus allowing the projecting length of the contact elements to be correspondingly adjusted. For a wedged device this is performed continuously, and for a stepped device, discontinuously, i.e., in steps.
[0013] One refinement of the invention provides that the adjustment device is designed as a removal device, and as a result of the removal the axial distance between the guide elements is decreased. As previously mentioned, the adjustment device is situated between the two guide elements. When these guide elements can be removed, the distance between the guide elements is reduced, and the guide elements meet one another when the only adjustment device that is situated therebetween is then removed. Of course, multiple adjustment devices which are all designed as removal devices may also be provided in a row in the axial direction, or the adjustment device may have multiple removable elements. When one of the removal devices or one of the elements is removed, the axial distance between the guide elements is decreased by a corresponding unit, resulting in a corresponding increase in the projecting length of the contact elements. The removal of another removal device or another element when the length of the contact element has been further reduced by wear in turn results in the possibility for correcting the projecting length. This procedure may be repeated often, and depends on the number of removal devices or elements situated in a row.
[0014] From the discussion above it is apparent that the axial distance between the guide elements may be adjusted by means of at least one element or the like provided between the guide elements. Since the guide elements are supported on this element, the element constitutes a spacer. If the spacer is preferentially changeable in thickness, it is possible according to the invention to adjust the projecting length of the contact elements. For the adjustment device under discussion it is possible, as previously mentioned, to provide the adjustment device between the guide elements. Alternatively, however, the adjustment device may be associated with another component of the contacting device and still change the axial position of the guide element associated with the ends of the test contacts in order to adjust the projecting length. For the at least one spacer under discussion, this spacer is situated between the at least two guide elements; i.e., the guide elements are directly or indirectly supported on the spacer. The thickness of the spacer may preferably be changed. To this end, once again an adjustment device and/or threaded adjustment device and/or pneumatic, hydraulic, and/or piezoelectric adjustment device and/or wedged device and/or stepped device and/or removal device may be provided.
[0015] According to one refinement of the invention, the axial distance may be adjusted by means of at least one removable and/or essentially radially displaceable spacer. The removable spacer may in particular have a frame-like design or be composed of frame parts. In this regard it is advantageous when the frame-like design is provided as a frame configuration that is open on at least one side. In this manner U-shaped frame parts may be obtained. When in particular multiple such spacers are provided which are stacked one on top of the other and individually removable, depending on the number of spacers removed it is possible to adjust the projecting length, and this procedure may be performed in succession; i.e., after corresponding wear of the contact elements at least one spacer is always removed from the consecutively axially situated spacers.
[0016] When the spacers have a frame-like, in particular a U-shaped, design, the spacers are preferably rotationally offset relative to one another about an axial axis; i.e., not all U's are flush with one another, but instead are rotationally offset, for example, by 180° or by 90° relative to one another, resulting in a more secure and better supporting interior space for the structure containing the contact elements.
[0017] The invention further relates to a method for contacting an electrical test piece to be tested, in particular a test piece provided with tin-plated contacts, preferably by use of the above-mentioned contacting device, the contacting taking place by means of contact elements which extend essentially axially and pass through at last two guide elements, the contact elements projecting from the test piece, on a side of the associated guide element facing the test piece, for contacting the test piece, and the axial distance between the guide elements or the axial position of the guide element facing the test piece being adjusted/adjustable to fit the projecting length.
DRAWINGS
[0018] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0019] The invention is illustrated by means of the drawings, with reference to exemplary embodiments, as follows:
[0020] FIG. 1 shows a schematic enlarged illustration of a contacting device for contacting an electrical test piece to be tested;
[0021] FIG. 2 shows a spacer for the contacting device for adjusting the projecting length of contact elements;
[0022] FIG. 3 shows a contacting device according to a further exemplary embodiment;
[0023] FIG. 4 shows a contacting device according to a further exemplary embodiment; and
[0024] FIG. 5 shows a contacting device according to a further exemplary embodiment.
DETAILED DESCRIPTION
[0025] 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.
[0026] FIG. 1 shows a contacting device 1 illustrated in enlarged and strictly schematic form. The contacting device has four guide elements 2 , 3 , 4 , and 5 , spaced parallel to one another in the axial direction a, between which spacer elements 6 , 7 , and 8 are provided. In particular, spacer element 6 is positioned between guide elements 2 and 3 , spacer element 7 is positioned between guide elements 3 and 4 , and spacer element 8 is positioned between guide elements 4 and 5 . Guide elements 2 , 3 , 4 , and 5 are designed as guide plates 9 , 10 , 11 , and 12 , and spacer elements 6 , 7 , and 8 have a frame-like design, thus forming cavities 13 , 14 , and 15 in the interior of the contacting device. The electrically nonconductive guide plates 9 through 12 have a plurality of respective openings 16 , 17 , 18 , and 19 , openings 16 , 18 , and 19 being axially aligned relative to one another and opening 17 being offset with respect to the alignment line in the radial direction r. A contact element 20 is axially inserted into openings 16 through 19 so that one end region 21 of the contact element projects from the opening 19 in the guide plate 12 with a projecting length H. The other end of the contact element 20 projects with an end region 22 from the opening 16 in the guide plate 9 with a length l. The configuration is arranged in such a way that the contact element 20 is provided in places with insulation 23 , and in the region of the guide plates 11 and 12 is not provided with insulation. In this latter area the contact element is accordingly made of an uninsulated material with good electrical conductivity. Alternatively, contact elements 20 without insulation may also be used. As a result of the opening 17 being offset relative to the other openings 16 , 18 , and 19 , a bend is imparted to the intrinsically elastic contact element 20 so that it is held in the contacting device in a self-retaining yet axially displaceable manner. Openings 16 through 19 are preferably designed as boreholes which in particular are produced by laser beam. The diameter of the contact element 20 is relatively small, for example having approximately the diameter of a human hair.
[0027] FIG. 1 shows that guide plates 9 through 12 are each illustrated in a broken manner; i.e., for simplicity the contacting device 1 is illustrated with only one contact element 20 . In reality, a plurality of such contact elements is provided to allow contacting of a corresponding number of test points 24 of an electrical test piece 25 to be tested, each at the respective end face 26 of the contact element 20 . For this purpose the test piece 25 is moved toward the end faces 26 . The opposite end 27 of the respective contact element 20 meets a countercontact surface (not illustrated) which is connected to an electronic test device. In this manner current paths to the test piece 25 may be generated to test the function thereof.
[0028] The contact elements are preferably designed as contact pins, in particular as contact needles. Due to their curvature they are also referred to as elbow needles.
[0029] During the testing the end face 26 of the end region 21 contacts the test point 24 of the test piece 25 , in the present case the test point 24 being formed by a solder point, i.e., a raised tin head. As the result of numerous contacting operations the end region of the contact element 20 contacting the test piece becomes soiled, and therefore it is abrasively cleaned from time to time. Not only is the soilage removed, but the material of the contact element 20 is always removed as well, with the result that the contact element becomes correspondingly shorter. This reduces the projecting length H, so that after a corresponding number of cleaning operations the control element 20 must be replaced. By use of the invention, however, this is not necessary, since the projecting length H may be adjusted by changing the distance between guide elements 4 and 5 according to the invention. For this purpose, an adjustment device 28 is provided between guide elements 4 and 5 , i.e., between guide plates 11 and 12 , or, as an alternative design, an adjustment device 28 which is not supported on guide element 4 , but instead is attached to another part of the contacting device 1 is associated with guide element 5 , so that guide element 5 is axially displaced, or may be axially displaced, relative to guide element 4 . In the exemplary embodiment of FIG. 1 , the adjustment device 28 is composed of multiple spacers 29 which are axially stacked. According to FIG. 2 each spacer 29 has a frame-like design, i.e., is a U-shaped frame part 30 . The scale of FIG. 2 does not match that of FIG. 1 , FIG. 2 being reduced in scale compared to FIG. 1 . However, it is apparent that the stacking of multiple U-shaped frame parts 30 results in the formation of an adjustment device 28 which is situated between guide plates 11 and 12 and thus specifies the distance between guide plates 11 and 12 . The stacking is preferably provided in a rotationally offset manner about a center axis M ( FIG. 2 ); for example, when two U-shaped frame parts are used these are offset relative to one another by 180°. When more than two U-shaped frame parts 30 are provided, these are preferably offset relative to one another in each case by an angle of 90°.
[0030] When the end region 21 no longer projects sufficiently from the opening 19 in the guide plate 12 after multiple cleaning operations, a spacer 29 , i.e., a U-shaped frame part 30 , is removed after prior loosening of the corresponding parts, and the device is then again tightly screwed, pressed, or the like. As a result, the projecting length H corresponding to the thickness of the removed spacer 29 is increased, so that once again a sufficient projecting length H is present. This procedure may be repeated multiple times, depending on the number of spacers 29 used.
[0031] FIG. 3 shows an exemplary embodiment corresponding to FIG. 1 ; reference is therefore made to the above description. The only difference is that in this case, the adjustment device 28 is designed as a threaded adjustment device 31 . For this purpose, preferably multiple threaded pins 32 hold guide plates 11 and 12 at an axial distance from one another. When the threaded pins 32 are rotated by inserting an appropriate tool (arrow 33 ), the distance between guide plates 11 and 12 changes, with the result that the projecting length H may be adjusted. For this purpose the threaded pins 32 must have opposing threads at their end regions. The threaded pins project into corresponding threaded boreholes in guide plates 11 and 12 . This is indicated in FIG. 3 for one of the threaded pins 32 in the region of guide plate 12 . By use of the threaded adjustment device 31 a continuous adjustment is possible; i.e., a continuously operating adjustment device 28 is present.
[0032] FIG. 4 shows a further exemplary embodiment which once again corresponds to the exemplary embodiment of FIG. 1 , so that reference is made to the above description. The only difference is the design of the adjustment device 28 , which in this case is provided as a piezoelectric adjustment device 34 . This adjustment device is situated between guide plates 11 and 12 , and may be acted on by a source of electrical voltage (not illustrated), with the result that the length b changes as a function of the voltage level, so that the distance between guide plates 11 and 12 and thus the projecting length H of the contact element 20 may be adjusted.
[0033] FIG. 5 shows a further exemplary embodiment of a contacting device 1 which once again corresponds to the exemplary embodiment FIG. 1 , the only difference being that in this case the adjustment device 28 is designed as a stepped device 35 . Two stepped devices 35 are provided which are used as spacers 29 and which have different thicknesses due to the respective step design 36 . In the position of the two stepped devices 35 shown in FIG. 5 , use is made of the maximum thickness of these devices in order to keep guide plates 11 and 12 at an appropriate distance from one another. When the projecting length H of the contact element 20 is no longer sufficient, the two stepped devices 35 , after prior loosening of appropriate components, may be moved radially outward, with the result that after subsequent assembly the guide plate 11 rests on a step surface 37 of the respective stepped device 35 , thereby reducing the distance between guide plates 11 and 12 and accordingly increasing the projecting length H by the corresponding distance.
[0034] The thickness of the spacers 29 according to FIG. 1 is preferably 150 μm, and is selected such that removal of a separating layer results in a contact element projection (projecting length H) which is long enough but not excessively long in relation to the diameter of the contact element 20 .
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The invention relates to a contacting device for contacting an electrical test piece to be tested, in particular a test piece provided with tin-plated contacts, comprising at least two guide elements having openings through which contact elements pass essentially axially and which project from the test piece, on a side of the associated guide element facing the test piece, for contacting the test piece. The invention is characterized in that the axial distance between the guide elements or the axial position of the guide element facing the test piece may be adjusted to fit the projecting length.
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This application claims benefit of Provisional Application Ser. No. 60,184,769 filed May 8, 1998.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates generally to structures and their components which have been treated with equipment and techniques that produce modifications to surface characteristics in either the structures or the components. More particularly, the present invention relates to equipment and techniques for treating substrates and components having commercial and industrial uses, particularly in industrial fabrics. Most particularly, the invention relates to plasma treated components and substrates together with equipment and techniques useful in treating the same in an efficient and accurate manner.
The prior art has recognized the advantages to be obtained by plasma treating and deposition techniques, at low pressure and at atmospheric pressure, to achieve desirable characteristics in a product. Most generally, the products treated in the prior art are single purpose products which were not intended to be exposed to a working condition or an active environment where the treated product is subjected to varying conditions over an extended time period. Furthermore, the prior art products were not exposed to varied treatment over time in a work environment. For example, industrial fabrics are frequently required to work under conditions of high mechanical stress and hostile environments. Special applications, like papermaking, require industrial fabrics that generally work in hot, moist and chemically hostile environments. As such, the fabric may be exposed to high water content in a formation step, heat, pressure and relatively high water content in a pressing step, and then, exposed to high temperatures in a drying step. Thus, the fabrics may see a variety of conditions in the process. Industrial fabrics may also be exposed to varying conditions in industries such as food processing, waste treatment, assembly line processes or surface painting and treating techniques.
The art has recognized that it would be desirable to have substrates and components with certain mechanical properties, such as strength, dimensional stability, and flexibility over extended periods. While these characteristics are desired as properties, it is sometimes desired to have surface properties which are contrary to these properties. For instance, it may be desirable to have a component which exhibits good internal resistance to moisture at its core while having an external affinity for moisture at its surface. It is not uncommon to have a conflict develop between the desired mechanical properties and the preferred surface properties. The prior art has recognized and there have been attempts at producing a mechanically robust core which supports a surface layer that has specific characteristics for the desired application. It has been recognized that important surface layer properties such as hydrophilicity, hydrophobicity, oleophilicity, oleophobicity, conductivity, chemical resistance and abrasion resistance may not necessarily be optimized in a single component which optimizes core properties such as strength, flexibility, and the like.
The present invention addresses the shortcomings of the prior art by providing structures and components which are treated with a highly efficient and controllable plasma treatment. If desired, the structure or component may be further enhanced or modified by exposure to a deposition treatment.
SUMMARY OF THE INVENTION
The present invention provides substrates and components having at least one inherent surface characteristic thereof modified by equipment and techniques which are particularly suitable for achieving that modification. The inherent surface property may be modified by a plasma treatment process which comprises the steps of providing a plasma treatment chamber which includes one or more hollow cathodes for generating a plasma within the chamber. The chamber includes means for focusing the generated plasma at the surface to be treated as it is introduced into the chamber and reacted with the plasma.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation showing a plasma treatment apparatus in accordance with the present invention in an opened condition.
FIG. 2 is an elevation of the other side of the plasma treatment apparatus of FIG. 1 taken along the line 2 — 2 of FIG. 1 .
FIG. 3 is an elevation of one side of the plasma treatment apparatus of FIG. 1 taken along the line 3 — 3 of FIG. 1 .
FIG. 4 is a side elevation of one arrangement for treating a substrate in accordance with the present invention.
FIG. 5 is a partial cutaway perspective view of a capillary drip system.
FIG. 6 is a side elevation of a solution bath.
FIG. 7 is an elevation, similar to FIG. 2, showing a plurality of discrete substrates being treating simultaneously.
FIG. 8 shows a plurality of substrates A-F in cross-section with or without plasma treating and secondary coating.
FIG. 9 shows an alternative arrangement of the plasma treatment chamber.
FIG. 10 shows a treatment chamber for metal deposition.
FIG. 11 shows a treatment chamber for vapor deposition of a monomer.
FIG. 12 shows a curing unit.
GLOSSARY
A component is a structural or modular element that is capable of producing a structure when a plurality thereof are assembled together.
A fabric structure is formed by arranging individual strands in a pattern, such as by weaving, braiding, or knitting.
A fiber is a basic element of a textile and is characterized by having a length at least 100 times its diameter.
A filament is a continuous fiber of extremely long length.
A hollow cathode is an energy efficient chamber for generating a plasma.
An industrial fabric is one designed for a working function such as transport devices in the form of a moving or conveying belt.
An inherent property or characteristic is one that exists prior to any treatment by plasma or other means.
A monofilament is a single filament with or without twist.
A multifilament yarn is a yarn composed of more than one filament assembled with or without twist.
A nonwoven structure is a substrate formed by mechanical, thermal, or chemical means or a combination thereof without weaving, braiding, or knitting.
A plasma is a partially ionized gas; commonly ionized gases are argon, xenon, helium, neon, oxygen, carbon dioxide, nitrogen, and mixtures thereof.
A strand is a filament, monofilament, multifilament, yarn, string, rope, wire, or cable of suitable length, strength, or construction for a particular purpose.
A structure is an assemblage of a plurality of components.
A substrate is any structure, component, fabric, fiber, filament, multifilament, monofilament, yarn, strand, extrudate, modular element, or other item presented for plasma treatment or coating.
A web is an array of loosely entangled strands.
A yarn is a continuous strand of textile fibers, filaments, or material in a form suitable for intertwining to form a textile structure.
A 100% solids solution is a fluid such as a monomer, combination of monomers or other coating material which includes no carriers or solvent.
A 100% solids bath is a tank filled with a fluid such as a monomer, which includes no carriers or solvent.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments will be described with reference to the drawing Figures wherein like numerals indicate like elements throughout.
With reference to FIG. 1, there is shown plasma treatment chamber 2 which is useful in accordance with the present invention. Plasma treatment chamber 2 is divided into a plasma generating side 4 and a plasma focusing side 6 . In use, the plasma generating side 4 and the plasma focusing side 6 are joined together in a sealed relationship except for openings 8 and 10 at the respective upper and lower ends. Entry and exit openings are created by the recesses 12 , 14 , 16 and 18 . Since the pressure in the plasma treatment chamber 2 is preferably below atmospheric pressure, the recesses 12 , 14 , 16 and 18 will be provided with air locks of foam material or loop pile material, such as is available under the trade name Velcro®. Presently, a closed cell polyolefin, such as polyethylene or polypropylene, foam is preferred. When chamber 2 is closed, the walls 20 and 22 will form a channel 24 through the apparatus 2 . A substrate passing between the air locks at openings 8 and 10 will pass into channel 24 and be sufficiently sealed against the atmosphere so as to maintain the desired vacuum level within the plasma treatment chamber 2 . The vacuum in chamber 2 is drawn through the outlet ducts 30 and 32 by a suitable vacuum generating device as will be known to those skilled in the art. Currently, the plasma is being generated between 900 milli torr (0.900 torr) and 3 torr. In earlier trials, plasma was generated at up to 34 torr.
With reference to FIG. 2, taken along line 2 — 2 of FIG. 1, there is illustrated a substrate 3 as it passes through the plasma treatment chamber 2 and the hollow cathode assemblies 36 . As shown in FIGS. 1 and 2, the hollow cathode assemblies 36 define multiple hollow cathodes 38 . The plasma generated in the hollow cathodes 38 will be initially focused in the vicinity of the substrate 3 . Additional focusing of the plasma on the substrate is accomplished by the focusing means included in plasma focusing side 6 .
Turning now to FIG. 3, there is a view of the plasma focusing side 6 of plasma treatment apparatus 2 that is taken along the line 3 — 3 of FIG. 1 . The plasma focusing side 6 includes a plurality of focusing arrays 50 which are located in space relative to each other so as to achieve a reinforcement of the magnetic focusing field. Surrounding the magnets 50 (shown in crosshatch for clarity) are the cooling ducts 52 which serve to control the temperature in the chamber, thereby protecting the magnets from overheating.
Plasma treatment to remove low molecular weight material or surface impurities will preferably use readily available, inexpensive, environmentally benign gases. In some applications, plasma treatment alone may be sufficient, however, it can be followed by coating with metals, ceramics, or polymerizable compounds. Preferred polymerizable compounds are radiation curable organic monomers containing at least one double bond, preferably at least two double bonds, especially alkene bonds. Acrylates are particularly well-suited monomers. Metals suitable for deposition include, but are not limited to Al, Cu, Mg, and Ti. Ceramics suitable for deposition include, but are not limited to, silicate-containing compounds, metal oxides particularly aluminum oxide, magnesium oxide, zirconium oxide, beryllium oxide, thorium oxides, graphite, ferrites, titanates, carbides, borides, silicides, nitrides, and materials made therefrom. Multiple coatings comprising metal, ceramic or radiation curable compound coatings are possible.
Plasma treatment leads to one or more of the following benefits: cleaning, roughening, drying, or surface activation. Plasma treatment can also lead to chemical alteration of a substrate by adding to a substrate or removing from a substrate, functional groups, ions, electrons, or molecular fragments, possibly accompanied by cross-linking.
All materials are of interest for plasma treatment or application of a secondary coating. Those of primary interest are polymers, such as aramids, polyesters, polyamides, polyimides, fluorocarbons, polyaryletherketones, polyphenylene sulfides, polyolefins, acrylics, copolymers and physical blends or alloys thereof. Preferred secondary layer coating thickness for polymers is in the range of 0.1 to 100 microns, more preferably 20 to 100 microns, most preferably 20 to 40 microns. Preferred metal or ceramic secondary layer coating thickness is in the range of 50 angstroms to 5 microns, more preferably 100 to 1000 angstroms. A preferred polymer is an acrylate of acrylic acid or its esters. The preferred acrylates have two or more double bonds.
Monoacrylates have the general formula
Wherein R 1 , R 2 , R 3 , and R 4 are H or an organic group.
Diacrylates are acrylates of formula I wherein either R 1 , R 2 , R 3 , or R 4 is itself an acrylate group. Organic groups are usually aliphatic, olefinic, alicyclic, or aryl groups or mixtures thereof (e.g. aliphatic alicyclic). Preferred monoacrylates are those where R 1 , R 2 and R 3 are H or methyl and R 4 is a substituted alkyl or aryl group.
Preferred diacrylates have the formula
where R 1 , R 2 , R 3 , R 5 , R 6 , R 7 are preferably H or methyl, most preferably H.
R 4 is preferably C 2 -C 20 alkyl, aryl, multialkyl, multiaryl, or multiglycolyl, most preferably triethylene glycolyl or tripropylene glycolyl. The notation, C 2 -C 20 alkyl, indicates an alkyl group with 2 to 20 carbon atoms.
R 4 in a mono- or multiacrylate is chosen to yield the desired surface properties after the monomer has been radiation cured to form a surface on a substrate. Table 1 contains a non-limiting list of examples.
TABLE 1
R 4
Surface Properties
—CH 2 CH 2 CH 2 OCH 2 CH 2 CH 2 OCH 2 CH 2 CH 2 —
Abrasion Resistance
—CH 2 CH 2 OCH 2 CH 2 OCH 2 CH 2 —
Abrasion Resistance
—CH 2 CH 2 COOH
Hydrophilicity
—CH 2 CH 2 OH
Hydrophilicity
Formula I and II can also include triacrylate and other polyacrylate molecules. Mixtures of diacrylates can be copolymerized, for example a 50:50 mix of two structurally different diacrylates. Diacrylates can also be copolymerized with other polymerizable components, such as unsaturated alcohols and esters, unsaturated acids, unsaturated lower polyhydric alcohols, esters of unsaturated acids, vinyl cyclic compounds, unsaturated ethers, unsaturated ketones, unsaturated aliphatic hydrocarbons, unsaturated alkyl halides, unsaturated acid halides and unsaturated nitriles.
Diacrylates of interest also include 1,2-alkanediol diacrylate monomers of formula
Where R 1 is in an acrylate radical having about 8 to 28 carbon atoms and R 2 is hydrogen or methyl (See for example U.S. Pat. No. 4,537,710).
The agent for promoting polymerization may be radiation, such as UV radiation or electron beam radiation. In some instances, it may be preferred to use a photoinitiator, such as an appropriate ketone.
Acrylate-based formulations of interest also include heterogeneous mixtures. These formulations contain a very fine dispersion of metal, ceramic, or graphite particles. These coatings are designed to enhance the abrasion resistance and/or the conductivity of the surface. For the photo-curing (UV/Visible) of these pigmented dark acrylate-based formulations, a long wave length (>250 nm) radiation source in combination with a compatible photoinitiator may be preferred.
Turning now to FIGS. 4 and 5, there are illustrated apparatuses for sequential plasma treatment, coating, and curing of a continuous substrate which may most easily be thought of as a strand 3 . In FIG. 4, a plasma treatment apparatus 2 , a coating applicator 60 , and a curing unit 70 , provide an integrated system for treatment of the strand 3 . The direction of movement of the strand 3 is indicated by the in and out arrows. The strand 3 moves over a guide roller 88 and enters the plasma treatment apparatus 2 at the opening 8 . To achieve uniform coverage, the strand 3 will not touch either wall 20 or wall 22 . However, the strand 3 will pass closer to wall 22 than to wall 20 . If it is desired to treat only one surface of a strand, the surface to remain untreated may be shielded, such as by contact with wall 22 . After the strand 3 passes through channel 24 , it exits the plasma apparatus 2 through opening 10 .
In the preferred embodiment, the coating applicator 60 , is a capillary drip system 400 including a reservoir 402 , a pump 404 , a dispensing manifold 406 , a plurality of capillary tips 408 , and a separating roller 410 having a plurality of grooves 412 dimensioned to receive a substrate as shown in FIG. 5 . The coating solution 61 is pumped from the reservoir 402 into the dispensing manifold 406 and through the plurality of capillary tips 408 . Each tip 408 is associated with a groove 412 in the separating roller 410 . In this arrangement, the roller 410 may rotate or be held stationary. The strand 3 is directed to engage the roller 410 horizontally or at an angle up to 45° above horizontal. The strand 3 travels around the roller 410 and continues vertically upward into the curing unit 70 . The variation in the initial angle θ determines how the strand 3 is coated. Depending on the angle θ, the strand contacts 25-50% of the roller 410 circumference. Use of this capillary tip system is accurate and efficient, requires less coating solution 61 , and provides a more uniform coating than other methods. This approach is believed to be beneficial because it allows for remote location of the reservoir 402 away from potential curing radiation which may impact a dip bath.
Returning to FIG. 4, the strand 3 then passes enters into the curing apparatus 70 through channel 72 and passes out of the apparatus at channel 74 . The channels 72 and 74 are defined by the extensions 75 and 76 . The central channel 77 is defined by the walls 78 and 79 of the curing apparatus 70 . After passing the last guide roller 88 , the strand 3 is handled in the usual manner associated with normal production of an unmodified product.
In one embodiment, curing apparatus 70 has one section 80 with a plurality of UV lamps (one lamp is noted as 82 ) and an opposed section 84 with a plurality of opposing mirrors (one mirror is noted as 86 ). In a preferred arrangement for curing certain monomer coatings, there are up to four lamps, in opposed pairs. Each lamp is preferably adjustable for controlling their combined output. The sections 80 and 84 are hinged relative to each other to allow access for startup and repair. The UV light used for curing preferably emits radiation between 150 and 400 nanometers. The series of guide rollers 88 change the direction of the strand 3 so it passes continuously through plasma treatment apparatus 2 , coating applicator 60 , and curing apparatus 70 .
The system components, plasma treatment apparatus 2 , coating applicator 60 , curing apparatus 70 , and rollers 88 , are secured in a stable manner to preserve the special relationship between them.
FIG. 7 illustrates the case for multiple strands 3 , such as monofilaments, passing through the plasma treatment apparatus 2 . The strands are spaced across the width, preferably in individual paths, so that the entirety of the strand is exposed to treatment. The individual strands are preferably guided by grooves cut in the rollers 88 . Using a series of grooved rollers 88 keeps the strands in the desired relationship as they move through the treatment process.
The treated substrate is tested according to Test Method 118 developed by the American Association of Textile Chemists and Colorists (AATCC). Drops of standard test liquids, consisting of a selected series of hydrocarbons with varying surface tensions, are placed on the surface and observed for wetting, wicking, and contact angle. The oil repellency grade is the highest numbered liquid which does not wet the surface. The method was modified to test for water repellency, using test liquids of isopropanol and water in ratios of 2:98, 5:95, 10:90, 20:80, 30:70, and 40:60 (in percent by volume) numbered one through six respectively. If surface wetting does not occur within 10 seconds, the next test liquid is applied. Lower ratings indicate oleo-or hydrophilicity while higher ratings indicate oleo-or hydrophobicity.
EXAMPLE 1
Using a continuous treatment system shown in FIGS. 1-5, a plurality of strands are treated. An extruder is adjusted to produce 10 ends of a polyethylene terephthalate monofilament with a nominal size of 0.26 mm×1.06 mm. These sizes have a tolerance of 0.22-0.304 mm and 1.01-1.11 mm respectively, with an expected yield of 2900 denier. Additionally the yarn would have a relative elongation at 3 grams per denier of 19%, and a free shrinkage at 200 degrees Centigrade of 6.5%. The production speed of the extruder line is set at 216.8 fpm, with the godet rolls and oven temperatures appropriately adjusted to give the specified yarn.
Immediately after exiting the extruder, nine of the ten strands are introduced into the plasma chamber, which is at 1.01 Torr, with constant induction of 400 ml/min of commercial grade Argon. The amplifier and tuner are adjusted to introduce 1326 Watts to the hollow cathode, with less than 10 Watts of reflected power. An external chiller is used, which maintains the temperature near room temperature, but above the dew point.
Upon exiting the plasma chamber, the nine ends are then directed to a grooved separator roll where monomer is applied. From a one inch manifold being supplied formulation MM2116 by a diaphragm pump, nine capillaries drop to individual grooves spaced evenly across the roller. The air-operated pump is adjusted with a micro air valve to supply a steady state of monomer to the monofilament. A weighing device is used to continually monitor the amount delivered. Coating thickness can be controlled by increasing or decreasing pump pressure, fiber speed or stopping the rotation of the roller.
After coating, the yarn proceeds directly upward, and enters the ultra violet cure box, which has three lamps operating. Two lamps are set on medium, and one is set on high, providing an immediate and complete cure of the monomer. In the upper section, two of the lamps are opposed to each other rather than having one lamp opposed by a mirror. Other applications may demand more or fewer lamps.
After the yarn exits the UV chamber, it continues down the line through a nip roll and onto the spools mounted on a conventional spool winder.
This particular run experienced an increase in the minor axis of 0.0274 mm and in the major axis of 0.1486 mm, causing an increase in weight of 178 grams per 9000 meters or approximately a 5.8% add on.
The resulting yarn has an oil, water rating of 4, 6 when tested with AATCC Test Method #118. The yarn was then woven into a filling float fabric using conventional processing methods. The yarn survives the rigors of warping and weaving without abrasion, or flaking indicating the coating is securely affixed. Resulting fabrics also have an oil, water rating of 4, 6 on one surface designated as the face. The untreated PET control has an oil, water rating of 0, 2-3.
In this particular example, a series of acrylate-based fluorinated monomer/oligomer formulations have been tested for this application. These materials cover a broad range of surface energies (hydrophobic/hydrophilic and oleophobic/oleophilic), crosslinking densities, abrasion resistance and adhesion to the substrate.
The formulation Sigma-MM-2116 is a solvent-free, acrylate based monomer/oligomer mix which contains 50-95% perfluorinated monoacrylate with fluorine content ranging from 30-64%. The formulation also contains 3-50% multi-functional, compatible crosslinking agents, e.g. di- and tri-acrylate monomers. Also 1-20% of an adhesion promoter was added to enhance diacrylate monomers functionalized with hydroxyl, carboxyl, carbonyl, sulfonic, thiol, or amino groups. The high fluorine content lowers the surface energy of the cured coating and turns the coated yarn into hydrophobic and oleophobic material. Combining the plasma treatment of the surface of the substrate with the functionalization of the coating with a specialty adhesion promoter formulation helps to achieve an excellent adhesion between the coating and the substrate while keeping the energy low, making the surface of the substrate both hydrophobic and oleophobic.
In addition to the formulation for hydrophobicity/oleophobicity, formulations are also contemplated in applications for electrostatic dissipation and abrasion resistance.
Although the presently preferred embodiment uses the capillary drip applicator, initial efforts called for a monomer bath. As shown in the sectional view of FIG. 6, the bath 418 is essentially a tub 420 for holding the monomer solution 61 and a submersible frame 422 for controlling passage through the monomer solution 61 . The frame 422 moves horizontally on shaft 424 and vertically on shaft 425 . The depth of roller 426 in the monomer solution 61 may be controlled by fixing the position of shaft 425 . When the roller 426 is submerged in the monomer solution 61 , each strand 3 is passed around the roller 426 so that it will exit vertically from the bath as indicated by the broken line.
EXAMPLE 2
Using a continuous treatment system as shown in FIGS. 1 to 5 , a polyethylene terephthalate (PET) monofilament of 0.5 mm diameter is treated. In this example, a sample monofilament is fed from the final extrusion process directly to the plasma treatment apparatus. The control sample is fed from the final extrusion process directly to a wind up roll. As used herein, directly means the absence of intermediate processing steps or storage between processing steps for an extrudate. The line speed in the test system is 200 ft/min but speeds up to 700 feet/min are employed during production. The gas in the plasma treatment apparatus may be 10% argon and 90% nitrogen but is more preferably 20% oxygen and 80% argon. The gas is introduced into the treatment chamber at a rate sufficient to achieve a stable plasma. The vacuum pressure is 10 −1 -10 −4 torr. Power supplied to the plasma chamber is about 2 kW (kilowatts). The power is created with direct current or alternating current but is preferably created with an alternating current in the range of 10 to 100 kHz, with 40 kHz being preferred. The monomer bath contains a solution of triethyleneglycol diacrylate. The lamps in the UV treatment apparatus are 15 inch Hanovia high pressure Hg lamps that generate 300 W/inch.
The treated monofilament is compared to the control monofilament by surface tension measurements using the oil and water tests described above.
It is preferred to use continuous or in-line processing where the substrate moves through the base processing step, such as extrusion, and plasma/coating treatment at the same speed.
Other alternative coating means may be used such as U shaped applicators, a kiss roll, eyelet applicators, and clamshell eyelet applicators. In a more traditional finishing device, the strand passes through a liquid-filled U-shaped device, and emerges with a coating around its entire perimeter. Where capillary action can be used to carry a coating around the strand, a kiss roll applicator may be used. In this technique, the strand is coated when it “kisses” a liquid covered roller which is rotating with or against the strand's direction of travel. In yet another embodiment, the strand passes through an eyelet through which the coating is pumped. The eyelet may have a clam-shell design to avoid the need for threading the strand through the eyelet.
FIGS. 8A through 8G illustrate exemplary cross-sections of coated strands which are producible in accordance with the above example. All cross-sections are greatly exaggerated to permit demonstration of the point. In FIG. 8A, the substrate 302 has a plasma-treated outer surface 303 surrounded by a coating layer 304 . More than one type of coating may be applied through repeated coating techniques. In FIG. 8B, the usually preferred embodiment, the first coating layer 304 and a secondary coating 306 surround the core 302 . In FIG. 8C, the outer layer 306 is disposed only partly around the first coating layer 304 . In FIG. 8D, the first coating 304 and the secondary coating 306 are disposed only partly around core 302 . In FIG. 8E, the coating layer 304 is only partly around the core 302 but the coating 306 is completely around the core 302 .
FIG. 8F illustrates exemplary cross-sections of rectangular strands. In FIG. 8F, the plasma-treated substrate 302 , like in 7 B, is coated with a first layer 304 , such as a metal or polyacrylate, and a second layer, 306 , such as a metal or polyacrylate. In FIG. 8G, like 7 D, the substrate 302 is covered for a portion thereof by a first layer 304 and a second layer 306 . Depending on the substrates dimensions, the cross-section in FIG. 8G can resemble that of a thin film.
In general, the coating is nonconformational. That is, it will tend to be self-leveling and will not conform to the geometry of the substrate.
FIGS. 9-12 show alternative plasma treatment chambers and coating and curing units.
FIG. 9 shows a representative upper chamber, 126 and a representative lower chamber, 127 , to illustrate one treatment arrangement. In FIG. 9, upper chamber 126 has the hollow cathodes arrays 36 and 36 , and lower chamber 127 has focusing magnets 50 . The arrangement of FIG. 9 will plasma treat only the upper surface 98 of a substrate 97 when it is relatively dense. For an open, less dense substrate, like a web or open fabric, it may be possible to treat surfaces 98 and 99 at one time.
If desired, additional hollow cathodes arrays 36 may be located in the adjacent lower chamber and additional focusing magnets 50 may be located in the adjacent upper chamber 126 , to simultaneously treat upper surface 98 and lower surface 99 . FIG. 9 does not show a gas feed connection for introducing gas to be ionized or electrical connections linked to the cathodes as these connections will be known to those skilled in the art as a matter of design choice.
FIG. 10 shows a representative upper chamber 128 and a representative lower chamber 129 in an arrangement for metal deposition. Lower chamber 129 has resistively heated boats 171 and a supply of aluminum wire 173 on spool 175 . As the wire 173 contacts the resistively heated boats 171 , the wire is vaporized. It then condenses on the lower surface 99 . Alternatively, one can create a ceramic coating by introducing oxygen in to chamber 129 to oxidize the aluminum and create aluminum oxide (Al 2 O 3 ).
FIG. 11 shows a representative upper chamber 124 and a representative lower chamber 125 for creating a monomer layer on surface 98 . A monomer vaporizer 180 creates a cloud of monomer vapor which will be deposited through condensation on the upper surface 98 . If desired, a vaporizer 180 , shown in phantom could be located as a mirror image in lower chamber 125 .
FIG. 12 shows a representative upper chamber 130 that has a bank 82 of UV emitting lights that irradiate and cure the monomers on surface 98 . Alternatively, the radiation device can be one that emits an electron beam. If the substrate is treated on both surfaces a second bank 190 , as shown in phantom will be located in chamber 131 .
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Methods and apparatus for plasma modifying a substrate are disclosed along with associated techniques for applying coatings to the substrate. Particular utility has been found using a hollow cathode to generate the plasma along with magnetic focusing means to focus the plasma at the surface of a substrate.
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[0001] This is a continuation application of copending application Ser. No. 11/742,668 filed on May 1, 2007; which is a continuation of application Ser. No. 11/168,814 filed on Jun. 28, 2005 and issued Jun. 5, 2007 as U.S. Pat. No. 7,225,885; which is a continuation of application Ser. No. 09/898,989 filed on Jul. 3, 2001 and issued Aug. 30, 2005 as U.S. Pat. No. 6,935,439; which is a continuation of application Ser. No. 09/562,503 filed on May 1, 2000 and issued Aug. 28, 2001 as U.S. Pat. No. 6,279,668; which is a continuation of application Ser. No. 09/066,964 filed on Apr. 27, 1998 and issued Jun. 27, 2000 as U.S. Pat. No. 6,079,506; the disclosures of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to underground boring tool guidance and, more particularly, to a remote walk over locator/controller configured for determining the underground location of a boring tool and for remotely issuing control commands to a drill rig which is operating the boring tool.
[0003] Installing underground utility cable using a steerable boring tool is well known in the art. Various examples are described in U.S. Pat. Nos. 5,155,442, 5,337,002, 5,444,382 and 5,633,589 as issued to Mercer et al (collectively referred to herein as the Mercer Patents), all of which are incorporated herein by reference. An example of the prior art Mercer technique is best illustrated in FIG. 1 herein which corresponds to FIG. 2 in the Mercer Patents. For purposes of clarity, the reference numerals used in the Mercer Patents have been retained herein for like components.
[0004] As seen in FIG. 1 , an overall boring machine 24 is positioned within a starting pit 22 and includes a length of drill pipe 10 , the front end of which is connected to the back end of a steerable boring head or tool 28 . As described in the Mercer Patents, the boring tool includes a transmitter for emitting a dipole magnetic field 12 which radiates in front of, behind and around the boring tool, as illustrated in part in FIG. 1 . A first operator 20 positioned at the starting pit 22 is responsible for operating the boring machine 24 ; that is, he or she causes the machine to let out the drill pipe, causing it to push the boring tool forward. At the same time, operator 20 is responsible for steering the boring tool through the ground. A second locator/monitor operator 26 is responsible for locating boring tool 28 using a locator or receiver 36 . The boring tool is shown in FIG. 1 being guided beneath an obstacle 30 . The locator/monitor operator 26 holds locator 36 and uses it to locate a surface position above tool head 28 . Once operator 26 finds this position, the locator 36 is used to determine the depth of tool head 28 . Using the particular locator of the present invention, operator 26 can also determine roll orientation and other information such as yaw and pitch. This information is passed on to operator 20 who then may use it to steer the boring tool to its target. Unfortunately, this arrangement requires at least two operators in order to manage the drilling operation, as will be discussed further.
[0005] Still referring to FIG. 1 , current operation of horizontal directional drilling (HDD) with a walkover locating system requires a minimum of two skilled operators to perform the drilling operation. As described, one operator runs the drill rig and the other operator tracks the progress of the boring tool and determines the commands necessary to keep the drill on a planned course. In the past, communication between the two operators has been accomplished using walkie-talkies. Sometimes hand signals are used on the shorter drill runs. However, in either instance, there is often confusion. Because an operating drill rig is typically quite noisy, the rig noise can make it difficult, if not impossible, to hear the voice communications provided via walkie-talkie. Moreover, both the walkie-talkie and the hand signals are awkward since the operator of the drill rig at many times has both of his hands engaged in operation of the drill rig. Confused steering direction can result in the drill being misdirected, sometimes with disastrous results.
[0006] The present invention provides a highly advantageous boring tool control arrangement in which an operator uses a walk-over locator unit that is configured for remotely issuing control commands to a drill rig. In this way, problems associated with reliable communications between two operators are eliminated. In addition, other advantages are provided, as will be described hereinafter.
SUMMARY OF THE INVENTION
[0007] As will be described in more detail hereinafter, there is disclosed herein a locator/control arrangement for locating and controlling underground movement of a boring tool which is operated from a drill rig. An associated method is also disclosed. The boring tool includes means for emitting a locating signal. In accordance with the present invention, the locator/control arrangement includes a portable device for generating certain information about the position of the boring tool in response to and using the locating signal. In addition to this means for generating certain information about the position of the boring tool, the portable device also includes means for generating command signals in view of this certain information and for transmitting the command signals to the drill rig. Means located at the drill rig then receives the command signals whereby the command signals can be used to control the boring tool.
[0008] In accordance with one aspect of the present invention, the means located at the drill rig for receiving the command signals may include means for indicating the command signals to a drill rig operator.
[0009] In accordance with another aspect of the present invention, the means located at the drill rig for receiving the command signals may include means for automatically executing the command signals at the drill rig in a way which eliminates the need for a drill rig operator.
[0010] In accordance with still another aspect of the present invention, drill rig monitoring means may be provided for monitoring particular operational parameters of the drill rig. In response to the particular operational parameters, certain data may be generated which may include a warning that one of the parameters has violated an acceptable operating value for that parameter. In one feature, the certain data regarding the operational parameters may be displayed at the drill rig. In another feature, the certain data regarding the operational parameters may be displayed on the portable device. The latter feature is highly advantageous in embodiments of the invention which contemplate elimination of the need for a drill rig operator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention may be understood by reference to the following detailed description taken in conjunction with the drawings, in which:
[0012] FIG. 1 is a partially broken away elevational and perspective view of a boring operation described in the previously recited Mercer Patents.
[0013] FIG. 2 is an elevational view of a boring operation being performed in accordance with the present invention in which a portable locator/controller is used.
[0014] FIG. 3 is a diagrammatic perspective view of the portable locator/controller which is used in the boring operation of FIG. 2 , shown here to illustrate details of its construction.
[0015] FIG. 4 is a partial block diagram illustrating details relating to the configuration and operation of the portable locator/controller of FIG. 3 .
[0016] FIG. 5 is a partial block diagram illustrating details relating to the configuration and operation of one arrangement of components located at the drill rig for receiving command signals transmitted from the portable locator/controller of the present invention.
[0017] FIG. 6 is a partial block diagram illustrating details relating to the configuration and operation of another arrangement of components located at the drill rig for receiving command signals transmitted from the portable locator/controller and for, thereafter, executing the commands signals so as to eliminate the need for a drill rig operator.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Turning again to the drawings, attention is immediately directed to FIG. 2 which illustrates a horizontal boring operation being performed using a boring/drilling system generally indicated by the reference numeral 70 . The drilling operation is performed in a region of ground 72 including a boulder 74 . The surface of the ground is indicated by reference numeral 76 .
[0019] System 70 includes a drill rig 78 having a carriage 80 received for movement along the length of an opposing pair of rails 82 which are, in turn, mounted on a frame 84 . A conventional arrangement (not shown) is provided for moving carriage 80 along rails 82 . During drilling, carriage 80 pushes a drill string 86 into the ground and, further, is configured for rotating the drill string while pushing, as will be described. The drill string is made up of a series of individual drill string sections or pipes 88 , each of which includes a suitable length such as, for example, ten feet. Therefore, during drilling, sections 88 must be added to the drill string as it is extended or removed from the drill string as it is retracted. In this regard, drill rig 78 may be configured for automatically adding or removing the drill string sections as needed during the drilling operation. Underground bending of the drill string sections enables steering, but has been exaggerated for illustrative purposes.
[0020] Still referring to FIG. 2 , a boring tool 90 includes an asymmetric face 92 and is attached to the end of drill string 86 . Steering of the boring tool is accomplished by orienting face 92 of the boring tool (using the drill string) such that the boring tool is deflected in the desired direction. Boring tool 90 includes a mono-axial antenna such as a dipole antenna 94 which is driven by a transmitter 96 so that a magnetic locating signal 98 is emanated from antenna 94 . Power may be supplied to transmitter 96 from a set of batteries 100 via a power supply 102 . A control console 104 is provided for use in controlling and/or monitoring the drill rig. The control console includes a drill rig telemetry transceiver 106 connected with a telemetry receiving antenna 108 , a display screen 110 , an input device such as a keyboard 112 , a processor 114 , and a plurality of control levers 116 which, for example, hydraulically control movement of carriage 80 along with other relevant functions of drill rig operation.
[0021] Still referring to FIG. 2 , in accordance with the present invention, drilling system 70 includes a portable locator/controller 140 held by an operator 141 . With exceptions to be noted, locator 140 may be essentially identical to locator 36 , as described in the Mercer Patents.
[0022] Turning to FIG. 3 in conjunction with FIG. 2 , the same reference numerals used to describe locator 36 in the Mercer Patents have been used to designate corresponding components in locator/controller 140 . In order to understand and appreciate the present invention, the only particular components of locator 36 that form part of locator 140 and that are important to note here are the antenna receiver arrangement comprised of orthogonal antennas 122 and 124 and associated processing circuitry for measuring and suitably processing the field intensity at each antenna and roll/pitch antenna 126 and associated processing circuitry 128 for measuring the pitch and roll of the boring tool. Inasmuch as the Mercer patents fully describe the process by which locator 140 is used to find the position of boring tool 90 , the reader is referred to the patents for a detailed description of the locating method.
[0023] Referring to FIGS. 2-4 , in accordance with the present invention, locator/controller 140 includes a CPU 144 , interfaced with a remote telemetry transceiver 146 , a joystick 148 and a display 150 . Remote transceiver 146 is configured for two-way communication with drill rig transceiver 106 via an antenna 152 . Joystick 148 is positioned in a convenient location for actuation by operator 141 . In accordance with one highly advantageous feature of the present invention, operator 141 is able to remotely issue control commands to drill rig 78 by actuating joystick 148 . Commands which may be issued to the drill rig by the operator include, but are not limited to (1) roll orientation for steering direction purposes, (2) “advance” and (3) “retract.” It should be appreciated that the ability to issue these commands from locator/controller 140 , in essence, provides for complete boring tool locating and control capability from locator/controller 140 . A locator/controller command is implemented using CPU 144 to read operator actuations of the joystick, interpret these actuations to establish the operator's intended command, and then transfer the command to remote transceiver 146 for transmission to the command drill rig telemetry transceiver 106 at the drill rig, as will be described immediately hereinafter.
[0024] Still referring FIGS. 2-4 , control commands are entered by using display 150 in conjunction with joystick 148 . Display 150 includes an enhanced roll orientation/steering display 154 having a clock face 156 which shows clock positions 1 through 12 . These clock positions represent the possible steering directions in which boring tool 90 may be set to travel. That is, the axis of the boring tool is assumed to extend through a center position 158 of the clock display and perpendicular to the plane of the figure. The desired roll orientation is established by moving joystick 148 either to the left or right. As the joystick is moved, a desired roll orientation pointer 160 incrementally and sequentially moves between the clock positions. For instance, if the desired roll pointer was initially located at the 12 o'clock position (not shown), the locator/controller operator may begin moving it to the 3 o'clock position by moving and holding the joystick to the right. CPU 144 detects the position of the joystick and incrementally moves the desired roll pointer to the 1 o'clock, then 2 o'clock, and finally the 3 o'clock position. At this point, the operator releases the joystick. Of course, at the 3 o'clock position, the command established is to steer the boring tool to the right. Similarly, the 6 o'clock position corresponds to steering downward, the 9 o'clock position corresponds to steering to the left and the 12 o'clock position corresponds to steering upward. As mentioned previously, steering is accomplished by setting face 92 of the boring tool in an appropriate position in accordance with the desired roll of the boring tool. With regard to boring tool steering, it is to be understood that boring tool steering has been implemented using concepts other than that of roll orientation and that the present invention is readily adaptable to any steering method either used in the prior art or to be developed.
[0025] Having established a desired steering direction, operator 141 monitors an actual roll orientation indicator 162 . As described in the Mercer patents, roll orientation may be measured within the boring tool by a roll sensor (not shown). The measured roll orientation may then be encoded or impressed upon locating signal 98 and received by locator/controller 140 using antenna 126 . This information is input to CPU 144 as part of the “Locator Signal Data” indicated in FIG. 4 . CPU 144 then causes the measured/actual roll orientation to be displayed by actual roll orientation indicator 162 . In the present example, operator 141 can see that the actual roll orientation is at the 2 o'clock position. Once the desired roll orientation matches the actual roll orientation, the operator will issue an advance command by moving joystick 148 forward. Advancement or retraction commands for the boring tool can only be maintained by continuously holding the joystick in the fore or aft positions. That is, a stop command is issued when joystick 148 is returned to its center position. If the locating receiver were accidentally dropped, the joystick would be released and drilling would be halted. This auto-stop feature will be further described in conjunction with a description of components which are located at the drill rig.
[0026] Still referring to FIGS. 2-4 , a drill string status display 164 indicates whether the drill rig is pushing on the drill string, retracting it or applying no force at all. Information for presentation of drill string status display 164 along with other information to be described is transmitted from transceiver 106 at the drill rig and to transceiver 146 in the locator/controller. Once the boring tool is headed in a direction which is along a desired path, operator 141 can command the boring tool to proceed straight. As previously described, for straight drilling, the drill string rotates. In the present example, after having turned the boring tool sufficiently to the right, the operator may issue a drill straight command by moving joystick 148 to the left and, thereafter, immediately back to the right. These actuations are monitored by CPU 144 . In this regard, it should be appreciated that CPU 144 may respond to any suitable and recognizable gesture for purposes of issuance of the drill straight command or, for that matter, CPU 144 may respond to other gestures to be associated with other desired commands. In response to recognition of the drill straight gesture, CPU 144 issues a command to be transmitted to the drill rig which causes the drill string to rotate during advancement. At the same time, CPU 144 extinguishes desired roll orientation indicator 160 and actual roll orientation indicator 162 . In place of the roll orientation indicators, a straight ahead indication 170 is presented at the center of the clock display which rotates in a direction indicated by an arrow 172 . It is noted that the straight ahead indication is not displayed in the presence of steering operations which utilize the desired or actual roll orientation indicators. Alternatively, in order to initiate straight drilling, the locator/controller operator may move the joystick to the left. In response, CPU 144 will sequentially move desired roll indicator 160 from the 3 o'clock position, to the 2 o'clock position and back to the 1 o'clock position. Thereafter, the desired roll indicator is extinguished and straight ahead indication 170 is provided. Should the operator continue to hold the joystick to the left, the 12 o'clock desired roll orientation (i.e., steer upward) would next be presented.
[0027] In addition to the features already described, display 150 on the locator/controller of the present invention may include a drill rig status display 174 which presents certain information transmitted via telemetry from the drill rig to the locator/controller. The drill rig status display and its purpose will be described at an appropriate point below. For the moment, it should be appreciated that commands transmitted to drill rig 78 from locator/controller 140 may be utilized in several different ways at the drill rig, as will be described immediately hereinafter.
[0028] Attention is now directed to FIGS. 2 and 5 . FIG. 5 illustrates a first arrangement of components which are located at the drill rig in accordance with the present invention. As described, two-way communications are established by the telemetry link formed between transceiver 106 at the drill rig and transceiver 146 at locator/controller 140 . In this first component arrangement, display 110 at the drill rig displays the aforedescribed commands issued from locator/controller 140 such that a drill rig stationed operator (not shown) may perform the commands. Display 110 , therefore, is essentially identical to display 150 on the locator/controller except that additional indications are shown. Specifically, a push or forward indication 180 , a stop indication 182 and a reverse or retract indication 184 are provided. It is now appropriate to note that implementation of the aforedescribed auto-stop feature should be accomplished in a fail-safe manner. In addition to issuing a stop indication when joystick 148 is returned to its center position, the drill rig may require periodic updates and if the updates were not timely, stop indication 182 may be displayed automatically. Such updates would account for loss of the telemetry link between the locator/controller and the drill rig.
[0029] Still referring to FIGS. 2 and 5 , the forward, stop and retract command indications eliminate the need for other forms of communication between the drill rig operator and the locator/controller operator such as the walkie-talkies which were typically used in the prior art. At the same time, it should be appreciated that each time a new command is issued from the locator/controller, an audible signal may be provided to the drill rig operator such that the new command does not go unnoticed. Of course, the drill rig operator must also respond to roll commands according to roll orientation display 154 by setting the roll of the boring tool to the desired setting. In this regard, it should be mentioned that a second arrangement (not shown) of components at the drill rig may be implemented with a transmitter at the locator/controller in place of transceiver 146 and a receiver at the drill rig in place of transceiver 106 so as to establish a one-way telemetry link from the boring tool to the drill rig. However, in this instance, features such as operations status display 174 and drill string status display 164 cannot be provided at the locator/controller.
[0030] It should be appreciated that the first and second component arrangements described with regard to FIG. 5 contemplate that the drill rig operator may perform tasks including adding or removing drill pipe sections 88 from the drill string and monitoring certain operational aspects of the operation of the drill rig. For example, the drill rig operator should insure that drilling mud (not shown) is continuously supplied to the boring tool so that the boring tool does not overheat whereby the electronics packaged housed therein would be damaged. Drilling mud may be monitored by the drill rig operator using a pressure gauge or a flow gauge. As another example, the drill rig operator may monitor the push force being applied to the drill string by the drill rig. In the past, push force was monitored by “feel” (i.e., reaction of the drill rig upon pushing). However, push force may be directly measured, for instance, using a pressure or force gauge. If push force becomes excessive as a result of encountering an underground obstacle, the boring tool or drill string may be damaged. As a final example, the drill rig operator may monitor any parameters impressed upon locating signal 98 such as, for instance, boring tool temperature, battery status, roll, pitch and proximity to an underground utility. In this latter regard, the reader is referred to U.S. Pat. No. 5,757,190 entitled A SYSTEM INCLUDING AN ARRANGEMENT FOR TRACKING THE POSITIONAL RELATIONSHIP BETWEEN A BORING TOOL AND ONE OR MORE BURIED LINES AND METHOD which is incorporated herein by reference.
[0031] Referring to FIG. 5 , another feature may be incorporated in the first and second component arrangements which is not requirement, but which nonetheless is highly advantageous with regard to drill rig status monitoring performed by the drill rig operator. Specifically, a rig monitor section 190 may be included for monitoring the aforementioned operational parameters such as drilling mud, push force and any other parameters of interest. As previously described, proper monitoring of these parameters is critical since catastrophic equipment failures or damage to underground utilities can occur when these parameters are out of range. In accordance with this feature, processor 114 receives the status of the various parameters being monitored by the rig monitor section and may provide for visual and/or aural indications of each parameter. Visual display occurs on operations status display 174 . The display may provide real time indications of the status of each parameter such as “OK”, as shown for drilling mud and push force, or an actual reading may be shown as indicated for the “Boring Tool Temperature”. Of course, visual warnings in place of “OK” may be provided such as, for example, when excessive push force is detected. Audio warning may be provided by an alarm 192 in the event that threshold limits of any of the monitored parameters are violated. In fact, the audio alarm may vary in character depending upon the particular warning being provided. It should be mentioned that with the two-way telemetry link between the drill rig and locator/controller according to the aforedescribed first component arrangement, displays 164 and 174 may advantageously form part of overall display 150 on locator/controller 140 , as shown in FIG. 4 , which may also include alarm 192 . However, such operational status displays on the locator/controller are considered as optional in this instance since the relevant parameters may be monitored by the drill rig operator. The full advantages of rig monitor section 190 and associated operations status display 174 will come to light in conjunction with a description of a fully automated arrangement to be described immediately hereinafter.
[0032] Referring to FIGS. 2 and 6 , in accordance with a third, fully automated arrangement of the present invention, a drill rig control module 200 is provided at drill rig 78 . Drill rig control module 200 is interfaced with processor 114 . In response to commands received from locator/controller 140 , processor 114 provides command signals to the drill rig control module. The latter is, in turn, interfaced with drill rig controls 116 such that all required functions may be actuated by the drill rig control module. Any suitable type of actuator (not shown) may be utilized for actuation of the drill rig controls. In fact, manual levers may be eliminated altogether in favor of actuators. Moreover, the actuators may be distributed on the drill rig to the positions at which they interface with the drill rig mechanism. For reasons which will become apparent, this third arrangement requires two-way telemetry between the drill rig and locator/controller such that drill string status display 164 and operations status display 174 are provided as part of display 150 on the locator/controller. At the same time, these status displays are optional on display 110 at the drill rig.
[0033] Still referring to FIGS. 2 and 6 , in accordance with the present invention, using locator/controller 140 , operator 141 is able to issue control commands which are executed by the arrangement of FIG. 6 at the drill rig. Concurrent with locating and controlling the boring tool, operator 141 is able to monitor the status of the drill rig using display 150 on the locator/controller. In this regard, display 174 on the locator/controller also apprises the operator of automated drill rod loading or unloading with indications such as, for example, “Adding Drill Pipe.” In this manner, the operator is informed of reasons for normal delays associated with drill string operations. Since push force applied by the drill rig to the drill string is a quite critical parameter, the present invention contemplates a feature (not shown) in which push force is measured at the drill rig and, thereafter, used to provide push force feedback to the operator via joystick 148 for ease in monitoring this critical parameter. The present invention contemplates that this force feedback feature may be implemented by one of ordinary skill in the art in view of the teaching provided herein. Still other parameters may be monitored at the drill rig and transmitted to locator/controller 140 . In fact, virtually anything computed or measured at the drill rig may be transmitted to the locator/controller. For example, locator/controller 140 may display (not shown) deviation from a desired path. Path deviation data may be obtained, for example, as set forth in U.S. Pat. No. 5,698,981 entitled BORING TECHNIQUE which is incorporated herein by reference. Alternatively, path deviation data may be obtained by using a magnetometer (not shown) positioned in the boring tool in combination with measuring extension of the drill string. With data concerning the actual path taken by the boring tool, the actual path can be examined for conformance with minimum bend radius requirements including those of the drill string or those of the utility line which, ultimately, is to be pulled through the completed bore. That is, the drill string or utility line can be bent too sharply and may, consequently, suffer damage. If minimum bend radius requirements for either the drill string or utility are about to be violated, an appropriate warning may be transmitted to locator/controller 140 . It should be appreciated that with the addition of the drill rig control module, complete remote operation capability has been provided. In and by itself, it is submitted that integrated locating capability and remote control of a boring tool has not been seen heretofore and is highly advantageous. When coupled with remote drill rig status monitoring capability, the present invention provides remarkable advantages over prior art horizontal directional drilling systems.
[0034] The advantages of the fully automated embodiment of the present invention essentially eliminate the need for a skilled drill rig operator. In this regard, it should be appreciated that the operator of a walkover locator is, in most cases, knowledgeable with respect to all aspects of drill rig operations. That is, most walkover locator operators have been trained as drill rig operators and then advance to the position of operating walkover locating devices. Therefore, such walkover locator operators are well versed in drill rig operation and welcome the capabilities provided by the present invention.
[0035] It should be understood that an arrangement for remotely controlling and tracking an underground boring tool may be embodied in many other specific forms and produced by other methods without departing from the spirit or scope of the present invention. Therefore, the present examples are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims.
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A drilling system performs underground boring using a drill rig and a boring tool which is configured for moving through the ground under control of the drill rig to form an underground bore. A monitoring arrangement, forming part of the system, includes a detection arrangement at the drill rig for monitoring at least one operational parameter to produce a data signal relating to at least one of a utility to be installed in the underground bore, the drill rig and the boring tool. A portable device forms another part of the system for receiving the data signal relating to the operational parameter for use by the portable device. A communication arrangement, for example using telemetry, transfers the data signal from the drill rig to the portable device. The operational parameter may be monitored for the purpose of preventing equipment failure.
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FIELD OF THE INVENTION
The present invention deals with high voltage devices that can withstand ESD events. In particular, it deals with high voltage devices that can reversibly withstand snapback mode.
BACKGROUND OF THE INVENTION
Numerous devices have been developed for handling electrostatic discharge (ESD) events. These ESD protection devices may be categorized as falling into two groups: the active devices that work in normal operating mode, and the snapback devices which are designed to be triggered and operate in snapback mode during an ESD event and then turn off again as voltage drops below the holding voltage of the device.
NLDMOS and DMOS devices are intended to be used in normal mode and will be destroyed if they go into snapback. Even high voltage NLDMOS and DMOS devices will only survive if the voltage they are handling does not exceed the capabilities of the device. While these devices typically are meant not to go into snapback, local overstresses due to current crowding can cause these devices to go into snapback, thereby damaging the device. Thus, in the case of an ESD event, unless the device is made extremely large, the device is pushed past its capabilities and goes into snapback, causing irreversible breakdown. Typically the margin is rather small before the devices go into snapback. This problem is exacerbated by the fact that the snapback voltage is dependent on gate bias and in practice high-voltage devices used for voltage regulation to provide a low voltage to internal circuits are often not directly connected to the power pad and ground. Thus they fail to provide local clamping of the high voltage pad and ground.
A typical NLDMOS, more correctly referred to as a drain extended MOS (DeMOS) is shown in cross-section in FIG. 1 , which includes an n-epitaxial layer 100 in which an n-well 102 is formed. In the case of a BiCMOS process an n-buried layer (NBL) 103 may also be formed in the n-epi 100 . An n+ drain 104 is formed in the n-well 102 , and an n+ source 106 is formed in a p-well 108 in the n-epi 100 . A polysilicon gate 110 is formed on top of the n− and p-wells 102 , 108 , the extended portion of the gate 110 being isolated from the n-well 102 by an isolation oxide 112 . As shown in FIG. 1 , the drain 104 includes a drain contact 114 , the source 106 includes a source contact 116 , and the gate 110 includes a gate contact 120 .
FIG. 2 shows another prior art device in cross-section, namely an NLDMOS-SCR, which is capable of operating in snapback mode but suffers from considerable on-state resistance losses during normal mode. This device includes an n-epitaxial layer 200 grown on a p-substrate 201 . An n-well 202 is formed in the n-epi 200 . In the case of a BiCMOS process an n-buried layer (NBL) 203 may also be formed in the n-epi 200 . In the n-epitaxial layer 200 , an n+ drain 204 is formed, and an n+ source 206 is formed in a p-well 208 in the n-epi 200 . A polysilicon gate 210 is formed on top of the n- and p-wells 202 , 208 , the extended portion of the gate 210 being isolated from the n-well 202 by an isolation oxide 212 . As shown in FIG. 2 , the drain 204 includes a drain contact 214 , the source includes a source contact 216 , and the gate 210 includes a gate contact 220 . Unlike the NLDMOS of FIG. 1 , this NLDMOS-SCR further includes a p-emitter region 222 formed under the drain contact. This device functions well insofar as it moves the hot spot (shown by region 130 ) away from the drain contact 214 . However, the inclusion of the p-emitter region 222 introduces additional process steps that are typically not required for the devices it supports. Also, the inclusion of the p-emitter region 222 results in a significant saturation NWELL resistor. Thus, the device on-state current is rather low since only the bottom portion of the NWELL under the p-emitter 222 can conduct the current.
The present invention seeks to provide an alternative solution for devices that will not only operate well during normal mode but are also capable of surviving a snapback scenario.
SUMMARY OF THE INVENTION
According to the invention there is provided an NLDMOS, DMOS or NMOS device (both extended and low voltage device) that provides good normal mode operation and is capable of performing a reversible snapback operation, comprising a drain with a plurality of n+ drain pickup contacts, and at least one p+ emitter region, wherein each p+ emitter region is formed between two drain contacts. Each p+ emitter region may include at least one emitter contact that is electrically connected to the n+drain pickup contacts. The device may include multiple p+ emitter regions each with at least one emitter contact, the p+ emitter regions being are formed between the n+ drain pickup contacts. Preferably, the emitter contacts and n+ drain pickup contacts are electrically interconnected by a common metal layer.
In one embodiment, the device comprises an array with multiple drain regions and multiple p+ emitter regions, at least one of the drain regions being provided with multiple drain contacts, and the p+ emitter regions being formed between the drain contacts. All of the drain regions of the array may include multiple drain pickup contacts, and the p+ emitter regions may be interdigitated between the drain pickup contacts of the drain regions. The p+ emitter regions may be interdigitated between each of the drain pickup contacts of each of the drain regions. The p+ emitter regions are typically each provided with at least one emitter contact, the emitter contacts and drain pickup contacts being electrically connected to each other. The emitter contacts and drain pickup contacts may for example be electrically connected to each other by a common metal layer.
Further, according to the invention, there is provided a method of making an NLDMOS, DMOS or NMOS device capable of withstanding snapback mode, comprising providing a first current path between source and drain for normal mode operation, and providing a discharge current path for handling dual injection current. The discharge current path may include a path through one or more p+ emitter regions formed between drain contacts. The p+ emitter regions preferably include emitter contacts electrically connected to the drain contacts. The discharge current path may include a path through multiple p+ emitter regions formed between the drain contacts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-section through a prior art NLDMOS device;
FIG. 2 a cross-section through a prior art NLDMOS-SCR device;
FIG. 3 a top view of one embodiment of an NLDMOS device of the invention;
FIG. 4 a top view of another embodiment of an NLDMOS device of the invention,
FIG. 5 shows a top view of yet another embodiment of an NLDMOS device of the invention, and
FIG. 6 shows a top view of yet another embodiment of an NLDMOS device of the invention.
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of the invention is show in FIG. 3 , which provides for the inclusion of a p+ poly-emitter 300 with contact 302 formed between the drain contacts 304 of n+ drain 306 . In this embodiment the other n+ drain 316 with its drain contacts 314 , formed on the other side of n+ source 320 , does not include any p+ emitter regions. The source 320 includes a bulk 322 and contacts 324 . The poly gate 330 with its gate contacts 332 is shown surrounding the source 320 .
During normal operation, the current will flow from the source to the drains 306 , 316 to be collected by the drain contacts 304 , 314 . However, under ESD conditions, the emitter region 300 provides the device with SCR characteristics and provides a second current path for dual injection current.
Another embodiment of the invention is shown in FIG. 4 , which shows an array 400 with drain fingers 402 and source fingers 404 . The drain fingers include drain contacts 406 with interdigitated p+ emitters 408 . The p+ emitters 408 include emitter contacts 410 which are electrically connected to the drain contacts by a common metal layer 414 . The rest of the structure includes a bulk 420 with bulk contacts 422 and source contacts 424 for the source fingers 404 . The gates 430 with their gate contacts 432 are shown surrounding the source fingers 404 . During normal mode, current flows from the source fingers 404 to the drain fingers as shown by the arrows 450 . During an ESD event the p+ emitters 408 provide an SCR operation mode. Thus, when the voltage drop due to avalanche drain current opens the p-emitter junction, dual injection current will flow to the p+ emitters 408 , the emitters 408 thus providing another current path for the dual injection current and allowing the device to go into reversible snapback mode.
In the case of an array such as the one described above with respect to FIG. 4 , the p+ emitters can be included in each of the drain fingers or only in one or some of the fingers.
FIG. 5 shows an embodiment in which the array 500 has five drain fingers 502 but only drain finger 504 is provided with p+ emitters 506 . The rest of the structure is substantially the same as that discussed with respect to FIG. 4 and is therefore not discussed in detail again. For instance, the source fingers 508 are formed between the drain fingers 502 and are surrounded by polygates 510 . As shown in FIG. 5 , the p+ emitters 506 are interdigitated between the drain contacts 512 , although at the top of the matrix two of the drain contacts are shown without an interdigitated p+ emitter. It will be appreciated that other embodiments could be manufactured in which only some or one pair of adjacent drain contacts includes an interdigitated p+ emitter.
Yet another embodiment of the invention is shown in FIG. 6 in which all of the drain fingers 600 include multiple drain contacts 602 and interdigitated p+ emitters 604 with contacts 606 . The source fingers 610 are formed between the drain fingers 600 and are surrounded by polygates 612 . During normal mode, current flow between source and drain is as shown by arrows 620 , while during snapback mode, the dual injection current makes use of the second current path provided by the p+ emitters 604 , as shown by the arrows 630 .
In each of the embodiments, the contacts to the p+ emitters are electrically connected to the drain contacts, e.g., by connecting them using a common metal layer.
The present invention is applicable in very large high voltage devices e.g. 50 V devices where the device can be entirely self protecting, and is also applicable in smaller devices such as 24 V devices where it may function as a second stage together with a local ESD clamp.
While the invention has been described with respect to a few exemplary embodiments, it will be appreciated that these were included by way of illustration only and are not intended to limit the scope of the invention as defined by the claims.
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In an NLDMOS, DMOS and NMOS device, the ability is provided for withstanding snapback conditions by providing one or more p+ emitter regions interdigitated between drain regions having drain contacts and electrically connecting the drain contacts to contacts of the emitter regions.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the mechanical connection between rail vehicles and, in particular, between vehicles for carrying passengers in mass transit applications. This invention more specifically relates to the emergency release of the draft gear or cushioning assembly permitting the vehicles to come together for more controlled absorption of energy and to prevent climbing after collision.
[0003] 2. Description of Related Art
[0004] In railway and transit vehicles, buffing and draft forces between connected vehicles are transmitted to the under frames of the vehicles through drawbars, draft gears and coupler heads (coupler assemblies). The draft gears have cushioning devices which accommodate normally expected forces. Adjacent vehicles are held coupled spaced apart. In the case of abnormal buffing forces which might be encountered on collision, it is desirable to enable the vehicles to come together so that anti-climbers on the ends of the vehicles prevent the end of the trailing vehicle from overriding the lead vehicle. Typically, this function is provided by collapsible draft gears which having release mechanisms based on shear bolts.
[0005] As is generally recognized in the railway coupling art, rail transit vehicle coupler assemblies make use of emergency release bolts that break at a designed buff force allowing the draft gear device to telescope into the draft gear housing. The emergency release bolts extend radially through the draft gear housing and into an emergency release ring. The draft gear housing contains an energy-absorbing device that bears against the emergency release ring and emergency release bolts.
[0006] The draft gear housing is an integral part of a coupler assembly which is mechanically secured to the underside of its associated vehicle. Coupling and inter-car forces are transmitted from the draft gear assembly to the emergency release ring and to the release bolts by the release ring. Existing coupler assemblies normally employ a rigid emergency release ring suspended in a rigid draft gear housing by radially extending emergency release bolts. A clearance must exist between the rigid emergency release ring and the rigid draft gear housing to permit assembly. The emergency release bolts are designed to shear and break in two pieces when the coupling forces between two vehicles exceed a designed limit as determined by the strength of the emergency release bolts.
[0007] Normally, the coupling forces that occur when a consist of rail vehicles is being assembled and connected together for travel with a locomotive or lead vehicle exert less load on the emergency release bolts than the designed limit. The assembly stays intact.
[0008] On hard coupling or collision events, forces in excess of the designed limit will be exerted. At this time, the emergency release bolts will break or shear. This allows portions of the draft gear assembly to slide within the draft gear housing and engage a secondary energy dissipation device.
[0009] In existing coupler assemblies, the emergency release ring is pulled against the inside wall of the draft gear housing to form a contact at a single location which corresponds to the first emergency release bolt tightened. A gap is formed between the housing and the release ring near the remaining release bolts. This gap allows for forces to repeatedly flex the emergency release bolts in a bending mode. This bending results in reduction in the fatigue strength of the bolts.
[0010] The overall structure of the drawbar, draft gear (cushioning unit) and coupler head of one type of mechanical connection for rail vehicles is disclosed in Grau et al. U.S. Pat. No. 6,499,613 entitled “Coupler with Extended Emergency Release and Towing Feature.” This patent discloses primary and secondary release devices, the primary release device being most relevant to this application. The structure of a shear bolt and the need of well-defined shear planes are disclosed Grau et al. U.S. Pat. No. 6,981,599 entitled “High Capacity Shear Mechanism.”
SUMMARY OF THE INVENTION
[0011] It is an object of this invention to provide a fatigue-resistant emergency release device for rail transit vehicle coupler assemblies. Specifically, the release device is provided with enhanced fatigue life performance for emergency release bolts by eliminating bending forces exerted on the emergency release bolts.
[0012] Briefly, according to one embodiment of this invention, there is provided a release device for a draft gear assembly. The draft gear assembly comprises a draft gear housing for slidably supporting a yoke and integral yoke shaft and capturing a cushion unit associated with the yoke shaft between buff and draft stops. The buff stop is designed to release from the housing under emergency buffing forces. The buff stop comprises a release ring having a cylindrical axis and an outer cylindrical surface with a diameter permitting sliding engagement within a cylindrical interior surface of the housing. The release ring is radially divided into two or more sections. There are flat chord surfaces parallel to the cylindrical axis on the outer surface of each section. A threaded bore extends into each section through and perpendicular to the flat chord surface in each section.
[0013] A retention system holding the sections of the release ring together includes at least one circumferential groove provided in the outer cylindrical surface of the release ring and an expandable split ring positioned in the groove. The retention system allows the independent release ring segments to accommodate radial and longitudinal misalignment of the sections relative to each other.
[0014] A plurality of emergency release bolts designed to shear under emergency buffing forces has threaded ends. There is a flat radial bearing surface between the ends of the emergency release bolts. When the release ring is positioned in the draft gear housing, release bolts may extend through the draft gear housing and into the sections of the release ring so that a flat surface extending radially from the release bolt will abut a flat chord surface of a release ring section establishing a well-defined shear plane. Nuts draw the sections radially outward minimizing flexing of the release bolts. The plurality of emergency release bolts directed radially through openings in the draft gear housing and corresponding to threaded holes in the sections of the emergency release ring enable each section to be drawn tightly against the inside surface of the draft gear housing facilitating pure longitudinal shearing load.
[0015] Briefly, according to this invention, there is also provided a draft gear assembly comprising a draft gear housing, a yoke and integral yoke shaft slidably secured in a housing, a cushion unit associated with the yoke shaft and captured between buff and draft stops secured in the housing. The buff stop comprises a release ring having a cylindrical axis and an outer cylindrical surface having a diameter permitting sliding engagement within a cylindrical interior surface of the housing. The release ring is radially divided into two or more sections. A threaded bore extends into each section. At least one circumferential groove is provided in the outer cylindrical surface of the release ring. An expandable split ring is positioned in the groove holding the sections of the release ring together.
[0016] A plurality of release bolts designed to shear under emergency buffing forces has threaded ends. When the release ring is positioned in the draft gear housing, release bolts may extend through the draft gear housing and into the threaded bore in the sections of the release ring. A nut turned on the other threaded end of the release bolts draws the section radially outward to the interior wall of the draft gear housing eliminating any gap and thus minimizing flexing of the release bolts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Further features and other objects and advantages will become clear from the following detailed description made with reference to the drawings in which:
[0018] FIG. 1 is a perspective view of drawbar, draft gear and coupler assembly for a modern transit vehicle;
[0019] FIG. 2 is an exploded perspective view of a draft gear according to this invention attached to a drawbar;
[0020] FIG. 3 is a section view of a draft gear according to this invention; and
[0021] FIG. 4 is an exploded perspective view of a release ring according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring now to FIG. 1 , a mechanical connection between transit vehicles comprises a drawbar 10 that is secured to the underside of the vehicle (not shown) by an anchor ring 12 enabling rotation about a generally vertical axis. The draft gear housing 14 is bolted to the drawbar by secondary release bolts 16 . On the upper side of the draft gear housing 14 , a follower slot 18 is supported to receive a curved guide rail 20 secured to the underside of the vehicle which also accommodates the rotation of the drawbar 10 and draft gear housing 14 about the vertical axis through the anchor ring 12 . A coupler head 22 for capturing the coupler head of an adjacent vehicle is mounted to a yoke 24 for rotation about a generally horizontal axis perpendicular to the axis of the drawbar 10 . The yoke 24 is integral with a yoke shaft 32 (not visible in FIG. 1 ) which is journaled in the draft gear housing 14 for some rotation about a horizontal axis parallel to the axis of the drawbar 10 . The yoke shaft 32 also moves slidably within the draft gear housing 14 . Also shown in FIG. 1 are the electrical coupler 26 and the pneumatic conduits for a brake pipe and reservoir supply pipe. The purpose of FIG. 1 is to illustrate one setting in which the present invention may be found. The multi-segment release ring arrangement which is the subject of the present invention can be used in many drawbars or couplers having draft gear configurations other than those shown in the figures. For example, it has application in light rail type couplers with a tail eye type anchor and integral coupler head.
[0023] Referring to FIG. 2 , the draft gear housing 14 is shown secured to the drawbar 10 . The housing has a hollow generally cylindrical interior. A release ring 30 is shown exploded out of the housing interior as are the yoke 24 , yoke shaft 32 and cushioning assembly 34 . When these components are slid into the housing, the release ring 30 is secured to the interior wall of the housing by release bolts 36 and nut 38 .
[0024] Referring to FIG. 3 , the yoke 24 is threadably connected to the yoke shaft 32 . At the far end, the yoke shaft 32 is threaded to a tail stud nut 42 . The release ring 30 is located radially outward of the tail stud nut 42 . The release ring 30 comprises the buff stop. A sleeve bearing 44 is positioned between the release ring 30 and the tail stud nut 42 . At the yoke end of the yoke shaft 32 , plug nut 46 is threadably secured to the interior of the housing and comprises the draft stop. Sleeve bearing 48 is positioned between the plug nut 46 and the yoke shaft 32 . Adjacent the buff and draft stops are followers 50 and 52 . Captured between the followers is the cushioning assembly 34 . Thus, in normal operation, the yoke shaft 32 can rotate about its axis and can shift in and out of the draft gear housing 14 restricted by the compression of the cushioning assembly 34 against either the buff stop or draft stop.
[0025] Referring to FIG. 4 , the release ring 30 has a cylindrical axis, an inner circular cylindrical surface and an outer mostly circular cylindrical surface. The ring is divided into four sections 30 a , 30 b , 30 c and 30 d that are separated by radial planes intersecting the axis of the ring. Each section has on its outer surface a flat chord surface 30 e and threaded bore 30 f with an axis perpendicular to the flat chord surface 30 e for receipt of release bolts 36 (see FIG. 3 ). The axis of the threaded bore 30 f intersects the cylindrical axis of the release ring 30 .
[0026] The release bolts 36 are designed to shear under emergency buffing forces. The release bolts 36 have two threaded ends of different diameters. One threaded end is turned into a threaded bore 30 f in a release ring section. The other threaded end extends through the draft gear housing 14 and has a torque nut 38 turned thereon. Preferably, a cylindrical shank extends between the threaded ends of the release bolts 36 . A flat radial surface is provided where the shank meets the threaded end for turning into a section of the release ring. A preferred release bolt is described in U.S. Pat. No. 6,981,599 noted above.
[0027] At each axial end of the release ring circumferential grooves 60 , 62 are provided to receive expandable split rings 64 , 66 . The rings 64 , 66 may make several loops and are preferably configured so that each loop of the ring lies on the same cylindrical plane. The split rings 64 , 66 when emplaced hold the sections of the release ring 30 together. The expandable split rings 64 , 66 provide the sections of the release ring with the ability to expand outward and to move relative to each other in the radial direction.
[0028] When the release ring 30 is positioned in the draft gear housing 14 , threads on one end of release bolts 36 extend through the draft gear housing 14 and into the sections of the release ring 30 until the flat radial surfaces of the bolts abut the flat chord surfaces 30 e of the release rings 30 . Thereafter, the torque nuts 38 are tightened to draw the sections of the release ring radially outward so that the outer surface of the release sections abut the inner surface of the draft gear housing eliminating any gap and minimizing flexing of the release bolts. The retention system for holding the release ring segments together can take other forms than split rings. Expandable retainers of various types may be applied to the outer diameter, inner diameter or the axial ends of the release ring sections.
[0029] It is an advantage of this invention that the multi-segmented release ring can be expanded radially outward to effectively contact the inside of the wall of the draft gear housing adjacent each emergency release bolt, thus eliminating any gap between the inside wall of the draft gear housing and the emergency release ring. This has the effect of equalizing the loads on the emergency release bolts. It also permits the equal preloading of all emergency release bolts at the time of assembly. Most important, this provides a close contact fit between the release ring and the housing at the shear plane eliminating bending forces that can fatigue the release bolts. Finally, the release ring can have an initial (unexpanded) diameter that facilitates in the assembly of the release ring in the draft gear housing.
[0030] Having thus described my invention in the detail and particularity required by the Patent Laws, what is desired protected by Letters Patent are set forth in the following claims.
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A release device for a draft gear assembly comprises a draft gear housing for slidably supporting a yoke shaft and capturing a cushion unit associated with the yoke shaft between buff and draft stops. The buff stop comprises a release ring within the interior of the draft gear housing being radially divided into two or more sections. A plurality of release bolts designed to shear under emergency buffing forces extend through the draft gear housing and into the sections of the release ring to draw the sections radially outward to the interior surface of the draft gear housing eliminating gaps and minimizing flexing of the release bolts.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/046,594, entitled Brush and Methods of Use, filed Sep. 5, 2014, which is incorporated by reference herein in its entirety.
FIELD
[0002] The present invention relates to brushes, and more particularly, to brushes used as applicators for coatings applied to surfaces.
BACKGROUND
[0003] Various brushes and applicators are known for use in applying coatings, such as paint, glues, topcoats, etc. Notwithstanding, improved and/or alternative brush designs and methods for using them remain desirable for various applications.
SUMMARY
[0004] The disclosed subject matter relates to a brush for applying viscous coatings. In one approach, the coating may be in the range of 2,500 CPS to 15,000 CPS and the brush has a brush head with a plurality of bristles having a modulus of elasticity in the range of 2-4 GPa, a diameter in the range of 0.25 mm to 1.0 mm and a free length of 1.5-2.5 inches. The overall brush thickness may be in the range of 0.75 inch to 1.0 inch. The brush may have a total bristle count of 2,500 to 3,500 and a width to thickness to height ratio in the range of 20:1.5:1.5 to 30:0.75:2.5.
[0005] In accordance with one aspect of the disclosure, The brush has a handle attached s to the brush head at an angle such that when the handle is held at an angle in the range of 10 to 40 degrees relative to the surface to be coated, the surface of the brush head defined by the terminal ends of the plurality of bristles is substantially flat on the surface +/−15 degrees.
[0006] In accordance with one aspect of the disclosure, an inner angle between the handle and the brush is about 120 degrees.
[0007] In accordance with one aspect of the disclosure, the brush head has a root portion with upper and lower portions, the lower portion attached to the bristles, the upper portion disposed at an inside angle of about 150 degrees relative to the lower portion, the handle connecting to and forming an angle of approximately 90 degrees relative to the upper portion.
[0008] In accordance with one aspect of the disclosure, the bristles are bent around a wire and crimped in a frame, the frame being attached to the root portion.
[0009] In accordance with one aspect of the disclosure, the bristles are nylon.
[0010] In accordance with one aspect of the disclosure, a support web extends between the handle and the brush head.
[0011] In accordance with one aspect of the disclosure, the inside angle between the bristles and the handle is about 120 degrees.
[0012] In accordance with one aspect of the disclosure, the brush head is attached to the handle by a tab and mating slot.
[0013] In accordance with one aspect of the disclosure, the brush head is attached to the handle by a mating sleeve and cylinder.
[0014] In accordance with one aspect of the disclosure, the brush head has a clamp for removably retaining a crimped metal frame in which the bristles are retained, the clamp removably attaching to the handle.
[0015] In accordance with one aspect of the disclosure, the brush head is attached to the handle by a mating threaded end of the handle received in a threaded aperture in the brush head.
[0016] In accordance with one aspect of the disclosure, the brush is capable of applying coatings in the viscosity range of 2,500 CPS to 15,000 CPS.
[0017] In accordance with one aspect of the disclosure, the film of the coating applied when the brush has an applied downforce of about 2 to 10 lbs. is between 25 to 50 mils.
[0018] In accordance with one aspect of the disclosure, the brush is capable of applying an even coating to a surface which has a roughness of about ⅛ inch without skips.
[0019] In accordance with one aspect of the disclosure, the bottom surface of the brush head has a surface area of about 18 inches 2 .
[0020] In accordance with one aspect of the disclosure, the bottom surface of the brush is substantially parallel to the surface to which the coating is applied when the handle is at 30 degrees relative to the surface to which the coating is applied.
[0021] In accordance with one aspect of the disclosure, the brush is capable of applying the viscous coating when pushed or pulled.
[0022] In accordance with one aspect of the disclosure, the root portion has an upper channel and a lower channel, the lower channel receiving the frame and the upper channel having a fastener that couples to a bracket on the handle.
[0023] In accordance with one aspect of the disclosure, further including a frame fastener extending into the lower channel retaining the frame portion within the lower channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] For a more complete understanding of the present disclosure, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings.
[0025] FIG. 1 is side view of a brush in accordance with an embodiment of the present disclosure in three alternative orientations relative to a surface.
[0026] FIG. 2 is an enlarged view of the brush of FIG. 1 showing the angular orientations of a face of the brush relative to the surface in the three orientations of FIG. 1 .
[0027] FIG. 3 is an exploded view of a brush in accordance with another embodiment of the present disclosure.
[0028] FIG. 4 is side view of the brush of FIG. 3 .
[0029] FIG. 5 is a cross-sectional view of the brush of FIG. 4 taken along line 5 - 5 and looking in the direction of the arrows.
[0030] FIG. 6 is a perspective view of a brush in accordance with another embodiment of the present disclosure.
[0031] FIG. 7 is a top view of the brush of FIG. 6 .
[0032] FIG. 8 is an exploded view of a brush in accordance with another embodiment of the present disclosure.
[0033] FIG. 9 is an exploded view of a brush in accordance with another embodiment of the present disclosure.
[0034] FIG. 10 is an exploded view of a brush in accordance with another embodiment of the present disclosure.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0035] FIGS. 1 and 2 shows a brush 10 with an elongated handle 12 made from wood, metal or plastic. A rubber/foam grip 12 G may be disposed on the handle 12 to soften the gripping surface for the hands of the user and/or to improve the grip that the user has on the handle 12 . The handle 12 is attached to a brush head 14 that features a bristle portion 16 having a plurality of bristles 16 B held within a bristle holder 18 . The brush 10 may be used to apply a coating 20 , such as driveway sealer or coating to a surface 22 , such as an asphalt or blacktop driveway. In applying the coating 20 , the brush may be held with the handle 12 at an angle A of, e.g., 10 to 40 degrees relative to the surface 22 and pushed by the user, forming a wave 20 W of coating 20 at the front of the brush 10 in the direction 24 that the brush 10 is pushed. The bottom surface 26 formed by the bristles 16 is maintained approximately parallel to surface 22 (position P 2 ), varying from angle B of about 15 degrees with the brush tilted back (position P 1 ) to angle C of 15 degrees with the brush tilted forward (position P 3 ), as the brush 10 is pushed over surface 22 to apply the coating 20 . When pushed along a surface 22 with a component of force D (down pressure) directed perpendicular to the surface 22 of about 2 to 10 pounds, the bristles 16 B are of a number and strength such that the bristles 16 curve only slightly at the tip. This type and level of bristle 16 B response to the pushing of the brush 10 interacts favorably when the brush 10 is used to apply a viscous coating 20 to a surface 22 , such as a driveway, which is anticipated to have a degree of surface roughness attributable to coarse aggregate, e.g., crushed 2 0 stone. In addition to a pushing motion in direction 24 , the brush may be pulled in the opposite direction, to spread the coating on the surface. When being pushed or pulled, the brush 10 engages the surface 22 closely enough to form a partial “seal” with the surface 22 , allowing a layer of coating 20 of an appropriate thickness to escape past the interface I between the brush 10 and the surface 22 and remain on the surface 22 after the brush 10 has passed over it. The “seal” formed at the interface I has a controlled “leakage,” which generates the coating layer 20 of appropriate thickness. The remainder of the coating 20 which does not pass through interface I, is pushed as a wave 20 W in front of the brush 10 . In traversing the rough surface 22 , the bristles 16 B have sufficient flexibility to accommodate the roughness of the surface 20 by localized bending without breaking the overall “seal” of the brush 10 to the surface 20 .
[0036] FIGS. 3 and 4 show a brush 110 in accordance with an embodiment of the present disclosure. The brush 110 has a handle 112 with a threaded end 112 T. The brush head 114 has a bristle portion 116 having dimensions approximating twenty-four (24) inches in width W, three-quarters (¾) inch in thickness T at the bottom surface 126 , and two (2) inches in free length/height H, resulting in a dimensional ratio of width to thickness to height (W:T:H) of 24:3/4:2 and bottom surface 126 having a surface area of 24*0.75=18 inches 2 . The bristle holder 118 has a root portion 118 R which is attached to a frame portion 118 F. The frame portion 118 F may be formed from sheet metal, e.g., steel, that is formed into a channel shape into which the bristles 116 B may be inserted and then the frame portion 118 F crimped down to retain the bristles 116 B. The root portion 118 R has a recess 118 RR to receive the frame portion 118 F therein, where it may be spot welded or otherwise attached, e.g., by sheet metal screws or an adhesive such as epoxy, to the root portion 118 R. The root portion 118 R may be provided with an aperture 118 RA to receive a handle 112 and both the handle 112 and the aperture 118 RA may be threaded to be matingly and threadedly attached. The root portion 118 R may have an upper portion 118 RU that is angularly offset from a lower portion 118 RL, i.e. by inside angle B of about 150 degrees corresponding to outside angle C of about 30 degrees. The handle 112 may insert into the upper portion 118 RU at approximately 90 degrees, resulting in an angle D between the lower portion 118 RL and the handle 112 of about 120 degrees. In this configuration, the bottom surface 126 of the bristle portion 116 will be substantially parallel to the surface 122 when the handle 112 is held at an angle E of about 30 degrees relative to the surface 122 .
[0037] The individual bristles 116 B may be made from a resilient material, such as nylon, which is compatible for use with the compounds and coatings it is intended to apply, e.g., asphaltic compounds and coatings, such that the solvents used to maintain such compositions in a flowable state would not dissolve the bristles 116 B. The same considerations apply to the bristle holder 118 , in that it can not be compromised, e.g., softened by the coating that the brush 110 is intended to apply. The bristles 116 B have a cylindrical cross-sectional shape with a diameter in the range of 0.25 mm to 1.0 mm and an overall length of about 2.0 to 3.0 inches, e.g., 2.5 inches (63.5 mm), 2.0 inches (50.8 mm) of which is free length and the remainder is captured in the frame portion 118 F. As shown in FIG. 5 , the bristles 116 B may be retained in the frame portion 118 F by a core 118 C, e.g., a wire, each bristle 116 B being bent into a U-shape over the core 118 C. This form of construction ensures that the bristles 116 B are securely retained in the bristle holder 118 along the entire width of the bristle portion 116 . If the individual bristles 116 B are made from nylon (typically having an elastic modulus E in the range of 2-4 GPa), the stiffness of each bristle 116 B may be calculated, e.g., k=(A (cross-sectional area)*E (elastic modulus))/L (length). If the total number of bristles 116 B (counting both sides of a U-shaped bristle bent over a core 118 C) is in the range 2500 to 3500 then the resultant cumulative stiffness k C =k*total number of bristles. If the surface area of the bottom surface 126 is in the range of 15 inches 2 to 25 inches 2 , then the stiffness per inch 2 may also be calculated. In accordance with an embodiment of the present disclosure, a brush 110 having a dimensional ratio of width to thickness to height (W:T:H) in the range of 20:1.5:2 to 30:0.75:2.5 made with nylon bristles having the dimensions and density described above will exhibit suitable bristle deformation and suitable leakage past the brush 110 when applying coatings having a viscosity in the range of 2500 CPS to 15000 CPS. A down force in a range of 2 to 10 lbs. may be applied on a handle 112 disposed at an angle in the range of 10 to 40 degrees relative to the surface 122 to which the coating 120 is applied. This results in a leakage past the brush 110 that effectively applies the coating 120 to the surface 122 .
[0038] FIG. 6 shows a brush 210 where the brush head 214 is supported by a sleeve 230 disposed about the handle 212 and braces 232 that attach to and extend from the sleeve 230 to the frame portion 218 F.
[0039] FIG. 7 shows a brush 310 with a brush head 314 having a support web 332 that may be formed from stamped metal or molded plastic. The web intermediates between and attaches to the root portion 318 R into which a handle 312 is received and to the frame portion 318 F of the brush head 314 .
[0040] FIG. 8 shows a brush 410 with a brush head 414 to which is attached a root portion 418 R. The root portion 418 R has an attachment cylinder 418 C that extends up from the root portion 418 R at an angle and is received in a coupling sleeve 412 S that is attached to the handle 412 . A rivet or screw 412 P may be used to retain the sleeve 412 S on the cylinder 418 C. The root portion 418 R may be spot welded, screwed or otherwise attached to frame portion 418 F.
[0041] FIG. 9 shows a brush 510 with a brush head 514 . The bristle holder 518 has a root portion 518 R. The root portion 518 R has an attachment tab 518 T that extends up from the root portion 518 R at an angle and is received in a slotted coupling 5125 that is attached to the handle 512 . One or more rivets or bolts/nuts 512 P may be used to retain the coupling 5125 on the tab 518 T. The root portion 518 R may be spot welded, screwed or otherwise attached to frame portion 518 F.
[0042] FIG. 10 shows a brush 610 with a brush head 614 and a bristle holder 618 with a root portion 618 R. The root portion 618 R has a lower channel 618 LC that can receive the frame portion 618 F. One or more bolts 618 B can be tightened down to grip the frame portion 618 F and retain it the lower channel 618 LC. An attachment bolt 618 AB that extends up from the root portion 618 R and is received in a coupling plate 612 P that extends from a coupling bracket 612 B which attaches to the handle 612 . The bracket 612 B may be glued, threadedly coupled, bolted or riveted to the handle 612 . A wing nut 612 W may be used to retain the plate 612 P to the root portion 618 R via attachment bolt 618 AB. The plate 612 P may be shaped to mate with the surface of the upper channel 618 UC. The brush 610 allows the bristle portion 616 to be replaced without disposing of the remainder of the brush head 614 .
EXAMPLE 1
[0043] A driveway sealer made from asphalt typically has a viscosity in the range of 2,500 to 15,000 CPS. The desired coating thickness or film to be applied with a driveway sealer of this type is 50 mils in total thickness. The total thickness of driveway sealer may be applied in 2 separate passes or coats which are allowed to dry between coats. In this example, the desired thickness for each coat of sealer is therefore 25 mils. Preferably, the coating applied will not exceed 50 mils in thickness for each coat and each coat will be substantially even. A brush 10 having attributes in accordance with the present disclosure was used to apply a coating of driveway sealer obtained from Gardner-Gibson and known by the brand Ultramaxx 1000. The bristle portion 16 B had the following dimensions: Width: 24 inches, Height (bristle free length): 2.5 inches, Thickness: 0.75 inches, having 130 bristles/inch, i.e., 3120 bristles full width of the 24 inch wide bristle portion 16 . The sealer had a measured viscosity of 8000 CPS at 77° F. The sealer was applied to a flat blacktop driveway having a surface roughness of about ⅛″ irregular. The temperature of the driveway surface at the time of application was 90° F. The handle 12 of the brush 10 was 5 feet long and held at an angle of about 30 degrees. The brush head 14 was weighted with a weight of ½ lb to generate a constant down force. A puddle of sealer having a volume of about 2 gallons was poured in front of the brush 10 and the brush 10 was advanced a distance of 20 feet in about 1 minute. Upon inspection, the coating 20 was applied with no skips or bare spaces in the coating layer. The area coated exhibited comprehensive coating of the rough surface, including low spots (valleys between aggregate) and high spots (at the points of the aggregate that extend upwardly). The coating of sealer was allowed to dry and the thickness of the coating was measured at various points on the coated surface and was found to be about 21 mils thick, varying by no more than about 5% over the coated surface.
[0044] A brush 10 , 110 , 210 , etc. in accordance with the present disclosure and used in accordance with the present disclosure functions like a squeegee when applying a viscous coating material. The bristles 16 B are firmly held and closely arranged together preventing passage of the coating 20 through the upper part of the bristle portion 16 , proximate the bristle holder 18 . The bristles 16 B do not bend excessively under the down force D typically required to advance the brush 10 over a surface 22 while applying viscous coating 20 on the surface 22 . The action of the brush 10 in pushing the coating 20 allows the coating 20 to penetrate nooks and crevasses in a rough surface, such as a blacktop driveway and maintains even coating over the area of application. When used for spreading a viscous coating 20 , the bristle portion 16 maintains its shape, in that the edges do not curl up.
[0045] In applying high viscosity coatings ranging from 2500 CPS to 15000 CPS, the brush 10 is able to adapt to the changing down force D required to spread the coating 20 without distortion of the bristles 16 B. The rubber/foam sleeve(s) 14 on the handle 12 allows the handle 12 to be gripped firmly without slipping and increases control of the user over the brush 10 , as well as reducing fatigue for the user. The brush 10 allows the user to redirect the brushing direction 24 by any angle, e.g., 90 or 180 degrees and still push the coating 20 in a continuous layer without gaps in coverage.
[0046] It will be understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the present application. All such variations and modifications are intended to be included within the scope of the present application and claims.
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A brush for applying a viscous coating to surfaces such as a driveway, has a composition and conformation promoting an even application of the coating. The brush has bristles of a given, number, density/spatial distribution, free length, thickness and elastic modulus that in combination provide a controlled leakage of viscous coating past the brush when the handle thereof is held at a given angle and subjected to a given downforce to facilitate applying the coating.
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FIELD OF THE INVENTION
The present invention relates to communication systems, and is particularly directed to a digital filtering scheme for filtering narrow band signals such as those transmitted over a satellite communication link.
BACKGROUND OF THE INVENTION
Concomitant with the growth and expansion of satellite communication networks has been the need for filtering schemes for reducing noise and cross talk within the communication channel. Problems with narrowband satellite communication links include the significant amount of Gaussian noise encountered, the need to reduce or prevent intersymbol interference within the channel and the need to reduce cross talk from adjacent channels. For the purpose of overcoming these problems, satellite communication modems have been configured to include analog filtering schemes that typically have a Bessel function characteristic and are classically configured to as closely as possible simulate an infinite impulse response. Unfortunately, these schemes are extremely complicated and difficult to implement, requiring an inordinate amount of hardware, thereby increasing the cost of the system.
With the increasing development of semiconductor technology and sophisticated data processing techniques, proposals for reducing analog hardware complexity by replacing conventional analog filtering schemes with digital implementations have become particularly attractive. Typically, the digital filter is configured to determine the values of successive samples of a filtered output signal by forming the sums of algebraic products of successive samples of an input signal. Namely, the filter typically performs the operation so that the output sample Y i of a sampling instant i may be expressed as ##EQU1## where α represents a multiplication coefficient and x i-k represents data samples. Filters of this type are referred to as non-recursive digital filters.
Conventionally, in order to perform the filtering algorithm calculations, digital filters have been implemented in the form of a plurality of delay shift register stages, multipliers (each providing a weighing coefficient) and an adder or accumulator coupled to the outputs of the multiplier stages. In addition, there have been proposed schemes which employ programmable read-only memories, programmed with weighting coefficients, in place of the multiplier stages, with a separate adder or accumulator provided at the output of the respective ROM. For an overview of digital filtering schemes of the type mentioned above, whether they be of the recursive or non-recursive type, attention may be directed to U.S. Pat. Nos. 3,777,130; 3,737,636; 3,794,816; 3,822,404; 3,914,588; and 4,146,931, as well as an article by Peled and Liu entitled "A new Hardware Realization of Digital Filters", IEEE Transactions on Acoustics, Speed and Signal Processing, Vol. 22, no. 6, December, 1974 pp. 456-461 and an article by S. L. Freeny entitled "Special-purpose Hardware for Digital Filtering", Proceedings of the IEEE, April 1975, pp 633-648.
Unfortunately, most classical digital filtering schemes, including approaches such as those described in the above-referenced literature, have been aimed at meeting a particular frequency response. Techniques such as window functions, etc., have been devised to improve the frequency characteristics, with some degradation in the time domain response. Brute force hardware implementations, for simulating an infinite impulse response, are extremely difficult to achieve and require an inordinate amount of hardware, as mentioned previously.
SUMMARY OF THE INVENTION
In accordance with the present invention, the signal transfer function requirements of a narrowband satellite communication channel are satisfied by a filtering scheme that simultaneously reduces Gaussian noise and intersymbol interference, enjoying a linear phase response, in-band. Rather than follow the classical approach of attempting to simulate an infinite impulse response with an extremely large number of stages, whether they be of analog or digital configuration, the filtering scheme according to the present invention simulates a finite impulse response which, advantageously, obeys a transfer function characteristic that is especially suited for the types of adverse signalling influences encountered in the satellite channel, but which readily adapts itself to a simplified hardware configuration.
To this end, the filter response characteristic is one having a raised-cosine function in the frequency domain, digitally implemented in the time domain for a finite impulse response. For a finite impulse input, the time domain response of the corresponding frequency domain raised cosine response is recreated in a programmable read-only memory, the contents of which are selectively addressed by the combination of the contents of a shift register and a counter. The shift register contains a prescribed number of successive data bits to be transmitted, while the counter is employed to identify or scan a plurality of successive finite filter response values, based upon the current contents of the shift register. For this purpose, the counter divides a sampling clock signal by some preselected number that is large enough to guarantee that Nyquist's criterion is satisfied and periodically updates or shifts new data bits into the shift register. The contents of the counter represent the least significant bits of the addressed memory location in the PROM, the most or upper significant bits are represented by the contents of the shift register. From the memory locations of the PROM corresponding to these successively generated addresses, values are read out representative of the overall or accumulated filter response attributable to the data bits stored in the shift register at the successive sample points determined by the contents of the counter. Each digital data word is converted to analog form by a D/A converter and then coupled through a low pass filter for application to downstream signal processing circuitry (e.g. an I.F. mixer).
Advantageously, this scheme offers a significantly simplified hardware configuration, as the total non-recursive filter function response is derivable from a single read-only memory. By basing the simulated response upon a finite impulse input, it is a simple matter to generate the signals necessary to address or interrogate the PROM. With the raised-cosine response characteristic it has been found that the number of signal samples and sampling points can be kept at a reasonable size, so that an inordinate memory capacity is not required. In an exemplary embodiment of the invention, a 2K (2048×8 bits) read-only memory has been found to be successful.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a conventionally configured non-recursive digital filter;
FIG. 2 is a schematic block diagram of a non-recursive digital filter in accordance with the present invention;
FIGS. 3(a) and 3(b) are signal sample illustrations for explaining the operation of the configuration shown in FIG. 2;
FIG. 4 shows the time domain representation of the finite impulse response for a raised-cosine function; and
FIG. 5 shows sample values of a raised-cosine function for positive and negative impulses.
DETAILED DESCRIPTION
As mentioned briefly above, the frequency domain response characteristic of the digital filter of the present invention is chosen to simulate a raised-cosine function, as this function has an in-band linear phase characteristic and acts to optimize, simultaneously, the problems of Gaussian noise and intersymbol interference for the narrow channel spacing of the satellite communication link. The filter is non-recursive so that it is an ideal filter for transmission filter. In order to appreciate the advantages of the digital implementation of the present invention, as contrasted to the conventional approach exemplified by those described in the above-referenced literature, consider a typical non-recursive digital filter as illustrated in FIG. 1.
The filter shown in FIG. 1 consists of a cascaded series of delay stages Z -1 , 1-1 . . . 1-N, to the first 1-1 of which the incoming data samples are applied, with the contents of the stages being successively clocked along the series of stages by a sampling clock f s . The contents of each delay stage are applied to a corresponding set of multipliers 2-1 . . . 2-N to which there are also applied respective filter coefficients a -K . . . a K . The outputs of the multipliers 2-1 . . . 2-N are coupled to an adder or accumulator 3, at the output of which there is obtained the filter response ##EQU2## where:
x i =data value,
a i =h (iTs),
Ts=1/f s =sampling period, and
h(t)=the desired filter impulse response characteristic.
As was mentioned briefly above, for a satellite communication channel the choice of a raised cosine function has particular utility, since its characteristic enables the filter to optimize both Gaussian noise and intersymbol interference. Now, with a raised-cosine spectrum chosen as the described frequency-domain filter characteristic H(ω), in the time domain, ##EQU3## where H(ω) is defined by ##EQU4## where
α=(1-m) .sup.ω c/2, and
m=the filter rolloff (0-1).
From the above expression, the general equation for the time domain representation of the filter transfer function is ##EQU5## To provide linear phase and satisfying Nyquist's criterion, a symmetric (even) filter with an even number of sample points may be employed. The expression for the filter coefficients is
h(k)=h.sub.I (TsK-Ts/2),
where K=1 . . . N/2 and, ##EQU6## with h I (t) being defined from the above expression for h(t). For such a filter, the frequency domain representation of the transfer function is ##EQU7## where
.sup.ω s is the sampling frequency and
N is the number of stages of the filter.
Unfortunately, a conventional implementation approach as illustrated in FIG. 1 cannot be made to match the desired cosine response exactly, since the filter has a finite impulse response and, therefore, an infinite frequency response. Increasing the number of stages and the ratio of the sampling (shift) clock f s to the data clock f c can improve the approximation; however, it will only be that, an approximation and not an exact match.
Now, consider inserting an impulse generator (e.g. a clocked flip-flop) for each delay stage of the configuration of FIG. 1, creating a shift register of some number of stages, where each impulse is one sampling period Ts wide, so that, for a binary representation, a positive impulse may be represented by a binary "1" and a negative impulse by a binary "0". Each output Y (nTs) of the "modified" classical approach contains ##EQU8## terms because of the insertion of the impulse generator; i.e. there are ##EQU9## impulses in the shift register at any time. As explained above, the impulse (positive or negative) may be represented by a binary function, so that there are 2 .sup.(N/f.sbsp.s /f .sbsp.c.sup.) unique impulse patterns that may be realized or generated for the filter.
By letting f s /f c =R, there are 2.sup.(N/R) unique patterns, each pattern thereby producing R outputs (Y(nTs)). Once these patterns have been read out, a new data sample x (t) is loaded into the first stage of the shift register as the contents of the other Z -1 stages are shifted. With this functional approach, there are at most R·2.sup.(N/R) unique filter outputs Y (nTs) for any n length finite impulse response shift register having an impulse generator configuration. These Y(nTs) can be stored in a read only memory and accessed by an address code, the most significant bits are defined by the contents of the shift register and the least significant bits (defining the sampling points ) are defined by a binary code representative of fs/fc or R.
FIG. 2 is a block-diagram illustration of a non-recursive digital filter in accordance with the present invention incorporating the above approach. Incoming data x(t) is coupled to an N stage shift register 21, and is clocked in at a shift clock rate determined by the output of a counter or divider 20. Counter 20 divides an incoming sampling clock signal f s by a factor of R to obtain a data clock frequency f c for successively loading data into shift register 21. Letting R=16, counter 20 may be a four stage binary counter, the contents of the respective stages of which are coupled over link 26 to the LSB portion of the address input to PROM 22. Link 26 is Y bits wide where ##EQU10## so that here Y=4. The MSB address bits are derived from the R stages of shift register 21, so that for a seven stage register, Y(4)+N(7)=11 bits defining a memory address in PROM 22. PROM 22 may be a commercially available EPROM having a (2048×8) bit capacity. The output of PROM 22 is an eight bit word representation of the filter response Y for a data sample pattern contained in shift register 21 and a sampling point specified by the contents of counter 20. This filter output value Y(t) is then converted into analog form by a D/A converter 23 and coupled through a low pass filter 24 to downstream conversion circuit, such as a mixer 25, for converting the signal from baseband up to I.F., for example.
As will be readily understood from a comparison of the configuration shown in FIG. 2 to the digital filter configurations depicted in the above-referenced literature, the implementation scheme of the present invention is extraordinarily simplified compared with conventional approaches. In order to fully appreciate how the PROM is programmed to perform its intended response function, consider the set of finite filter responses shown in FIG. 3(b). As each new data sample value is loaded into shift register 21, the contents of the shift register will take on some arbitrary sequence as governed by the N=7 most recent data samples. FIG. 3(a) illustrates a binary sequence representative of the contents of shift register 21 for some arbitrary series of values 1011011. Each of these values is shifted in time by the period of the data clock from its adjacent value, and may be employed to generate, or determine, a finite impulse response for a filter having the desired spectrum characteristic (here a raised cosine function has been chosen). By considering each sample value individually and ignoring adjacent values, there may be derived a filter characteristic response function such as illustrated in FIG. 3(b). Here a one bit value represents a positive impulse response, while a zero bit value represents a negative impulse response.
FIG. 4 illustrates in greater detail the time domain characteristic curves of the raised cosine finite impulse response, described above, whereas the response impulse curves shown in FIG. 3(b) are reduced for simplicity of illustration. As shown in FIG. 4, the raised-cosine response undergoes a significant variation over the centroid of the sampling window +T about the peak, but tapers off after several such intervals.
FIG. 5 shows the raised cosine characteristic of FIG. 4 for both positive and negative impulses, sampled at 16 points per sampling interval, using an amplitude value scale of eight bits, so that the number 256 represents the maximum peak value attributable to the response at the centroid of the curve. Curve I illustrates sampled response values for a positive impulse while curve II shows the sample response values for a negative impulse. While, in reality the values are determined over the entire seven sample span of shift register 21, the values for only a three symbol span form are shown in FIG. 5 to simplify the drawings. (As it turns out, the contribution after three to four bit periods to the eight bit number derived from the PROM becomes insignificant.) Once the response values for an individual impulse for any bit position have been calculated from the h(t) definition, it is a straightforward matter to determine the values, for the other six bit positions, simply by shifting the sample points of interest to the right or left. All of these values over the entire seven-bit span of the shift register (112 individual sample points) are summed for all seven bit state possibilities, an exemplary one of which is shown in FIG. 3(a), so as to derive 2048 response Y values, each of which is represented by an eight bit binary code. One calculated, these values are stored in the respective 2048 locations of PROM 22. Thus, for each new successive data sample clocked into shift register 21, sixteen successive filter values (covering one entire bit period) are produced by PROM 22 from its stored 2048×8 bit words, as counter 20 counts sample clock signals f s . These values are then converted into analog format by D/A converter 23. Low pass filter 24 smooths the successive analog values to provide the resultant filtered output signal for subsequent up conversion and transmission.
In the foregoing example of the addressing scheme for the read-only memory 22, a sample span of seven bits with sixteen sample points per data sample, has been described for numerical values that may be used for accessing a 2K PROM. It should be understood, however, that the present invention is not limited to these parametric ranges. Other data sample spans and number of sample points may be used. Of course, although Nyquist's criterion governs sampling, it should be noted that the greater number of sample points per data bit, the greater accuracy is the filter output Y(t) for each sample point. In the present example, sixteen sample points, requiring four bits of each address word were employed. In this circumstance, the size of the PROM must be tailored to meet the sampling criterion. This may, in part, be influenced by the filtering function chosen. In the present example, considering the effects of Gaussian noise and intersymbol interference in a narrowband satellite communication link, a raised-cosine filter characteristic was selected. However, other filtering functions are adaptable to the simplified digital filtering approach employed in accordance with the present invention. Note also, that with all possible values of Y(t) for a data symbol span of interest being stored by the PROM, a change in data rate does not require a reconfiguration or recalculation of filter output values. All that is required is a change in the sampling clock frequency fs input to counter 20.
While I have shown and described one embodiment in accordance with the present invention, it is understood that the same is not limited thereto but is susceptible of numerous changes and modifications as known to a person skilled in the art, and I therefore do not wish to be limited to the details shown and described herein but intend to cover all such changes and modifications as are obvious to one of ordinary skill in the art.
|
A digital filter, having a raised-cosine function in the frequency domain, is implemented in the time domain. For positive and negative impulse inputs, the time domain response of the corresponding frequency domain raised cosine response is created by way of a programmable read-only memory (PROM), the contents of which are selectively addressed by the combination of the contents of a shift register and a counter. The shift register contains a prescribed number of digital samples of successive data bits to be transmitted, while the counter is employed to identify or scan a plurality of successive finite filter response values, based upon the current contents of the shift register. From the memory locations of the PROM corresponding to successively generated address, values are read out representative of the overall or accumulated filter response attributable to the data bits stored in the shift register at the successive sample points determined by the contents of the counter.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/550,686, filed Oct. 24, 2011, entitled METHOD FOR GENERATING DENSE DISPARITY MAP, naming Buyue Zhang et al. as inventors, which is hereby fully incorporated herein by reference for all purposes.
BACKGROUND
[0002] The disclosures herein relate in general to image processing, and in particular to a method, system and computer program product for enhancing a depth map.
[0003] An image processing system can try to determine respective depths of pixels within a stereoscopic image. Nevertheless, if a pixel's respective depth is indeterminate (e.g., as a result of occlusion, and/or exceeding a search range boundary, within the stereoscopic image), then various operations (e.g., view synthesis, background substitution, and gesture control) of the image processing system are potentially compromised. In attempts to handle this problem, previous techniques (e.g., bilinear interpolation) have introduced other shortcomings, such as blurred edges between different objects and/or different regions within the stereoscopic image.
SUMMARY
[0004] A first depth map is generated in response to a stereoscopic image from a camera. The first depth map includes first pixels having valid depths and second pixels having invalid depths. In response to the first depth map, a second depth map is generated for replacing at least some of the second pixels with respective third pixels having valid depths. For generating the second depth map, a particular one of the third pixels is generated for replacing a particular one of the second pixels. For generating the particular third pixel, respective weight(s) is/are assigned to a selected one or more of the first pixels in response to value similarity and spatial proximity between the selected first pixel(s) and the particular second pixel. The particular third pixel is computed in response to the selected first pixel(s) and the weight(s).
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a block diagram of an information handling system of the illustrative embodiments.
[0006] FIG. 2 is a diagram of an example orientation of dual imaging sensors of a camera of FIG. 1 .
[0007] FIG. 3 is a diagram of viewing axes of a human's left and right eyes.
[0008] FIG. 4A is an example stereoscopic image received from the camera of FIG. 1 .
[0009] FIG. 4B is an example initial depth map for the stereoscopic image of FIG. 4A .
[0010] FIG. 4C is an example valid/invalid depth mask for the initial depth map of FIG. 4B .
[0011] FIG. 5 is a flowchart of an operation of a computing device of FIG. 1 .
[0012] FIG. 6A is a diagram of a first example window for an adaptive bilateral filter of the operation of FIG. 5 .
[0013] FIG. 6B is a diagram of a second example window for the adaptive bilateral filter of the operation of FIG. 5 .
[0014] FIG. 6C is a diagram of a third example window for the adaptive bilateral filter of the operation of FIG. 5 .
DETAILED DESCRIPTION
[0015] FIG. 1 is a block diagram of an information handling system (e.g., one or more portable battery-powered electronics devices, such as mobile smartphones), indicated generally at 100 , of the illustrative embodiments. In the example of FIG. 1 , a scene (e.g., including a physical object 102 and its surrounding foreground and background) is viewed by a stereoscopic camera 104 , which: (a) captures and digitizes images of such views; and (b) outputs a video sequence of such digitized (or “digital”) images to an encoding device 106 . As shown in FIG. 1 , the camera 104 includes dual imaging sensors, which are spaced apart from one another, namely: (a) a first imaging sensor for capturing, digitizing and outputting (to the encoding device 106 ) a first image of a view for a human's left eye; and (b) a second imaging sensor for capturing, digitizing and outputting (to the encoding device 106 ) a second image of a view for the human's right eye.
[0016] The encoding device 106 : (a) receives the video sequence from the camera 104 ; (b) encodes the video sequence into a binary logic bit stream; and (c) outputs the bit stream to a storage device 108 , which receives and stores the bit stream. A decoding device 110 : (a) reads the bit stream from the storage device 108 ; (b) in response thereto, decodes the bit stream into the video sequence; and (c) outputs the video sequence to a computing device 112 .
[0017] The computing device 112 : (a) receives the video sequence from the decoding device 110 (e.g., in response to a command from a display device 114 , such as a command that a user 116 specifies via a touchscreen of the display device 114 ); and (b) outputs the video sequence to the display device 114 for display to the user 116 . Substantially concurrent with such receiving (from the decoding device 110 ) and such outputting (to the display device 114 ) in real-time, the computing device 112 automatically: (a) generates respective depth maps for images of the video sequence, as discussed hereinbelow in connection with FIGS. 2 through 6C ; (b) performs various operations (e.g., view synthesis, background substitution, and gesture control on the display device 114 ) in response to such depth maps, so that results of such operations are displayed to the user 116 by the display device 114 ; and (c) writes such depth maps for storage into the storage device 108 .
[0018] The display device 114 : (a) receives the video sequence from the computing device 112 (e.g., in response to a command that the user 116 specifies via the touchscreen of the display device 114 ); and (b) in response thereto, displays the video sequence (e.g., stereoscopic images of the object 102 and its surrounding foreground and background), which is viewable by the user 116 with 3D effect. The display device 114 is any suitable display device that includes a stereoscopic display screen whose optical components enable viewing by the user 116 with 3D effect, such as a suitable plasma display screen, liquid crystal display (“LCD”) screen, or light emitting diode (“LED”) display screen. In one example, the display device 114 displays a stereoscopic image with 3D effect for viewing by the user 116 through special glasses that: (a) filter the first image against being seen by the right eye of the user 116 ; and (b) filter the second image against being seen by the left eye of the user 116 . In another example, the display device 114 displays the stereoscopic image with 3D effect for viewing by the user 116 without relying on special glasses.
[0019] The encoding device 106 performs its operations in response to instructions of computer-readable programs, which are stored on a computer-readable medium 118 (e.g., hard disk drive, nonvolatile flash memory card, and/or other storage device). Also, the computer-readable medium 118 stores a database of information for operations of the encoding device 106 . Similarly, the decoding device 110 and the computing device 112 perform their operations in response to instructions of computer-readable programs, which are stored on a computer-readable medium 120 . Also, the computer-readable medium 120 stores a database of information for operations of the decoding device 110 and the computing device 112 .
[0020] The system 100 includes various electronic circuitry components for performing the system 100 operations, implemented in a suitable combination of software, firmware and hardware, such as one or more digital signal processors (“DSPs”), microprocessors, discrete logic devices, application specific integrated circuits (“ASICs”), and field-programmable gate arrays (“FPGAs”). In one embodiment: (a) a first mobile smartphone includes the camera 104 , the encoding device 106 , and the computer-readable medium 118 , which are housed integrally with one another; and (b) a second mobile smartphone includes the decoding device 110 , the computing device 112 , the display device 114 and the computer-readable medium 120 , which are housed integrally with one another.
[0021] In an alternative embodiment: (a) the encoding device 106 outputs the bit stream directly to the decoding device 110 via a network, such as a mobile (e.g., cellular) telephone network, a landline telephone network, and/or a computer network (e.g., Ethernet, Internet or intranet); and (b) accordingly, the decoding device 110 receives and processes the bit stream directly from the encoding device 106 substantially in real-time. In such alternative embodiment, the storage device 108 either: (a) concurrently receives (in parallel with the decoding device 110 ) and stores the bit stream from the encoding device 106 ; or (b) is absent from the system 100 .
[0022] FIG. 2 is a diagram of an example orientation of the dual imaging sensors 202 and 204 (of the camera 104 ), in which a line between the sensors 202 and 204 is substantially parallel to a line between eyes 206 and 208 of the user 116 . In this example, while the sensors 202 and 204 have such orientation, the camera 104 captures and digitizes images with a landscape aspect ratio.
[0023] FIG. 3 is a diagram of viewing axes of the left and right eyes of the user 116 . In the example of FIG. 3 , a stereoscopic image is displayed by the display device 114 on a screen (which is a convergence plane where viewing axes of the left and right eyes naturally converge to intersect). The user 116 experiences the 3D effect by viewing the stereoscopic image on the display device 114 , so that various features (e.g., objects) appear on the screen (e.g., at a point D 1 ), behind the screen (e.g., at a point D 2 ), and/or in front of the screen (e.g., at a point D 3 ).
[0024] Within the stereoscopic image, a feature's disparity is a horizontal shift between: (a) such feature's location within the first image; and (b) such feature's corresponding location within the second image. The limit of such disparity is dependent on the camera 104 . For example, if a feature (within the stereoscopic image) is centered at the point D 1 within the first image, and likewise centered at the point D 1 within the second image, then: (a) such feature's disparity=D 1 −D 1 =0; and (b) the user 116 will perceive the feature to appear at the point D 1 on the screen, which is a natural convergence distance away from the left and right eyes.
[0025] By comparison, if the feature is centered at a point P 1 within the first image, and centered at a point P 2 within the second image, then: (a) such feature's disparity=P 2 −P 1 will be positive; and (b) the user 116 will perceive the feature to appear at the point D 2 behind the screen, which is greater than the natural convergence distance away from the left and right eyes. Conversely, if the feature is centered at the point P 2 within the first image, and centered at the point P 1 within the second image, then: (a) such feature's disparity=P 1 −P 2 will be negative; and (b) the user 116 will perceive the feature to appear at the point D 3 in front of the screen, which is less than the natural convergence distance away from the left and right eyes. The amount of the feature's disparity (e.g., horizontal shift of the feature from P 1 within the first image to P 2 within the second image) is measurable as a number of pixels, so that: (a) positive disparity is represented as a positive number; and (b) negative disparity is represented as a negative number.
[0026] FIG. 4A is an example pair of images received from the camera 104 , including: (a) a first image 402 , as captured by the sensor 202 , for viewing by the left eye 206 ; and (b) a second image 404 , as captured by the sensor 204 , for viewing by the right eye 208 . For example, in association with one another, the first and second images 402 and 404 are contemporaneously (e.g., simultaneously) captured, digitized and output (to the encoding device 106 ) by the sensors 202 and 204 , respectively. Accordingly, the first image and its associated second image are a matched pair, which correspond to one another, and which together form a stereoscopic image for viewing by the user 116 with three-dimensional (“3D”) effect on the display device 114 . In the example of FIG. 4A , disparities (of various features between the first and second images) exist in a horizontal direction, which is parallel to the line between the sensors 202 and 204 in the orientation of FIG. 2 .
[0027] The computing device 112 receives the matched pair of first and second images from the decoding device 110 . Optionally, in response to the database of information (e.g., training information) from the computer-readable medium 120 , the computing device 112 : (a) identifies (e.g., detects and classifies) various low level features (e.g., colors, edges, textures, focus/blur, object sizes, gradients, and positions) and high level features (e.g., faces, bodies, sky, foliage, and other objects) within the stereoscopic image, such as by performing a mean shift clustering operation to segment the stereoscopic image into regions; and (b) computes disparities of such features (between the first image and its associated second image). The computing device 112 automatically generates a depth map (or “disparity map”) that assigns respective depth values to pixels of the stereoscopic image (e.g., in response to such disparities), so that a pixel's depth value indicates such pixel's disparity and vice versa.
[0028] FIG. 4B is an example initial depth map, which is generated by the computing device 112 in response to the stereoscopic image of FIG. 4A , where: (a) the first image 402 is a reference image; and (b) the second image 404 is a non-reference image. In the example initial depth map of FIG. 4B : (a) brighter intensity pixels (“shallower pixels”) indicate relatively nearer depths of their spatially collocated pixels within the reference image, according to various levels of such brighter intensity; (b) darker intensity pixels (“deeper pixels”) indicate relatively farther depths of their spatially collocated pixels within the reference image, according to various levels of such darker intensity; and (c) completely black pixels (“indeterminate pixels”) indicate that depths of their spatially collocated pixels within the reference image are indeterminate, due to at least one error in the depth map generation by the computing device 112 (“depth error”). The depth errors are caused by one or more conditions (e.g., occlusion, and/or exceeding a search range boundary, within the stereoscopic image of FIG. 4A ).
[0029] FIG. 4C is an example valid/invalid depth mask, in which: (a) all of the indeterminate pixels are black, which indicates that their spatially collocated pixels have invalid depth values (e.g., depth errors) within the initial depth map ( FIG. 4B ); and (b) all of the remaining pixels are white, which indicates that their spatially collocated pixels have valid depth values within the initial depth map ( FIG. 4B ).
[0030] FIG. 5 is a flowchart of an operation of the computing device 112 . At a step 502 , the computing device 112 receives a stereoscopic image of the scene from the decoding device 110 (e.g., in response to a command that the user 116 specifies via the touchscreen of the display device 114 ). The stereoscopic image includes a left image LeftI (e.g., image 402 ) and a right image RightI (e.g., image 404 ).
[0031] At a next step 504 , the computing device 112 generates a right-to-left depth map DBasicR2L(m,n) in response to: (a) the left image LeftI as the reference image; and (b) the right image RightI as the non-reference image. At the step 504 , for each pixel RightI(m, n) in the right image RightI, the computing device 112 searches for a corresponding pixel (along a spatially collocated row in the left image LeftI) that most closely matches RightI(m, n). Accordingly, at the step 504 , the computing device 112 generates DBasicR2L(m,n) as:
[0000]
DBasicR
2
L
(
m
,
n
)
=
argmin
k
{
∑
i
=
-
M
M
∑
j
=
-
N
N
LeftI
(
m
+
i
,
n
+
j
+
k
)
-
RightI
(
m
+
i
,
n
+
j
)
,
k
∈
[
negR
,
PosiR
]
}
(
1
)
[0000] where M×N is a block size, and [negR, PosiR] is a negative/positive disparity search range. In one example, M=3, N=3, negR=−10%·imageWidth, and PosiR=+10%·imageWidth, where imageWidth is a width of LeftI or RightI.
[0032] Similarly, at a next step 506 , the computing device 112 generates a left-to-right depth map DBasicL2R(m,n) in response to: (a) the right image RightI as the reference image; and (b) the left image LeftI as the non-reference image. Accordingly, at the step 506 , the computing device 112 generates DBasicL2R(m,n) as:
[0000]
DBasicL
2
R
(
m
,
n
)
=
argmin
k
{
∑
i
=
-
M
M
∑
j
=
-
N
N
RightI
(
m
+
i
,
n
+
j
+
k
)
-
LeftI
(
m
+
i
,
n
+
j
)
,
k
∈
[
negR
,
PosiR
]
}
(
2
)
[0033] At a next step 508 , the computing device 112 generates an initial depth map Drefine. In one example, an initial value of Drefine is:
[0000] D refine D Basic R 2 L (3)
[0034] At the step 508 , for each pixel (i, j) in the initial depth map Drefine, where i=1, 2, . . . imageHeight, and j=1, 2, . . . imageWidth, the computing device 112 determines whether such pixel (i, j) is located: (a) in an occluded area; and/or (b) on the boundary of the image. To detect occlusion, the computing device 112 compares: (a) the depth value (or “disparity estimate”) for such pixel (i, j) in the right-to-left depth map DBasicR2L; and (b) the depth value for its corresponding pixel (as determined at the step 504 ) in the left-to-right depth map DBasicL2R. If the two disparity estimates are inconsistent, then the computing device 112 : (a) determines that such pixel (i, j) is located in an occluded area; and (b) accordingly, marks such pixel (i, j) as an indeterminate pixel (“hole”) within the initial depth map Drefine. Similarly, at the step 508 , if the disparity estimate for such pixel (i, j) in the initial depth map Drefine causes an out-of-boundary horizontal shift (exceeding a left or right boundary of the image in a horizontal direction), then the computing device 112 marks such pixel (i, j) as a hole within the initial depth map Drefine.
[0035] The computing device 112 operation at the step 508 is summarized in Equations (4), (5), (6) and (7).
[0000] diff( i,j )= D Basic L 2 R ( i,j+D Basic R 2 L ( i,j ))+ D Basic R 2 L ( i,j ) (4)
[0000] If |diff| i,j∥>LR Thresh, D refine( i,j )=DISP_REJECT (5)
[0000] If ( j+D Basic R 2 L ( i,j ))<1 ,D refine( i,j )=DISP_REJECT (6)
[0000] If ( j+D Basic R 2 L ( i,j ))>imageWidth, D refine( i,j )=DISP_REJECT (7)
[0036] In one example, the computing device 112 sets: (a) LRThresh to 4 for 8-bit image data; and (b) DISP_REJECT to −200, so that DISP_REJECT is a value outside the negative/positive disparity search range [negR, PosiR].
[0037] Various operations (e.g., view synthesis, background substitution, and gesture control) of the computing device 112 would be potentially compromised by the holes in the initial depth map Drefine. To improve those various operations, the computing device 112 generates a final depth map Ddense that: (a) fills such holes by replacing them with pixels that have valid depth values; and (b) preserves edges from within the initial depth map Drefine. Accordingly, the computing device 112 performs those various operations in response to the final depth map Ddense instead of the initial depth map Drefine.
[0038] At a next step 510 , in response to the initial depth map Drefine(k,l), the computing device 112 implements an adaptive bilateral filter to generate the final depth map Ddense(k,l), which the computing device 112 computes as:
[0000]
Ddense
(
k
,
l
)
=
∑
m
=
k
-
N
k
+
N
∑
n
=
l
-
N
l
+
N
ABF
(
m
,
n
;
k
,
l
)
Drefine
(
m
,
n
)
,
(
8
)
[0000] where ABF(m,n; k,l) is the adaptive bilateral filter for filling the holes. Accordingly, Ddense(k,l) includes no holes, so that all of its pixels have respective valid depth values.
[0039] For each hole, whose respective coordinate is [k,l] within Drefine(k,l), the adaptive bilateral filter ABF(m,n; k,l) specifies respective weights of other pixels having valid depth values within a (2N+1)×(2N+1) window that is centered at the coordinate [k,l] within Drefine(k,l). The computing device 112 computes the adaptive bilateral filter ABF(m,n; k,l) as:
[0000]
ABF
(
m
,
n
;
k
,
l
)
=
{
r
k
,
l
-
1
exp
(
-
(
(
m
-
k
)
2
+
(
n
-
l
)
2
2
σ
d
(
N
)
2
)
)
exp
(
-
1
3
∑
i
=
1
3
(
LeftI
(
m
,
n
,
i
)
-
LeftI
(
m
-
k
,
n
-
l
,
i
)
)
2
2
σ
r
2
)
,
[
m
,
n
]
∈
Ω
k
,
l
and
Drefine
(
m
,
n
)
is
valid
0
,
else
(
9
)
[0000] where [k,l] is the coordinate of the center pixel of the window, σ d (•) is the standard deviation of the domain Gaussian filter and a function of N, σ r is the standard deviation of the range Gaussian filter, r k,l normalizes volume under the filter to unity as shown in Equation (10), Ω k,l ={[m,n]:[m,n]ε[k−N, k+N]×[l−N, l+N]}, and N is the half size of the window.
[0000]
r
k
,
l
=
∑
m
=
k
-
N
k
+
N
∑
n
=
l
-
N
l
+
N
exp
(
-
(
(
m
-
k
)
2
+
(
n
-
l
)
2
2
σ
d
(
N
)
2
)
)
exp
(
-
1
3
∑
i
=
1
3
(
LeftI
(
m
,
n
,
i
)
-
LeftI
(
m
-
k
,
n
-
l
,
i
)
)
2
2
σ
r
2
)
(
10
)
[0040] In this example, Equations (9) and (10) are functions of the left image LeftI, because the initial value of Drefine is DBasicR2L. By comparison, in a different example: (a) the initial value of Drefine is DBasicL2R instead of DBasicR2L; and (b) accordingly, Equations (9) and (10) are functions of the right image RightI instead of the left image LeftI.
[0041] Different red-green-blue color (“RGB”) values often represent different objects or different regions that: (a) are separated by edges; and/or (b) have different disparities. Accordingly, the adaptive bilateral filter ABF(m,n; k,l) assigns smaller weights to pixels that either: (a) have spatially collocated pixels whose RGB values within LeftI are more different from the RGB value of coordinate [k,l] within LeftI; or (b) are spatially more distant from the center pixel's coordinate [k,l]. Conversely, the adaptive bilateral filter ABF(m,n; k,l) assigns larger weights to pixels that both: (a) have spatially collocated pixels whose RGB values within LeftI are more similar to the RGB value of coordinate [k,l] within LeftI; and (b) are spatially more proximate to the center pixel's coordinate [k,l]. In that manner, the computing device 112 avoids grouping disparities across edges and likewise avoids grouping disparities from different objects.
[0042] FIG. 6A is a diagram of a first example (2N+1)×(2N+1) window 602 for the adaptive bilateral filter ABF(m,n; k,l), within a representative portion of the initial depth map Drefine. FIG. 6B is a diagram of a second example (2N+1)×(2N+1) window 604 for the adaptive bilateral filter ABF(m,n; k,l), within the representative portion of the initial depth map Drefine. FIG. 6C is a diagram of a third example (2N+1)×(2N+1) window 606 for the adaptive bilateral filter ABF(m,n; k,l), within the representative portion of the initial depth map Drefine. The center pixel's coordinate [k,l] is indicated by an “X” in FIGS. 6A through 6C .
[0043] For clarity, in FIGS. 6A through 6C , white pixels are holes, and black pixels have valid depth values. To fill such holes, the computing device 112 adaptively grows the half size N of the (2N+1)×(2N+1) window, which is centered at the coordinate [k,l]. The computing device 112 : (a) starts with N=1, so that the (2N+1)×(2N+1) window is initially the 3×3 window 602 ( FIG. 6A ); and (b) determines whether the 3×3 window 602 includes at least one pixel that has a valid depth value. In the example of FIG. 6A , the 3×3 window 602 includes only holes.
[0044] In response to determining that the 3×3 window 602 includes only holes, the computing device 112 : (a) increases N by 1, so that N=2, which grows the (2N+1)×(2N+1) window into the 5×5 window 604 ( FIG. 6B ); and (b) determines whether the 5×5 window 604 includes at least one pixel that has a valid depth value. In the example of FIG. 6B , the 5×5 window 604 includes only holes.
[0045] In the same manner, the computing device 112 continues increasing N by a successive increment of 1 until at least one pixel has a valid depth value within the (2N+1)×(2N+1) window. Accordingly, in response to determining that the 5×5 window 604 includes only holes, the computing device 112 : (a) increases N by 1, so that N=3, which grows the (2N+1)×(2N+1) window into the 7×7 window 606 ( FIG. 6C ); and (b) determines whether the 7×7 window 606 includes at least one pixel that has a valid depth value. In the example of FIG. 6C , the 7×7 window 606 includes six pixels that have valid depth values, so the final value for N is 3.
[0046] Moreover, a threshold in the domain Gaussian filter σ d (N) is a function of N, as follows:
[0000]
σ
d
(
N
)
=
N
2
(
11
)
[0047] In the illustrative embodiments, a computer program product is an article of manufacture that has: (a) a computer-readable medium; and (b) a computer-readable program that is stored on such medium. Such program is processable by an instruction execution apparatus (e.g., system or device) for causing the apparatus to perform various operations discussed hereinabove (e.g., discussed in connection with a block diagram). For example, in response to processing (e.g., executing) such program's instructions, the apparatus (e.g., programmable information handling system) performs various operations discussed hereinabove. Accordingly, such operations are computer-implemented.
[0048] Such program (e.g., software, firmware, and/or microcode) is written in one or more programming languages, such as: an object-oriented programming language (e.g., C++); a procedural programming language (e.g., C); and/or any suitable combination thereof. In a first example, the computer-readable medium is a computer-readable storage medium. In a second example, the computer-readable medium is a computer-readable signal medium.
[0049] A computer-readable storage medium includes any system, device and/or other non-transitory tangible apparatus (e.g., electronic, magnetic, optical, electromagnetic, infrared, semiconductor, and/or any suitable combination thereof) that is suitable for storing a program, so that such program is processable by an instruction execution apparatus for causing the apparatus to perform various operations discussed hereinabove. Examples of a computer-readable storage medium include, but are not limited to: an electrical connection having one or more wires; a portable computer diskette; a hard disk; a random access memory (“RAM”); a read-only memory (“ROM”); an erasable programmable read-only memory (“EPROM” or flash memory); an optical fiber; a portable compact disc read-only memory (“CD-ROM”); an optical storage device; a magnetic storage device; and/or any suitable combination thereof.
[0050] A computer-readable signal medium includes any computer-readable medium (other than a computer-readable storage medium) that is suitable for communicating (e.g., propagating or transmitting) a program, so that such program is processable by an instruction execution apparatus for causing the apparatus to perform various operations discussed hereinabove. In one example, a computer-readable signal medium includes a data signal having computer-readable program code embodied therein (e.g., in baseband or as part of a carrier wave), which is communicated (e.g., electronically, electromagnetically, and/or optically) via wireline, wireless, optical fiber cable, and/or any suitable combination thereof.
[0051] Although illustrative embodiments have been shown and described by way of example, a wide range of alternative embodiments is possible within the scope of the foregoing disclosure.
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A first depth map is generated in response to a stereoscopic image from a camera. The first depth map includes first pixels having valid depths and second pixels having invalid depths. In response to the first depth map, a second depth map is generated for replacing at least some of the second pixels with respective third pixels having valid depths. For generating the second depth map, a particular one of the third pixels is generated for replacing a particular one of the second pixels. For generating the particular third pixel, respective weight(s) is/are assigned to a selected one or more of the first pixels in response to value similarity and spatial proximity between the selected first pixel(s) and the particular second pixel. The particular third pixel is computed in response to the selected first pixel(s) and the weight(s).
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[0001] The present invention relates generally to the performance enhancement of prefetching in a network environment and particularly to energy-efficient prefetching of files in a network environment.
BACKGROUND OF THE INVENTION
[0002] In networked environments, such as the Internet or communications networks, fetch latency is inevitable. Fetch latency is the time lag between when an object (e.g., a document or file) is requested and when the object is received. In a computer network environment, fetch latency is often referred to as page fetch latency. Page fetch latency is measured by the time lag between when users of client computer systems click on a page link to when the page actually appears on their screens. Page fetch latency may vary depending upon many factors, including available bandwidth.
[0003] Two responses to high page fetch latency in the World Wide Web (“WWW”) context are the use of mirroring and caching. Mirroring reduces fetch latency. However, mirroring requires manual target selection, which can be difficult to administer. Caching is typically implemented by having a proxy server store (i.e., cache) copies of frequently accessed objects. The proxy server, which may also be called a cache server, is typically located near one or more client computers, and is used to reduce network load. User requests for objects are initially directed to the proxy server, instead of the web servers at the network addresses specified in the user requests. If the object specified by the user request is in the proxy server, the proxy server sends the object to the requesting client without accessing the web server at the specified network address. Caching reduces fetch latency for repeatedly accessed objects, but does not improve first retrieval.
[0004] The world wide web allows caching at multiple points, so a cache mechanism is also typically implemented as part of the user agent program (e.g., a web browser) that runs on a client computer. Alternatively, or in addition, a proxy cache server can be implemented as an application or process that runs on the client computer, separate from the user agent program. The use of a proxy cache server located on the same computer as the user agent program is sometimes used to extend the functionality of the user agent program without directly modifying that program, while preserving the benefits of locating the cache on the same computer.
[0005] Prefetching can also be used to avoid, or at least to reduce, fetch latency. Prefetching is a technique whereby a client predicts a future request for a file on a remote server, fetches (i.e., prefetches) the file in advance, and stores the prefetched file in a local cache. Thus, the file is stored in the local cache before the client makes an explicit request for it. Access by the client to the local cache is much faster than access to the remote server. Thus, if the client does indeed request the file as predicted, the fetch latency is less than it would have been if the client requested the file from the remote system without prefetching.
[0006] Prefetching can improve retrieval times for even first-time page fetch requests, which is not possible with caching alone. However, prefetching can also result in the waste of system resources when a prefetched file is not requested by the user during the time that the prefetched file remains in the client computer's cache. Prefetching can even result in an increase in fetch latency when the prefetching of files interferes with demand fetching, which is the fetching of files actually requested by the user. More generally, the extra load imposed on client, server and network resources by prefetching may degrade performance of one or more of the client, server and network, especially if a large number of files are prefetched and the accuracy of the prefetching is low.
[0007] The present invention is based, in part, on the observation that energy efficiency is not a factor considered in prior art prefetching schemes. Energy efficiency is particularly important in battery powered, portable devices, and is also important in other contexts. Prefetching may increase energy usage by the client, server and/or network because the total number of files fetched is increased by the prefetching, since at least some of the prefetched files will not be used by the client computer while the files remain in the client computer's cache. The lower the accuracy of the prefetch predictions, the higher the energy usage will be. However, there may also be energy usage efficiencies associated with prefetching, because fetching multiple files in a burst may be more energy efficient than fetching the same files one at a time with periods of inactivity between the individual file fetches. More generally, there is a tradeoff between energy efficiency and the extent to which average fetch latency is decreased through the use of prefetching.
[0008] It would therefore be advantageous to provide an energy-efficient prefetching system and method that improves user-perceived network performance with prefetching.
SUMMARY OF THE INVENTION
[0009] In summary, the present invention is a system and method for performing energy efficient data prefetching in conjunction with a client computer system. The client computer system uses a prefetch prediction model having energy usage parameters to predict, or otherwise take into account, the impact of prefetching specified files on the system's energy usage. A prefetch prediction engine utilizes the prefetch prediction model to evaluate the specified files with respect to prefetch criteria, including energy efficiency prefetch criteria, and generates a prefetch decision with respect to each file of the specified files. For each specified file for which the prefetch prediction engine generates an affirmative prefetch decision, an identifying entry is stored in a queue. The client computer system fetches files identified by entries in the queue, although some or all of the entries in the queue at any one time may be deleted if it is determined that the identified files are no longer likely to be needed by the client.
[0010] In an other aspect of the invention, a server computer includes a server module for responding to a request from a client computer for a specified file and for generating a reply to the request. The reply includes a content portion comprising the specified file and a supplemental portion distinct from the content portion. A prefetch predictor identifies additional files for possible prefetching by the client computer. The server module includes in the supplemental portion of the reply to the request from the client computer prefetch hint information identifying at least one of the additional files.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Additional objects and features of the invention will be more readily apparent from the following detailed description and appended claims when taken in conjunction with the drawings, in which:
[0012] [0012]FIG. 1 is a block diagram of a client computer system with a prefetch prediction engine and prefetch prediction model in accordance with a preferred embodiment of the present invention.
[0013] [0013]FIG. 2 depicts the data structure of a server's response to a request by a client computer in accordance with an embodiment of the present invention.
[0014] [0014]FIG. 3 is a block diagram of a prefetch prediction model.
[0015] [0015]FIG. 4 is a block diagram of system components interoperating with a prefetch prediction engine.
[0016] [0016]FIG. 5 is a flow chart of an energy efficient prefetching method performed by a client computer.
[0017] [0017]FIG. 6 is a block diagram of a server computer system with a prefetch predictor and prefetch prediction model in accordance with a preferred embodiment of the present invention.
[0018] [0018]FIG. 7 is a block diagram of a server-side prefetch efficiency model.
[0019] [0019]FIG. 8 is a block diagram of a server module having a prefetch hint pruner as well as a prefetch predictor and prefetch efficiency model.
[0020] [0020]FIG. 9 depicts the data structure of a client's request message to a server in accordance with an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring to FIG. 1, a client computer system 100 is shown in accordance with the present invention. The system 100 includes memory 108 for storing applications executable by one or more central processing units 102 and data structures such as queues and databases. A user interface 104 allows input by and output to a user of the system. A network interface 106 allows communication through communications network(s) 140 with servers (server computer systems) 220 . The network 140 may be the Internet or other wide area network, an intranet, a local area network, a wireless network, or a combination of such communication networks.
[0022] In one embodiment, memory 108 , which typically includes high speed random access memory as well as non-volatile storage such as disk storage, stores:
[0023] an operating system 110 , for providing basic system services;
[0024] file system 112 , which maybe part of the operating system;
[0025] application programs 114 ;
[0026] a browser 116 , for viewing and requesting documents, such as documents downloaded from servers via the Internet or an intranet;
[0027] a prefetch prediction model 118 , which includes energy usage parameters (see FIG. 3) for predicting the impact of prefetching specified files on energy usage by the system;
[0028] a model updater 120 , which is a software module for updating the prefetch prediction model 118 based on energy efficiency and utilization of previously prefetched files;
[0029] a prefetch prediction engine 122 , which determines, based on the prefetch prediction model 118 , which files of a set of prefetch candidates should be prefeteched;
[0030] fetch queues 126 , including a demand fetch queue 128 and a prefetch queue 130 ;
[0031] a scheduler 132 for scheduling downloads of files listed in the demand fetch queue 128 and prefetch queue 130 ; and
[0032] a cache 134 for storing copies of previously downloaded files, including prefetched files.
[0033] Memory 108 may also optionally store a battery meter procedure 124 for receiving information concerning the remaining energy stored in a battery. The remaining energy is sometimes herein called the “current energy supply level.” Many of the features of the present invention are not necessarily distinct applications. For example, the prefetch prediction engine 122 and model updater 120 can be implemented using a single software application that implements their joint functionality. In another example, the prefetch prediction model 118 may be implemented as part of the prediction engine 122 .
[0034] The interaction of the prefetch prediction model 118 , model updater 120 , prefetch prediction engine 122 , battery meter 124 , and fetch queues 126 is explained in more detail with reference to FIG. 4. The scheduler 132 is explained in more detail with reference to FIG. 5.
[0035] Referring to FIG. 2, a message 150 sent by a server to a client in response to a client request typically includes a header 151 and a body 154 . The header 151 stores information about the message, such as its source, content-type and encoding. In one preferred embodiment, the header 151 also includes an additional field 152 for storing prefetch hints. The prefetch hints are URLs or network addresses of files that the client computer may decide to prefetch. For instance, the client computer may prefetch one or more of the files represented by the prefetch hints 152 while decoding the file or other content in the body 154 of the message 150 . The body 154 of the message contains the content of the message, such as a file or HTML page, and that content may include links or tags 156 that reference other files. The files referenced by the links or tags 156 are also candidates for prefetching by the client computer. In one embodiment the prefetch hints include a probability value for each URL or network address listed in the prefetch hints. The probability value indicates the predicted probability that the associated file will be requested by the client which sent the client request.
Prefetch Prediction Model
[0036] Referring to FIG. 3, the prefetch prediction model 118 in a preferred embodiment includes several types of parameters, such as energy usage parameters, user usage pattern parameters, network characteristics and so on. More specifically, the prefetch prediction model 118 preferably includes two or more of the following types of parameters:
[0037] CPU energy usage parameters 160 , for instance indicating CPU energy usage per prefetch, additional CPU energy used for downloading various types of files, CPU energy during idle time, CPU fixed energy required to send a packet, CPU energy/byte required to send a packet, CPU fixed energy required to receive a packet, and CPU energy/byte required to receive a packet;
[0038] Network interface energy usage parameters 162 , for instance network interface fixed energy required to send a packet, network interface energy/byte (energy usage per byte) required to send a packet, network interface fixed energy required to receive a packet, network interface energy/byte (energy usage per byte) required to receive a packet, network interface energy to enter sleep mode, network interface time to enter sleep mode, network interface energy to exit sleep mode, network interface time to exit sleep mode, network interface power during idle mode, and network interface power during sleep mode;
[0039] Memory access energy usage parameters 163 , for instance memory read/write energy costs per byte or word, and energy costs of DMA operations;
[0040] Energy supply parameters 164 , for instance total energy availability, efficiency loss as a function of power drain, and energy efficiency as a function of power usage mode (e.g., as a function of level of power load, and pulsed mode vs continuous mode);
[0041] User behavior and preference parameters 166 , for instance estimate of user's apparent think time (estimate of mean or median time between a client's request for a file and the client's subsequent request for another file), preference for speed versus battery lifetime, preference for speed versus battery lifetime as a function of remaining battery lifetime, history of user's recent references, and prefetch-benefit threshold;
[0042] Network characteristics parameters 168 , for instance link bandwidth, current link utilization, and round-trip time to server;
[0043] Client cache status 170 , for instance the degree of utilization of a cache, allowable cache lifetime, cache entries, and stale cache entries; and
[0044] Prefetch benefit determination parameters 172 , for instance the estimated energy costs and benefits of doing a given prefetch or type of prefetch.
[0045] While the above description of the prefetch prediction model 118 refers to parameters concerning “a user,”when the client computer system is a multi-user system the prefetch prediction model and mechanisms of the present preferably take into account the preferences and actions of multiple users of a client computer system.
Operation of Prefetch System Components
[0046] Referring to FIG. 4, prefetch model updater 120 receives usage statistics, such as prefetch utilization statistics (concerning the quantity and types of prefetched files which were used by the client computer prior to the prefetched files being evicted from the cache 134 ) and energy usage statistics (concerning the energy used by prefetch operations and the net energy saved or lost by prefetch operations), and uses that information to adjust prefetch prediction model 118 to changing conditions. Prefetch prediction engine 122 uses prefetch prediction model 118 , along with user information and system status data to predict the net impact on energy usage by the client computer that would result from prefetching specified files in a list of prefetch candidates, and to determine which prefetch candidates to add to the prefetch queue 130 . The information and data used by the prefetch prediction engine 122 for this purpose preferably includes at least two of the following types of information and data:
[0047] user behavior and preferences,
[0048] the content currently being viewed or used by the client,
[0049] the rate at which the user has been requesting new files or pages,
[0050] the status (e.g., fullness) of the client computer cache 134 ,
[0051] the current energy level (battery meter reading) of the client computer;
[0052] current network congestion;
[0053] bandwidth availability between the client computer system and the server; and
[0054] round-trip time from client to server.
[0055] In another embodiment, the prefetch prediction engine 122 predicts the net impact on energy usage by the overall system (including client, server and other system components) that would result from prefetching specified files from a list of prefetch candidates.
[0056] If an entry or item in the list of prefetch candidates identifies a specified file that is already in the demand fetch queue 128 , the prefetch prediction engine preferably deletes that entry from the list of entries to be added to the prefetch queue 130 . If an entry corresponding to a specified file is in cache 134 , the prefetch prediction engine 122 does not add it to the prefetch queue 130 , unless the entry in the cache is stale. If an entry corresponding to a specified file is already in prefetch queue 130 , the corresponding entry in prefetch queue may be removed or modified as appropriate.
[0057] Referring to FIG. 5, if there is a prefetch candidate available (step 200 ) and if the prefetch candidate is not in the cache, demand fetch queue, or prefetch queue (step 202 ), then a decision—based upon the candidate, status information and other data—is made as to whether to prefetch the candidate (step 204 ). As discussed above, the prefetch decision at step 204 is made by the prefetch prediction engine 122 using the prefetch prediction model 118 to determine if the benefits of prefetching the candidate are predicted to outweigh the costs, including energy usage associated with the prefetch operation. If the decision is to prefetch, the candidate is added to the prefetch queue (step 206 ). Optionally, the prefetch prediction engine may include queue pruning instructions for re-evaluating entries in the queue and flushing from the queue any entries in the queue deselected by the re-evaluating (step 208 ). For instance, the prefetch prediction engine may replace (at step 208 ) a least desirable entry in the prefetch queue with an entry for the candidate currently being processed.
[0058] In a preferred implementation, the prefetch queue is completely or partially flushed (at step 208 ) when the prefetch prediction engine determines that all or some of the queued prefetches are not likely to be useful. For example, such a flushing of the prefetch queue may be performed when an application in the client computer issues a request for an object that is not in the local cache, is not in the process of being demand fetched, and is not in the prefetch queue. If these conditions are satisfied (i.e., a miss occurs), then the entity (e.g., the prefetch prediction engine 122 ) that re-evaluates the prefetch queue (e.g., at step 208 , FIG. 5) may decide that some or all of the pending prefetch entries correspond to a “path”that the client is unlikely to follow, and that therefore these entries should be deleted. On the other hand, despite the miss, the prefetch prediction engine may nevertheless continue to predict that some of the items in the prefetch queue will be required in the future, in which case those items are not flushed from the prefetch queue. The items remaining in the prefetch queue are prefetched when the client computer system is able to schedule those items to be fetched.
[0059] After the current candidate has been processed and a decision has been made with regard to that candidate, the prefetch candidate filtering process resumes at step 200 .
[0060] The prefetch queue 130 may be reevaluated and modified (step 208 ) at any time prior to scheduling downloading of the files listed in the prefetch queue (step 214 ).
[0061] A scheduler 132 (FIG. 1) reads the entries in the prefetch queue 130 and demand fetch queue 128 and schedules the downloading of the files listed in those entries (step 214 ). Typically, entries in the demand fetch queue 128 are given higher priority by the scheduler than entries in the prefetch queue 130 . The files scheduled for downloading are fetched (step 216 ) in accordance with their scheduling for use by the client computer and/or for storage in the cache 134 for possible later use by the client computer.
Server Computer Prefetch Prediction
[0062] Referring to FIG. 6, a server computer system (server) 220 is shown in accordance with the present invention. The server computer system 220 includes memory 230 for storing applications executable by one or more central processing units 222 and data structures such files and the like. A network interface 224 allows communication through communications network(s) 140 with clients (client computer systems) 100 .
[0063] In one embodiment, memory 230 , which typically includes high speed random access memory as well as non-volatile storage such as disk storage, stores:
[0064] an operating system 232 , for providing basic system services;
[0065] a file system 234 , which may be part of the operating system;
[0066] application programs 236 ;
[0067] a server module 238 , for receiving and processing client requests, such as a request for a specified file;
[0068] a prefetch predictor 240 , for identifying files for possible prefetching by a client 228 ;
[0069] a prefetch efficiency model 242 ;
[0070] a prefetch hint pruner 244 , for utilizing the prefetch efficiency model to prune the set of identified files so as to improve energy efficiency in prefetching and to eliminate prefetches that the system decides, upon re-evaluation, are not likely to be requested by the client.
[0071] The interaction of the server module 238 , prefetch predictor 240 , prefetch efficiency model 242 , and prefetch hint pruner 244 is explained in more detail with reference to FIG. 8.
[0072] Referring to FIG. 7, the server-side prefetch efficiency model 242 in a preferred embodiment includes several types of parameters, such as transmission thresholds, accuracy statistics and so on. Some of the parameters in the server-side prefetch efficiency model 242 have values that change dynamically in accordance with changes in the operating environment of the server computer system. The prefetch efficiency model 242 preferably includes one or more of the following types of parameters for use by the server-side prefetch predictor 240 :
[0073] transmission thresholds 250 , for instance the maximum number of hints to send per reply, and the maximum size (in bytes) of hints to send per reply; and
[0074] prefetch accuracy statistics 254 (e.g., statistics received from one or more client computers).
[0075] In addition, the prefetch efficiency model 242 preferably includes one or more of the following types of parameters for use by the server-side prefetch pruner 244 :
[0076] client attribute parameters 256 , for instance parameters sent by the client from the client's prefetch prediction model;
[0077] network attribute parameters 258 , for instance the bandwidth and congestion level of the network connection between the server and each client with which it has a current client-server session; the network attribute parameters 258 enable the server's prefetch pruner to determine an estimated data transfer time for each prefetch candidate; and
[0078] a hint log 260 , for instance a log of the URLs or network addresses for which the server has sent prefetch hints to each client during a current client-server session; the log may also include a record of the files fetched by each client, and may further indicate the time that the files were fetched so as to enable the server to determine which of those files may be considered to be stale (i.e., beyond the allowed cache lifetime).
[0079] Referring to FIG. 8, server module 238 receives a request from client computer for a specified file. Prefetch predictor 240 , utilizing data provided by the server module 238 , identifies additional files for possible prefetching. Prefetch hint pruner 244 , before forwarding the additional files to the server module 238 , prunes the list of identified additional files in accordance with prefetch efficiency model 242 . The pruning consists of removing from the list references to one or more of the files that do not meet the requirements of the prefetch efficiency model 242 . The server module 238 then sends a reply to the client computer. The reply includes a content portion (see FIG. 2) containing the specified file and a supplemental portion containing prefetch hint information identifying at least one of the additional files.
[0080] Referring to FIG. 9, a request message 300 sent by a client to a server typically includes a header 301 and a body 304 . The header 301 stores information about the message, such as its destination and encoding. In one preferred embodiment, the header 301 also includes an additional field 302 for storing client hints. The client hints are a subset of the parameters of the client's prefetch prediction model, or parameters derived at least in part from the client's prefetch prediction model. For instance, the client hints 302 may include the client's costs for sending and receiving data bytes and packets and the client's threshold value for predicted prefetch probabilities. The body 304 of the request message contains the client request, such as the URL or network address of the document being requested by the client and parameters (if any) for specifying dynamic content to be produced by the server while responding to the client request.
Alternate Embodiments
[0081] In an alternate embodiment, the prefetch prediction model (client computer system, FIG. 1) or prefetch efficiency model (server computer system, FIG. 6) includes cost prediction parameters not based on energy usage or not solely based on energy usage. In this alternate embodiment, it is advantageous to reduce the monetary charges incurred by the client's network activity. For instance, the prefetch prediction model may include one or more parameters that take into account network usage charges associated with each packet or message transmission, or based on the number of bytes transmitted, without regard to the amount of energy used. In some implementations, the use of predictive prefetching may increase the monetary charges incurred by the client computer system. In these implementations the role of the prefetch prediction engine and prefetch prediction model are to ensure that only the most cost efficient prefetches are performed. One or more threshold parameters (e.g., a threshold probability that each prefetched file will be used by the client) in the prefetch prediction model are based on the amount of additional cost the client is willing to incur, on average, in exchange for the latency reduction obtained by prefetching files predicted to be needed by the client in the future.
[0082] In another alternate embodiment, a client computer system has multiple wireless network 10 interfaces (e.g., radios) that operate simultaneously, each having different energy/byte and latency/byte costs. In such an embodiment, the client computer system may be configured to use the wireless interface with the lowest energy/byte for prefetches of files that are not likely to be required by the client immediately or that are less likely to be used by the client, and to otherwise use a wireless interface with higher energy/byte costs (and presumably lower latency/byte).
[0083] The present invention can be implemented as a computer program product that includes a computer program mechanism embedded in a computer readable storage medium. For instance, the computer program product could contain the program modules shown in FIGS. 1 or 6 or both. These program modules may be stored on a CD-ROM, magnetic disk storage product, or any other computer readable data or program storage product. The software modules in the computer program product may also be distributed electronically, via the Internet or otherwise, by transmission of a computer data signal (in which the software modules are embedded) on a carrier wave.
[0084] While the present invention has been described with reference to a few specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications may occur to those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims.
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A computer system uses a prefetch prediction model having energy usage parameters to predict the impact of prefetching specified files on the system's energy usage. A prefetch prediction engine utilizes the prefetch prediction model to evaluate the specified files with respect to prefetch criteria, including energy efficiency prefetch criteria, and generates a prefetch decision with respect to each file of the specified files. For each specified file for which the prefetch prediction engine generates an affirmative prefetch decision, an identifying entry is stored in a queue. The computer system fetches files identified by entries in the queue, although some or all of the entries in the queue at any one time may be deleted if it is determined that the identified files are no longer likely to be needed by the computer system.
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CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to a wedge element to immobilize objects in a box of cardboard, corrugated or similar solid fiber material, with a square or rectangular cross-section, particularly for shipping and transportation of said objects, such boxes featuring a flat bottom of polygonal shape (generally rectangular or square) and four faces or side walls.
[0007] The technical domain of the invention is that of machinery for the manufacture, processing or closing of packaging materials and that of the manufacture and application of wedge materials for such packaging.
[0008] The present invention concerns more particularly a wedge element intended for being placed inside boxes used for the preparation and shipping of orders for single or multiple articles and more generally for boxes the content of which occupies a variable volume from one box to the next, and, most of the time, significantly less than the total volume of the box, in which case said wedging material serves to immobilize the items inside the useful volume of the box.
[0009] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
[0010] It is known that boxes of this type are created by machines from one or several flanks of pliable rigid sheeted material and that their upper part features various flaps and turned-down pieces assembled by gluing or adhesive tape or a lid fitted over said upper part. A characteristic of these boxes is that they offer a constant volume once they have been produced and closed.
[0011] Several means are applied by the users or are integrated into the box forming or closing machines to fasten by wedges the objects which vary by number and unit volume from one box to another.
[0012] One is familiar, for example with wedging means constituted by heat-shrinking plastic film where one or several layers are secured to the bottom or the side walls of the box during its shaping. After the box has been filled, these films are lowered onto the pile of objects and then retracted by passing through a heating tunnel.
[0013] Such a process presents several disadvantages. As a matter of fact:
this heat-shrink plastic film must necessarily be separated from the carton packaging prior to possible collection and recycling of the corresponding waste; this collection is a complex and very costly operation; this wedging material is itself expensive; its application is difficult and requires either complex automated machines or a great number of man-hours; the cost of these operations is therefore high.
[0017] Also known is the use of polystyrene particles or other light materials which are spread inside the box after insertion of the objects, in order to fill unused space.
[0018] Another fastening method consists of using inflatable plastic pockets which are placed inside the boxes to fill any unused space.
[0019] One is also familiar with the use of chips, particles, pelletized balls, . . . of paper, carton or wood which are put, in various forms, inside the boxes to fill unoccupied space between the objects.
[0020] Such production methods also present several disadvantages. As a matter of fact:
the distribution dosage of these wedging materials so they fill exactly the unused space is an operation that is difficult to automate which requires either complex automated machines or a great number of man-hours; the cost of these operations is therefore high; collection of these materials after opening the packaging requires a number of different elements and is thus an operation not easily taken care of by the end user.
[0023] And one is also familiar with wedging elements presenting themselves in the form of a sheet of cardboard, corrugated or equivalent solid fiber featuring a central part which is put into contact with the upper surface of the pile of objects placed inside the box and flexible flaps on at least two sides of the central part of the sheet which are turned down and fastened, for instance by gluing, against the inside face of the side walls of said box.
[0024] Such wedging elements are, for example, described in the document EP-1 197 436. Documents FR-2 828 169, DE-2 02 04 975, EP-1 452 453, EP-0 251 945, U.S. Pat. No. 6,216,871, FR-1 575 635, FR-919 469, U.S. Pat. No. 3,108,731, U.S. Pat. No. 2,883,046, and FR-2 770 447 illustrate other implementations of wedging elements of this type or the technological background.
[0025] The implementation of the wedging element described in document EP-1 197 436 presents numerous advantages:
This wedging element is not meant to fill up all the unused space inside the box; the quantity of material used is always the same and remains moderate, even when the previously packaged objects occupy only a very small portion of the volume of the box; This sheet can be made of a material similar to that used for producing the box itself, thereby greatly simplifying the recycling operations of the waste resulting from the elements constituting such a packaging. Placement and fastening of this sheet inside the box are mechanical operations which can be automated.
[0029] But the implementation of such a wedging element also presents some inconveniences.
[0030] As a matter of fact:
the flat central part of the wedging sheet must be sufficiently sturdy and rigid to resist the constraints involved in the transportation of the box and maintain in a stable manner the products contained in it; under these conditions, it is often necessary to exert considerable efforts to deform it so that the largest portion of its surface will be in contact with the upper surface of the pile of objects; these efforts are inevitably transmitted to some of these objects and may damage them, if some of them are fragile; when the lid of the box is removed, this wedging sheet constitutes an obstacle which prevents direct access to the packaged goods; for that this sheet needs to be torn away, but this operation is made difficult due to the absence of a grip area; to make this operation easier, it is known that the manufacturers usually put a plastic ribbon, called a pull strap, on the lower surface of box lids so as to facilitate opening of the lid by tearing the lid along the line created by this ribbon; the problem is that this pull strap can easily be put by the manufacturers only on the face of the lid on which grooves (also called channels) are made which mark the location of the folds of the flaps; on a lid, this face corresponds properly to the lower face; in the case of a wedging sheet as described, the face on which the grooves are made corresponds to the upper face of the wedge; it is thus not possible to easily place a pull strap on the bottom face of the wedge; the material used for producing such a wedging sheet is most often corrugated board; this material, constituted in its so-called “single flute” version by 3 layers of paper (two flat sheets enclosing a corrugated sheet), poses a particular problem due to its anisotropic character: in effect, the folding of the various flaps along the grooves positioned perpendicularly to the flutes of the material does not pose a particular problem, whereas the folding of the flaps along the grooves positioned parallel to the flutes of the material has a tendency to deviate from the theoretical folding line created by the groove for the benefit of a most often polygon folding line, corresponding to the smallest effort needed to fold the flap taking into account the positions of the waves of the flute in the folding zone; the result of this deviation is an incorrect wedge geometry with dimensions between the turned-down flaps which may vary by significant proportions (in the order of the thickness of the wedging sheet, which is to say several millimeters); the folding zone which connects the flaps to the central portion of the sheet is a zone of fragility; if special precautionary measures are not taken during the production of this wedge sheet, there exists a major risk of tearing of the material along this fold.
[0035] The problem at hand is therefore to provide a wedge in the form of a cardboard sheet, corrugated board or equivalent solid fiber material featuring a central portion which is put into contact with the upper surface of the pile of objects placed inside the box and flexible flaps, on at least two sides of the sheet, which are meant to be turned down and fastened, for example by gluing, to the internal face of the sidewalls of the box, this sheet:
must have a central portion that is sufficiently sturdy and rigid to resist the constraints during the transportation of the box and properly keep the product in these conditions, but must also be sufficiently pliable so that the largest portion of its surface can be put into contact with the upper surface of the pile of objects without exerting any major stress on these objects; must allow a precise folding of the flaps along the theoretical folding line at their articulation with the central portion of the sheet, without making this articulation overly fragile.
[0038] The device described in document FR-2 828 169 does not allow to efficiently resolve the problem previously described. This device is constituted by a plate made of a semi-rigid material, such as cardboard or corrugated board, comprising a polygonal central portion with at least two parallel sides that are articulated by folding lines, strips or flaps the sides of which that are opposite the side walls of the container or box containing the items to be shipped are provided with an adhesive enabling them to become integral with said walls. It is pointed out, incidentally, that the central portion features folding lines parallel to two of its parallel sides which make it possible to deform said plate to apply it to portions of different heights of mixed lots of items to maintain in position in the boxes. According to the implementation illustrated in FIG. 3 of document FR-2 828 169, the polygonal central portion of the wedge plate features only two folding lines or grooves parallel to its short sides. Said central portion features, on the other hand, two weakening lines close together parallel to its large sides, however, these are not folding lines but perforating lines associated with a pull strap provided with a tab or “snake head” for traction.
[0039] Such a layout of the wedge sheet does not resolve the problem of efficient wedging of unusually shaped objects.
[0040] As a matter of fact,
either the wedge sheet is made of material that is too rigid and, in this case: it cannot mold very closely the uneven upper surface of the pile of objects; it can exert significant pressure on said upper surface so that certain fragile objects may get crushed or damaged by this pressure. or the wedge sheet is made of too soft material and risks being split open if the score lines yield under the pressure, leading to the tearing of said wedge sheet as it is being pushed into the box.
BRIEF SUMMARY OF THE INVENTION
[0045] The solution to the problem at hand consists of creating a wedge allowing to block objects, in particular unusually shaped objects, in a box featuring a bottom and at least four faces or side walls connected to said bottom by folding lines or articulations, this wedge being constituted by a sheet of cardboard, corrugated board or other equivalent rigid and flexible material, featuring a central portion of polygonal shape, for example square or rectangular, of dimensions essentially equivalent to those of the bottom of the box, said central portion being attached, on at least two of its parallel sides to at least one and preferably several flexible flaps, by means of folding lines or articulations, said wedge being especially noteworthy in that its central portion features several grooves (also called channels and constituted by curved or straight segments along which the material is crushed and its thickness reduced), the two ends of which terminate at the periphery of said central portion and, preferably, at the ends of the articulations between the various flaps and said central portion or outside of said articulations, these grooves not being parallel to each other, nor to the long sides of the central portion of the wedge, nor to the short sides of said central portion.
[0046] According to an advantageous arrangement, the ends of the grooves terminate on two adjacent sides of the central portion of the wedge sheet.
[0047] Advantageously, when the material used is corrugated board or any other material with a corrugated sheet, the articulations which are parallel to the flute, between the various flaps and the central portion, are not contiguous but are preceded and succeeded by straight or curved segments belonging to the periphery of the central portion of said wedge and essentially tangent to said articulations.
[0048] Advantageously, when the material used is corrugated board or any other material with a corrugated sheet, the articulations which are not parallel to the flute (or, if the material is homogenous, all articulations), between the various flaps and the central portion, are not contiguous but are preceded and followed by straight or curved segments the ends of which are essentially tangent to the periphery of said flaps at the points of intersection with said articulations.
[0049] From these arrangements, it results that the wedge can be made of a sturdy rigid and resistant material but that it can nevertheless be deformed, without exerting a very great effort, by folding the material around grooves which have been made on the central portion of said wedge. In an advantageous implementation, said central portion features also a score for starting a tear (constituted by a succession of curved or straight segments along which the material is perforated over all or part of its thickness) which delimits a closed contour with small surface.
[0050] Advantageously, said central portion features also other perforations spread out over the surface of said central portion beginning at the small closed contour of the score for starting a tear.
[0051] These other perforations delimit tear tabs for obtaining, by simple traction, a large opening of the central portion of the wedge, thus giving access to the articles located inside the box.
[0052] Advantageously, when the material used is corrugated board or any other material with a corrugated sheet, the articulations which are parallel to the flute, between the different flaps and the central portion, are characterized by the superposition of a groove, and, on at least a portion of the articulation, of a perforation, without these perforations reaching the end of said articulations.
[0053] It ensues also that it is possible to proceed to the opening of the wedge by removing material located inside of the closed contour with a small surface; this removal can be made by pushing said material in or by tearing it out.
[0054] It is then possible to proceed to the removal of a large part of the central portion of said wedge by tearing up the material along the score lines which are spread out over the surface of said central portion and that it is thus possible to easily access the objects which had previously been placed inside the box.
[0055] It follows, on the other hand, that the flaps which are connected to the possibly present flute, can be easily and precisely turned down along the perforations which have been made at said articulations, in the alignment of the periphery of said central portion, but that these articulations are not overly made brittle to the extent that the end of said perforations is distanced from the end of said articulations.
[0056] And it also follows that the articulations which are not perpendicular to the flute (or, if the material is homogenous, all the articulations) between the flaps and said central portion are not made brittle to the extent where the end of said articulations is not tangential to the periphery of the material.
[0057] Thus, thanks to the invention, one has at one's disposal a wedge for perfectly immobilizing, in a stable manner, the objects inside the box, without exerting a high constraint on said objects and while producing an ecological packaging which can be easily recycled after use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] The advantages obtained by this invention will be better understood through the following description which refers to the attached drawings illustrating, without being in any way limiting, a particular implementation of a wedge according to the invention.
[0059] FIG. 1 is a perspective view of an empty box usable for wedging objects with a wedge according to the invention, shown without its lid.
[0060] FIG. 2 is a perspective view of a wedging element according to the invention, before use.
[0061] FIG. 3 is a perspective view of a wedge according to the invention, the flaps of which have been turned down before its insertion in the box to wedge objects.
[0062] FIG. 4 is a plan view, with partial removal, of a wedge according to the invention.
[0063] FIGS. 5 , 6 , 7 , and 8 are detail and plan views of four different zones of a wedge according to the invention.
[0064] Reference to said drawings is made to describe an advantageous, although by no means limiting, example of production of a fastening wedge of the objects placed in a box, according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0065] FIG. 1 shows a type of box 1 which is composed of a bottom 1 e and of four side walls 1 a , 1 b , 1 c , and 1 d , this type of box being in current use for shipping parcels containing various articles of different shapes which, when placed in the box, may present a very uneven upper surface.
[0066] According to the example shown, the bottom 1 e has a rectangular shape so that the box provided with this bottom has the shape of a parallelepiped rectangle. It is shown that, according to this example, the side walls 1 a and 1 c are parallel to the width of the box 1 and that the side walls 1 b and 1 d are parallel to the length of the box 1 .
[0067] It is emphasized that the bottom and the side walls could have a different shape, for example a square shape or a generally square or rectangular shape with cut angles.
[0068] This box 1 may be produced of solid fiber, corrugated board or any other equivalent sheeted material presenting the required qualities of rigidity and folding possibilities.
[0069] FIG. 2 shows a wedge produced according to the invention. Said wedge 2 features a central portion 2 k of shape and dimensions essentially equivalent to those of the bottom 1 e of the box 1 , so it can slide without any notable play between the side walls of said box when it is pushed into the latter. Said wedge 2 also features flexible flaps 2 a , 2 b , 2 c, 2 d , 2 e , 2 f , 2 g , 2 h , 2 i , and 2 j.
[0070] Said wedge 2 may be constituted by a rigid sheet made of rigid and deformable board, corrugated board or of any other equivalent sheeted material identical or not to that of which the boxes are made that are likely to receive such a wedging element.
[0071] Shown are the articulations of the flaps constituted by grooves or channels 3 a , 3 b , 3 c, 3 d , 3 e , 3 f , 3 g , 3 h , 3 i , and 3 j which connect said flaps to said central portion. Also shows are grooves 4 a , 4 b , 4 c, 4 d , 4 e , 4 f , 4 g , 4 h , 4 i , and 4 j that said flaps are equipped with, parallel to said articulations. It is known that said grooves 4 a , 4 b , 4 c, 4 d , 4 e , 4 f , 4 g , 4 h , 4 i , and 4 j constitute folding lines which allow reducing the surface of said flaps that is applied against the inside face of said four side walls for the benefit of the surface put into contact with said pile of objects when it is not plane and has therefore a surface larger than that of said central portion 2 k.
[0072] FIG. 3 shows said wedge 2 made according to the invention, constituted by the central portion 2 k and the flexible flaps 2 a , 2 b , 2 c, 2 d , 2 e , 2 f , 2 g , 2 h , 2 i , and 2 j . On this figure, said flaps have been turned upward around said articulations 3 a , 3 b , 3 c, 3 d , 3 e , 3 f , 3 g , 3 h , 3 i , and 3 j.
[0073] Shown are glue lines 5 c , 5 d , 5 e , 5 f , and 5 g , deposited respectively of the outside face of said flaps 2 c, 2 d , 2 e , 2 f , and 2 g , intended to be applied against the side walls of the box, when the wedge element has been pushed into the latter.
[0074] It is clear that glue lines or points (not shown) are also deposited on said flaps 2 a , 2 b , 2 h , 2 i , and 2 j.
[0075] It is known that after insertion of said wedge 2 in the box 1 , [after] putting said wedge in contact with said pile of objects positioned in said box, and deformation of said wedge 2 to optimally adapt to the shape of the upper face of said pile of objects, said flaps find themselves turned down and flattened against the inside face of the side walls 1 a , 1 b , 1 c , and 1 d of said box 1 .
[0076] It is also known that there are means other than gluing to firmly attach said flaps to said side walls, such as stapling, fitting material parts into each other or any other means to obtain an equivalent result.
[0077] FIG. 4 also shows said wedge 2 produced according to the invention, and shown in the flat, before folding and raising the peripheral flaps.
[0078] One sees the central portion 2 k and the flexible flaps 2 a , 2 b , 2 c, 2 d , 2 e , 2 f , 2 g , 2 li , 2 i , and 2 j connected to said central portion 2 k by means of the articulations 3 a , 3 b , 3 c, 3 d , 3 e , 3 f , 3 g , 3 h , 3 i , and 3 j.
[0079] According to a first characteristic arrangement of the invention, the central portion 2 k of the sheet features a plurality of grooves 6 a , 6 b , 6 c , 6 d constituted by curved and straight segments along which the material the sheet is made of, is crushed and its thickness reduced. The two end or each groove 6 a , 6 b , 6 c , 6 d end at the periphery or in proximity of the periphery of said central portion 2 k of said sheet; on the other hand, the two ends of this groove or of each groove end, preferably, at the end of the articulations 3 a , 3 b , 3 c, 3 d , 3 e , 3 f , 3 g , 3 h , 3 i , and 3 j between said flexible flaps and said central portion 2 k , or outside of said articulations.
[0080] According to the invention, the grooves 6 a , 6 b , 6 c , 6 d are not parallel to each other, nor to the sides of the central portion 2 k of the sheet 2 (in the case of a central portion of square shape), nor with the long sides of the central portion 2 k of the plate 2 , nor with the short sides of said central portion (in the case of a central portion of rectangular shape).
[0081] According to an advantageous arrangement, the two ends of each groove 6 a , 6 b , 6 c , 6 d end on two adjacent sides, respectively 3 j - 3 i - 3 h 3 g - 3 f ; 3 g - 3 f 3 e - 3 d - 3 c ; 3 e - 3 d - 3 c 3 b - 3 a ; 3 b - 3 a 3 j - 3 i - 3 h , of the central portion 2 k of the wedge 2 .
[0082] The two ends of each groove 6 a , 6 b , 6 c , 6 d end at the ends of the articulations 3 a , 3 b , 3 c , 3 d , 3 e , 3 f , 3 g , 3 h , 3 i , 3 j between the flexible flaps and the central portion, or outside of said articulations.
[0083] Said groove 6 a has one end essentially merged with one of the ends of said articulations 3 d and 3 e of said flaps 2 d and 2 e and its other end terminates between the ends of said articulations 3 f and 3 g of said flaps 2 f and 2 g and away from the ends of two successive articulations. Likewise, said groove 6 b has one end which terminates between the ends of said articulations 3 f and 3 g of said flaps 2 f and 2 g and away from the ends of said successive articulations and its other end is essentially merged with one of the ends of said articulations 3 h and 3 i of said flaps 2 h and 2 i , said groove 6 c has one end essentially merged with of the ends of said articulations 3 i and 3 j of said flaps 2 i and 2 j and away from the ends of said successive articulations and its other end terminates between the ends of said articulations 3 a and 3 b of said flaps 2 a and 2 b , and said groove 6 d has one end which terminates between the ends of said articulations 3 a and 3 b of said flaps 2 a and 2 b and away from the ends of said successive articulations and its other end essentially merged with one of the ends of said articulations 3 c and 3 d of said flaps 2 c and 2 d.
[0084] It is understood that the grooves 6 a , 6 b , 6 c , and 6 d constitute folding lines for said central portion 2 k , which facilitate the deformation of said wedge 2 which can assume a large variety of shapes in order to conform optimally to the shape of the upper surface of said pile of objects, in particular when said wedge is made of a sturdy and rigid material.
[0085] As indicated previously, the central portion 2 k of the sheet could feature channels of diverse shapes adapted to specific articles to be expedited and shipped in the boxes.
[0086] One also sees, on FIG. 4 , the score 7 , in the form of a non-circular ring. This score 7 is constituted by a succession of straight or curved segments along which the material is scored over all or part of its thickness. Said score 7 delimits a closed contour of small surface. One understands that the portion of material included in this closed contour is attached to said central portion 2 k but can easily be detached from said central portion 2 k by pushing said material in or by tearing it out.
[0087] One also sees on FIG. 4 the score groups 8 a , 8 b , 8 c , and 8 d . One understands that, when the portion of material included in the closed contour delimited by said score 7 has been detached, it is possible to open said central portion 2 k , by exerting traction beginning at the opening caused by tearing away the portion of material delimited by the score 7 , so as to detach and lift the material tabs 14 a , 14 b , comprised between the pairs of score 8 a , 8 b and 8 c , 8 d , and thereby to open a large part of the central portion 2 k , one now has easy access to the articles previously placed in the box.
[0088] One also sees, on FIG. 4 , the zones A, B, C, and D. These zones of said wedge 2 are shown in greater detail on FIGS. 5 , 6 , 7 , and 8 , respectively.
[0089] Finally FIG. 4 shows zone E. In the particular presentation mode shown by FIG. 4 , the material used for the creation of said wedge 2 consists of corrugated board or another material integrating an undulated sheet. Said zone E shows a “peel-away” view of said wedge 2 which reveals the flute of said material.
[0090] One sees that in the particular presentation mode of FIG. 4 , the articulations 3 a , 3 b , 3 f , and 3 g are parallel to the flutes 15 of the corrugated board sheet, whereas the articulations 3 c, 3 d , 3 e , 3 h , 3 i , and 3 j are perpendicular to said flutes 15 .
[0091] FIG. 5 shows in detail zone A of said wedge 2 produced according to the invention. This figure shows the central portion 2 k and the flexible flap 2 f . FIG. 5 also shows the articulation 3 f which connects said flap 2 f to said central portion 2 k.
[0092] It is known that said articulation 3 f is parallel to the flute of the material used for the creation of said wedge 2 when it is made of corrugated board, and FIG. 5 also shows that said articulation 3 f is constituted by the superposition of a groove 9 f and a score 10 f , itself constituted by a succession of straight segments along which the material has been scored over all or part of its thickness.
[0093] One understands that the articulations 3 a , 3 b , and 3 g , parallel to the flute of the material used for the creation of said wedge 2 , are themselves constituted by the superposition of a groove and a score.
[0094] FIG. 6 shows in detail zone B of said wedge 2 created according to the invention. FIG. 6 shows the central portion 2 k and the flexible flap 2 j . FIG. 6 also shows the articulation 3 j which connects said flap 2 j to said central portion 2 k . FIG. 6 also shows the flexible flap 2 a and the articulation 3 a which connects said flap 2 a to said central portion 2 k.
[0095] FIG. 6 also shows point 11 ja which corresponds to one of the angles of the rectangle formed by said central portion 2 k in the particular representation mode shown. One sees that said point 11 ja is located at the intersection of the straight lines aligned on said articulations 3 j and 3 a . The same is true with respect to the angles of the rectangle located respectively at the intersection of the straight lines aligned on said articulations 3 b and 3 c , 3 e and 3 f , and 3 g and 3 h.
[0096] FIG. 6 also shows the point 3 ja which corresponds to one of the two ends of articulation 3 j . Then again, one knows that said articulation 3 j is perpendicular to the flute of the material used for the creation of said wedge 2 .
[0097] FIG. 6 also shows the curved segment 13 ja which belongs to the periphery of said central portion 2 k . The characteristic of said segment 13 ja is that it is tangential to the periphery of said flexible flap 2 j at point 3 ja . One realizes that thanks to this characteristic said articulation 3 j is prevented from becoming brittle by the creation of a starting point of a fracture at point 3 ja . One understands that other curved segments similar to segment 13 ja are likewise tangents to the periphery of said flexible flaps 2 c , 2 e , and 2 h.
[0098] FIG. 6 also shows that said articulation 3 a is constituted by the superposition of a groove 9 a and a score 10 a.
[0099] FIG. 6 also shows the point 3 aj which corresponds to one of the two ends of the articulation 3 a.
[0100] It should also be remembered that according to one implementation said articulation 3 a is parallel to the flute of the material used for the production of said wedge 2 .
[0101] FIG. 6 also shows the straight segment 12 aj which belongs to the periphery of said central portion 2 k . A characteristic of said segment 12 aj is that it is tangential to said articulation 3 a at the point 3 aj . It is clear that this characteristic facilitates the folding of said flap 2 a along said groove 9 a and said score 10 a beginning at point 3 aj.
[0102] It is clear that other straight segments similar to segment 12 aj are, likewise, tangential to said articulations 3 b , 3 f , and 3 g.
[0103] FIG. 7 shows in detail the zone C of said wedge 2 produced according to another implementation of the invention. This figure shows the central portion 2 k and the flexible flap 2 a . FIG. 7 also shows the articulation 3 a constituted by the superposition of the groove 9 a and the score 10 a which connects said flap 2 a to said central portion 2 k . FIG. 7 also shows the flexible flap 2 b and the articulation 3 b constituted by the superposition of the groove 9 b and the score 10 b which connects said flap 2 b to said central portion 2 k.
[0104] It should also be remembered that said articulations 3 a and 3 b are parallel to the flute of the material used for the production of said wedge 2 .
[0105] FIG. 7 also shows the grooves 6 c and 6 d made on said central portion 2 k and it can be seen that the ends of said grooves 6 c and 6 d are located in the same zone as the end 3 ab of the articulation 3 a and as the end 3 ba of the articulation 3 b , but outside of said articulations.
[0106] FIG. 7 also shows the straight segment 12 ab which belongs to the periphery of said central portion 2 k . The characteristic of said segment 12 ab is that it is tangential to said articulation 3 a , at point 3 ab , and to be also tangential to said articulation 3 b , at point 3 ba . It is clear that this characteristic facilitates the folding of said flap 2 a along said groove 9 a and said score 10 a , beginning at point 3 ab as well as folding of said flap 2 b along said groove 9 b and said score 10 b , beginning at point 3 ba.
[0107] It is clear that another straight segment similar to segment 12 ab is, likewise, tangential to articulations 3 f and 3 g.
[0108] FIG. 8 shows, in detail, the zone D of said wedge 2 produced according to another example of implementation of the invention. This figure shows the central portion 2 k and the flexible flap 2 h . FIG. 8 also shows the articulation 3 h which connects said flap 2 h to said central portion 2 k . FIG. 8 also shows the flexible flap 2 i and the articulation 3 i which connects said flap 2 i to said central portion 2 k.
[0109] It should also be remembered that said articulations 3 h and 3 i are perpendicular to the flute of the material used for the production of said wedge 2 .
[0110] FIG. 8 also shows the groove 6 b made on said central portion 2 k and it shows that the end of said groove 6 b is situated in the same zone as the end 3 hi of the articulation 3 h and as the end 3 ih of the articulation 3 i , but outside of said articulations.
[0111] FIG. 8 also shows the curved segment 13 hi which belongs to the periphery of said central portion 2 k . It is characteristic of said segment 13 hi to be tangential to the periphery of said flexible flap 2 h at point 3 ih . One realizes that thanks to this characteristic said articulations 3 h and 3 i are prevented from becoming brittle by the creation of a starting point of a fracture at points 3 hi and 3 ih.
[0112] It is clear that other curved segments similar to segment 13 hi are, likewise, tangential to the periphery of said flexible flaps 2 i and 2 j, 2 c and 2 d , and 2 d and 2 e.
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A wedge used to wedge objects in a box the wedge being a sheet made of a rigid, resistant and foldable material, including a central portion having a polygonal shape and size substantially equivalent to those of the bottom of the box, the sheet including at least one foldable flap, attached to the central portion via folding lines or hinges, wherein the central portion is provided with multiple grooves being segments of a curve or of a straight line, along which the material is crushed and the thickness thereof is reduced, the grooves constituting folding lines inside the central portion, which facilitate the deformation of the wedge, the grooves leading to the periphery or the proximity thereof of the central portion of the wedging sheet and they are not parallel to one another or to the sides of the central portion.
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The U.S. Government has rights in this invention pursuant to Contract No. F08635-77-C-0173 awarded by the United States Air Force.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to mechanisms for locking and actuation of the firing pins of gun bolts in automatic guns, such as Gatling type guns, and, more particularly, to such mechanisms in gun bolts where the bolts are locked by cammed locking lugs.
2. Description of the Prior Art
The use of cammed locking lugs to lock gun bolts to gun barrels is well known, and is shown, for example, in "The Machine Gun" by G. M. Chinn, Vol. IV, Parts X and XI, pp. 371, 384, 385, Dept. of the Navy, 1955. Therein are shown for example: "FIG. 6-76-Locking Rollers Are Cammed Free of Barrel Extension by Rails in Receiver." "FIG. 6-89 [and 6-90]-Recoiling Barrel Extension Cams Lugs Free of Bolt." In U.S. Pat. No. 3,608,427 issued Sept. 28, 1971 to R. H. Colby, there is shown a gun bolt which is locked by lugs which are nested in pockets in the recoiling gun barrel extension and which are swung out to lock the gun bolt by cam followers which ride in a stationary cam track. In U.S. Pat. No. 3,603,201, issued Sept. 7, 1971 to A. J. Aloi there is shown a firing pin in a drop lock type gun bolt in a Gatling type gun which is actuated by an aft annular cam. In U.S. Pat. No. 4,295,410, issued Oct. 20, 1981 to R. A. Patenaude et al there is shown a gun bolt in a Gatling type gun which is locked by locking lugs which are operated by a slide which is controlled by a supplemental annular cam.
BRIEF DESCRIPTION OF THE INVENTION
It is an object of this invention to provide a mechanism for precluding projection of the firing pin of a gun bolt forward of the face of the gun bolt when the gun bolt is not in its locked position.
A feature of this invention is the provision of a gun bolt having a firing pin which is movable to and between an aft disposition whereat the forward end of said pin is aft of the face of the gun bolt and a forward disposition whereat said forward end is forward of said face, locking means movable to and between a locked disposition whereat said gun bolt is locked to fixedly close the chamber of the gun and an unlocked disposition, and intermediate means responsive to the disposition of said locking means for locking said pin in its aft disposition when said locking means is not in its locked disposition.
BRIEF DESCRIPTION OF THE DRAWING
These and other objects, features and advantages of the invention will be apparent from the following specification thereof taken in conjunction with the accompanying drawing in which:
FIG. 1 is a perspective view of a portion of a gun bolt of the type shown in U.S. Pat. No. 4,294,158, issued Oct. 13, 1981 to R. A. Patenaude et al, which is improved by the incorporation of an embodiment of this invention;
FIG. 2 is a top view of the gun bolt of FIG. 1 showing the gun bolt unlocked;
FIG. 3 is similar to FIG. 2 but showing the gun bolt partially locked;
FIG. 4 is similar to FIG. 3 but showing the gun bolt fully locked;
FIG. 5 is a partial detail view in transverse cross-section showing the locking slide captured to the body of the gun bolt;
FIG. 6 is partial detail view in longitudinal cross-section showing the wing lock in elevation as nested in the pocket in the rotor;
FIG. 7 is a partial detail view in transverse cross-section showing the gun bolt journaled in the rotor;
FIG. 8 is a partial detail view in longitudinal cross-section showing the cam follower and detent mechanism of the locking slide;
FIG. 9 is a top view in partial cross-section of the gun bolt of FIG. 1 showing a portion of the firing pin mechanism and the gun bolt unlocked;
FIG. 10 is similar to FIG. 9 but showing the gun bolt partially locked;
FIG. 11 is similar to FIG. 10 but showing the gun bolt fully locked;
FIG. 12 is a detail view in side longitudinal cross-section of the gun bolt showing a portion of the firing pin mechanism;
FIG. 13 is a detail view in front cross-section of the gun bolt showing a portion of the firing pin mechanism; and
FIG. 14 is a detail side view of the gun bolt with locking lug removed.
DESCRIPTION OF THE INVENTION
This invention is incorporated in a gun bolt of the type shown in U.S. Pat. No. 4,294,158, issued Oct. 13, 1981 to R. A. Patnaude et al, which in turn is incorporated in a gun of the type having a small diameter rotor shown in U.S. Pat. No. 3,834,272 issued Sept. 10, 1974 to R. A. Patenaude et al and U.S. Pat. No. 4,114,511 issued Sept. 19, 1978 to R. A. Patenaude. Of course, the invention has utility in other gun bolts in other guns.
The gun bolt embodying this invention as shown in FIG. 1 includes a bolt body 10 and a slide 12. As shown in FIG. 5, the body has, in part, a T-shaped cross-section wherein the ends of the "T" provide rails 14 and the slide has a pair of depending and inward-going sides 16 encircling the rails to capture the slide to the body while permitting longitudinal relative motion. There are a plurality of gun bolts, e.g., three, one for each gun barrel 17. The gun barrels are fixed to the rotor 18 which is journaled for rotation in a housing 19, and each gun bolt is journaled for longitudinal reciprocation in a respective channel 20 in the rotor, as shown in FIG. 7. As is well known, the rotor in a Gatling type gun serves as a receiver.
Each of a symmetric pair of locking lugs 22 is nested in a respective recess 24 in the rotor 18 adjacent the channel 20. A pin 26, which passes through a bore 28 in the lug 22 into a blind bore 30 in the rotor, pivotally captures the lug in the rotor.
Each gun bolt body 10 has a stud 32 fixed thereto on which is journaled a cam follower roller 34 which rides in a cam track 36 formed in the interior wall of the housing 19, and which cam track serves to reciprocate the bolt fore and aft as the rotor revolves about its longitudinal axis. The rotor may be driven by appropriate means, such as an external drive, as shown in U.S. Pat. No. 3,834,272, supra. Each slide 12 has a stud 38 fixed thereto on which is journaled a cam follower roller 40 which rides in a cam track 42 formed in the interior wall of the housing, and which cam track serves to reciprocate the slide relative to its respective gun bolt, as the assembly of the gun bolt and the slide reciprocates relative to the rotor. The cam track 42 is not continuous, but rather is provided only where necessary to provide relative movement between the slide and the bolt body. A detent mechanism is provided to hold the slide and the bolt body against relative movement. A plunger 43 is disposed in a blind bore 43a and is biased outwardly by a helical compression spring 43b. The plunger has a main body portion 43c of relatively large diameter and a cam follower portion 43d of relative smaller diameter. The follower portion clears and passes through a slot 43e in the slide. The body portion 43c will seat in either of two cups 43f or 43g in the slot, and when so seated, locks the slide of the bolt body. The plunger is withdrawn from either cup by means of a cam surface 43h depressing the follower against the bias of the spring.
Each of a symmetric pair of actuator lugs 44 is pivotally captured to the slide 12 by a respective pin 46 and nested within a respective recess 48 into the side of the gun bolt body 10. Each recess 48 has a respective ramp surface 50, which serves to cam the distal end of the lug 44 outwardly when the slide 12 is moved aft relative to the gun bolt body 10. As the distal end of the lug 44 moves outwardly it abuts a cam following surface 51 of the aft end 52 of the adjacent locking lugs 22 which is journaled on pivot 26 in the rotor and swings said aft end 52 outwardly and, thereby, the forward end 54 of the locking lug inwardly. As the forward end 54 swings inwardly, it enters a recess 55 in the bolt body aft of the head 56 of the bolt. This recess has an aft facing surface 58 which receives the forward facing and end surface 60 of the locking lug. Thus pressure against the face of the head 56 of the bolt body 10 is transmitted across the surfaces 58 and 60, through the locking lugs 22, to an arcuate surface 61 of the rotor 18.
Each of the pair of locking lugs 22 also has a respective stud 62 fixed to the forward end. The forward end of the slide 12 has a pair of somewhat arcuate slots 64 cut into its underface. As the slide 12 progressively moves aft, the lugs 44 progressively swing out, the lug aft ends 52 progressively move out, and the lug forward ends 54 progressively move in and the lugs 62 progressively enter into the respective arcuate slots 64. When the slide 12 is fully aft, the lugs 62 are fully into the blind forward ends of the slots, so that the slide precludes any pivotal movement of the locking lug.
Thus the slide 12 which is controlled by its cam follower 40 in the cam track 42, not only drives the locking lugs into their bolt locking configuration by means of the ramp surfaces 50 and the actuator lugs 44, but also captures the locking lugs in their bolt locking configuration by means of the arcuate slots 64, so that any possibility of unlocking movement of the locking lugs at the time of firing is precluded.
The slide also has a symmetric pair of shoulders with respective ramp surfaces 66, which project into respective recesses 67 in each locking lug 22. Each recess has a cam following surface 68, and as the slide moves forwardly on the bolt body, the ramp surface 66 engages the surface 68 to cam the locking lugs outwardly, while concurrently the cut out 64 clears the stud 62.
A stud 70 is integral with the body of the gun bolt and has a cross bar having two ends 72 which overlie an upwardly facing surface 74 of the slide. These overlying ends preclude any possible upward movement of the slide which might otherwise tend to permit disengagement of the studs 62 from the arcuate slots 64.
A firing pin 100 is disposed in a longitudinal bore 102 in the gun bolt body 10. A cocking lever 104 passes through a radially extending slot 106 in the aft end of the body 10 and is fixed to the aft end of the firing pin. The cocking lever rides on the cam surface 108 of an annular firing cam 110 which has a low or forward uncocked level 112, a ramp or cocking level 114, an up or aft cocked level 116, and a firing drop off 118. A helical firing spring 120 is disposed on the firing pin and is compressed and released by the operation of the cocking lever.
The firing pin has a substantially conical head 122 which is adapted to pass through a reduced opening 124 into the face 126 of the head 56 of the gun bolt. The pin has a portion 126a of reduced diameter which provides a forward facing annular shoulder 128. A pair of retainer lugs 130 are disposed in a cross-slot 132 formed in the bolt body and extending between the recesses 55. Each lug 130 is pivotally mounted to the body by a pin 134 passing through respective bores in the bolt body. Each lug 130 also has a cam follower pin 136 projecting therefrom. The forward underside portion of the slide 12 has a part of stepped cam surfaces 140, 142, 144, for driving the respective pins 136. The forward ends of the retainer lugs 130 are normally biased apart by a helical compression spring 146 whose ends project into blind bores 148 in the lugs 130. The aft ends of the lugs, which have respective curved surfaces to straddle the reduced portion 126a of the firing pin, are thus normally biased together and abut the forward facing shoulder 128 of the firing pin, thereby precluding forward movement of the firing pin. When the slide 12 is forward relative to the bolt body, in the bolt unlocked disposition shown in FIG. 9, the part of inner cam surfaces 144 respectively abut the pair of cam follower pins 136, and holds the part of retainer lugs 130 in their firing pin blocking disposition. When the slide 12 is aft relative to the bolt body, in the bolt locked disposition shown in FIG. 11, the cam surfaces 144 are clear of the pair of cam follower pins 136, but the spring 146 would continue to bias the aft ends of the retainer lugs together. However, when the forward ends 54 of the bolt locking lugs 22 are each present and are swung inwardly into their bolt locking disposition, they respectively abut the forward ends of the retainer lugs 130 and cam them together against the bias of the spring 146, so that the aft ends of the retainer lugs 130 clear the annular shoulder 128 and the firing pin is free to move forward under the control of the cocking lever 104 and the spring 120. If both locking lugs 22 are not present and swung into their bolt locking dispositions, the retaining lugs will not both be released from the annular shoulder 128, and the firing pin will be blocked from camming forward and projecting forward of the face of the gun bolt, irrespective of the action of the cocking lever and the main spring.
While the invention has been shown embodied in a Gatling type gun, it will be obvious that it has application to single barrel guns wherein the gun bolt is driven by rotating drum cam, such as is shown in U.S. Pat. No. 1,786,207 issued to R. F. Hudson on Dec. 23, 1930. In such case the two cam tracks 36 and 42 will be formed on the drum cam, rather than on the housing, and the gun bolt assembly will reciprocate in the receiver. In either case relative motion is provided between the cam tracks and the gun bolt assembly.
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A feature of this invention is the provision of a gun bolt having a firing pin which is movable to and between an aft disposition whereat the forward end of said pin is aft of the face of the gun bolt and a forward disposition whereat said forward end is forward of said face, locking means movable to and between a locked disposition whereat said gun bolt is locked to fixedly close the chamber of the gun and an unlocked disposition, and intermediate means responsive to the disposition of said locking means for locking said pin in its aft disposition when said locking means is not in its locked disposition.
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BACKGROUND OF THE INVENTION
The present invention relates to a self service terminal, such as an automated teller machine (ATM).
At present self service terminals often comprise two separate interfaces: a data entry keyboard and a display screen for displaying instructions or information to a user. The keyboard has a fixed number of keys with the character or characters that each key represents printed on them. Thus, keyboards are manufactured to a specified layout and if a different keyboard layout is required then there would have to be changes in the manufacturing process. Also a disabled person may have difficulty in operating such a terminal, particularly if such a person is visually impaired or has limited use of upper limbs.
It is known that each key of a keyboard can comprise a light emitting diode (LED) or a liquid crystal display (LCD) mounted on its top face whereby the character displayed can be varied. For example, a letter on a key may be changed from upper case to lower case.
It is also known for self service terminals to employ touch screens in which areas on the screen act as keys if they are touched. However, some users find it difficult to key in information on a touch screen since the user does not get a positive tactile response.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a self service terminal having improved user interface means for alleviating the problems referred to above.
According to the present invention there is provided a self service terminal including a central processing unit (CPU) connected to a keyboard incorporating a plurality of separate, individually operable keys whose user engagable surfaces are arranged in a two-dimensional array, each key incorporating an LCD, characterized by the image displayed by each LCD being changeable under the control of said CPU, whereby said keyboard also serves as a display means for the terminal.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of an ATM adapted to be in accordance with the invention;
FIG. 2 is a block diagram representation of the ATM of FIG. 1; and
FIGS. 3 to 5 are views of the keyboard at the ATM showing typical displays which are provided by the keyboard at different stages of an ATM transaction.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2, there is shown therein an ATM 10 having a CPU 12 connected to a conventional card reader 14, cash dispenser 16 and receipt printer 18, and to a keyboard 20 in accordance with the invention which, as will be described in more detail later, serves both as a data entry means and as a display means for displaying instructions and information to a user of the terminal.
The module comprising the card reader 14, the cash dispenser 16 and the receipt printer 18 are respectively associated with slots which are provided in a front panel 22 of the ATM 10 and which in FIG. 1 have the same reference numerals as the respective modules. Thus, the card reader 14 has a card slot through which a user can insert a user's identifying card at the commencement of a transaction to be conducted by the user. The cash dispenser 16 has a cash slot through which currency notes stored inside the dispenser 16 can be delivered to the user during the transaction. The printer 18 has a slot through which an account statement may be delivered to the user or through which a receipt in respect of the transaction is delivered to the user at the termination of the transaction.
Turning now to FIGS. 3 to 5, the keyboard 20 comprises a plurality of separate individually operable user engagable surfaces 24 arranged in a two-dimensional array. Any selected user engagable surface 24 can be operated in a conventional manner by pressing it down. In the particular embodiment described, the keyboard 20 comprises an array of seventy-seven (11 by 7) individual user engagable surfaces 24, but it should be understood that if desired a different number of user engagable surfaces 24 could be provided. Each user engagable surface 24 is formed by an LCD, the image displayed by the LCD being controlled by the CPU 12. These LCDs are used to display text, characters, or other images to a user of the ATM 10. Thus, no separate display means such as a monitor is required.
The LCD forming each user engagable surface 24 can display a single character. It can also display part of an overall image where this image is displayed across a plurality of user engagable surfaces 24 with the CPU coordinating what is shown by adjoining user engagable surfaces 24. The image may, for example, be a picture, some text or a combination of both.
FIG. 3 shows the display on keyboard 20 at the commencement of an ATM transaction. Thus, the keyboard 20 displays instructions to the user to insert his bankers card into the card reader 14. Note that the top two rows of user engagable surfaces 24 display a text instruction, whereas the LCDs of the rest of the user engagable surfaces 24 are coordinated to display an image of a card being inserted into the card slot of the card reader 14 by a human hand.
Even though the edges of the user engagable surfaces 24 are not contiguous, but spaced, the image is sufficiently coordinated to be clear.
Next, as shown in FIG. 4, instructions appear on the keyboard 20 display for the user to enter his or her personal identity number (PIN). At the same time, twelve of the user engagable surfaces 24 not involved in displaying instructions now appear as a conventional data entry keyboard, these user engagable surfaces 24a-l respectively displaying the digits 1 to 0 and CANCEL and ENTER. Note, for example, that user engagable surface 24d displays the number "4". Thus, if user engagable surface 24d is pressed the CPU 12 records that the number "4" has been entered as part of the PIN.
The twelve user engagable surfaces 24a-l which appear as a conventional data entry keyboard are highlighted to indicate that they can be pressed. This highlighting is done by making them visually different from the rest of the user engagable surfaces, especially those which are displaying text or an image. For example, the background color of these twelve user engagable surfaces 24a-l may be white whereas the background color of the rest of the user engagable surfaces may be black. Thus, it is obvious to the user which user engagable surfaces he can press in order to indicate his response to instructions displayed where in this case his response is to key in his PIN.
Thus, it can be seen that if a user engagable surface 24d highlighted to be pressed is pressed, the CPU 12 will perform a function associated with the image displayed. It is also possible for the same user engagable surface 24d to be subsequently highlighted to be pressed with a different image displayed, so that if this same user engagable surface 24d is pressed the CPU 12 will now perform a different function.
After the correct PIN is entered, menus are displayed by the keyboard 20 to enable the user to carry out a desired transaction. A transaction may comprise one or more ATM services such as the dispensing of cash to the user by the dispenser 16 (see FIGS. 1 and 2), or the provision of an account statement or the display of the user's account balance.
FIG. 5 illustrates the display which may appear on the keyboard 20 when a user requires cash to be dispensed. Note that the user engagable surfaces 24m-t act as the equivalent of conventional ATM function keys. When one of the user engagable surfaces 24m-t is pressed the appropriate function is performed by the CPU 12 which in this case is to implement the process of dispensing the amount of cash displayed on that key.
The user operated terminal in accordance with the invention as described has a number of advantages.
Firstly, the keyboard 20 is of a tactile type whereby a user gets a positive tactile response from every keystroke made. This is an advantage over touch screens where a user does not get a positive tactile response.
Also, as mentioned previously, conventional self service terminals normally have two interfaces: a data entry keyboard and a display screen. Disabled people who are visually impaired or with limited use of their upper limbs have difficulty in interacting between the two interfaces. Having a keyboard that also acts as a display screen provides a single surface for the disabled user to interact with, thereby reducing the amount of hand to eye coordination required by a disabled user.
However, since a separate display means such as a monitor is no longer needed, less space is required by a terminal, in accordance with the invention.
Since the image displayed on each user engagable surface 24 is controlled by the CPU 12, it is possible to display characters and text of different languages on the keyboard 20 by programming the CPU 12 accordingly.
The keyboard 20 can be manufactured with a fixed number of keys. The displayed layout of the keyboard 20 can be varied to suit different customers by programming the CPU 12 accordingly without the need to change the physical number or type of keys. This simplifies the manufacturing process and reduce the cost of manufacture. Once in use, the keyboard 20 can have its displayed layout changed by the CPU 12.
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A self service terminal (10) has a central processing unit (CPU) (12) connected to a keyboard (20) on which images can be displayed. The keyboard comprises a plurality of separate, individually operable keys whose user engagable surfaces are arranged in a two-dimensional array. Each key incorporates a liquid crystal display (LCD) (24) where the image displayed by each LCD is changeable and under the control of the CPU. The keyboard is used to display text, characters or other images to the user of the self service terminal. Thus, no separate display is required. The keyboard serves also as a data entry device.
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This is a continuation of application Ser. No. 09/026,902, filed Feb. 20, 1998, now U.S. Pat. No. 6,092,824. This application claims the benefit of Provisional Application Ser. No. 60/039,485, filed Feb. 28, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to wheelchairs and more particularly to an anti-rollback assembly that operatively associates with a wheelchair to prevent the wheelchair from rolling backwards and away from its occupant as the occupant attempts to mount or dismount the wheelchair, yet permits the wheelchair in an unoccupied state to be moved in a forward direction.
The anti-rollback assembly of the present invention is especially suitable for wheelchairs of invalids, the cognitively impaired, the elderly, and sufferers of physically and mentally disabling diseases such as Alzheimer's.
2. Description of the Related Art
Almost all wheelchairs possess a parking brake in one form or another which, when actuated, maintains the wheelchair in a stationary position by preventing one or both of the large drive wheels of the wheelchair from rotating about a common central axis. Perhaps the most crucial periods for the wheelchair to remain stationary are when a person attempts to sit down in and occupy the wheelchair and when the occupant attempts to stand up from and vacate the wheelchair. The natural motion of a person performing these acts imparts a force in the rearward direction on the wheelchair, which, without the benefit of an actuated parking brake, causes the wheelchair to move backwards and away from the person.
As a consequence of the mental and physical infirmities suffered by many wheelchair occupants, especially patients suffering from Alzheimer's disease and other mental frailties, occupants often forget to actuate manually-operated parking brakes prior to attempting to rise from the wheelchair, or neglect to inspect the parking brake to ensure it is engaged in a locked position prior to attempting to sit down into the wheelchair. Failure to engage the manually-operated parking brake in its locked position presents a serious hazard of injury to both the occupant and his or her caretaker, since the wheelchair is unimpeded from rolling back and away from the occupant as the occupant attempts to rise from or sit down in the wheelchair.
To address the shortcomings of manually-operated parking brakes, several different automatically-operated locking brake assemblies have been proposed. U.S. Pat. No. 5,203,433 sets forth a discussion of some conventional automatic locking brake assemblies. Each of the conventional assemblies mentioned in U.S. Pat. No. 5,203,433 is characterized by the provision of a locking member that, unless manually disengaged, prevents or at least substantially obstructs both the forward or rearward movement of the wheelchair with which the assembly is associated when the wheelchair is unoccupied.
However, one of the most important functions served by an automatic wheelchair brake is that it not only prevent the wheelchair from rolling backwards and away from its occupant as the occupant mounts or dismounts the wheelchair, but that the brake also not substantially obstruct the forward motion of the wheelchair when unoccupied so that the unoccupied wheelchair can be easily maneuvered to a desirable location for use or temporary storage.
A long-felt need therefore exists to provide an automatically-operated anti-rollback assembly for a wheelchair that biases a braking mechanism into an activated position when the wheelchair is unoccupied to prevent the wheelchair from rolling back when it is mounted or dismounted in normal operation, yet, while in the activated position, permits the forward motion of the unoccupied wheelchair.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an anti-rollback assembly that solves the aforementioned problems associated with the related art as well as other problems and addresses the long-felt need outlined above.
It is another object of the present invention to provide an automatic anti-rollback assembly which is reliable in operation, easy to use, and economical to manufacture.
A further object of the present invention is to provide an automatic anti-rollback assembly that can be easily and inexpensively retrofitted to existing wheelchairs.
It is another object of the present invention to provide an automatic anti-rollback assembly that, when operatively associated with a wheelchair, permits the unoccupied wheelchair to freely roll in a forward direction, yet impedes only the rearward motion of the wheelchair, so that the unoccupied wheelchair can be used, for example, as a walker.
Still another object of the present invention is the provision of a wheelchair having an automatic anti-rollback assembly with an ambulation monitor which activates an alarm when the wheelchair occupant attempts to vacate the wheelchair.
In accordance with the principles of the present invention, these and other objects are attained by the provision of an automatic anti-rollback assembly that is adapted or adaptable for use in combination with a wheelchair. The automatic anti-rollback assembly generally comprises a one-way brake assembly supportable on a frame structure of a wheelchair, biasing member, and a brake releasing assembly. The one-way brake assembly includes a one-way brake member (or brake arm). When used in combination with a wheelchair, the one-way brake assembly is movable between a non-activated position in which the one-way brake member is positioned to permit the rear drive wheel assembly to rotate in forward and rearward directions to enable the wheelchair to move freely in both the forward and rearward directions, and an non-activated position in which the one-way brake member is positioned to prevent rotation of the rear drive wheel assembly in the rearward direction so as to prevent movement of the wheelchair in the rearward direction, yet continues to permit rotation of the rear drive wheel assembly in the forward direction for forward movement of the wheelchair. The biasing member serves to impart a biasing force to urge the one-way brake assembly towards the activated position. The brake releasing assembly is operatively associated with the one-way brake assembly and the biasing member, and is movable in response to the wheelchair being occupied to overcome the biasing force of the biasing member so as to move the one-way brake assembly from the activated position to the non-activated position, thereby enabling the wheelchair to freely move in both the forward and rearward directions unencumbered by the one-way brake member.
In accordance with the present invention, the occupant of the wheelchair is not required to set a conventional parking brake. Instead, the wheelchair is automatically immobilized against backward movement by the anti-rollback device when the occupant is attempting to rise from or sit himself in the seat member. In addition, when the occupant is fully seated in the seat member, the anti-rollback device is disengaged, i.e., the one-way brake assembly is moved into a non-activated position, so that the wheelchair can be freely moved forward or backwards unencumbered by the one-way brake member.
These and other objects, features, and advantages of the present invention will become apparent from the following detailed description when taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate an embodiment of the present invention. In such drawings:
FIG. 1 is a perspective rear view of a wheelchair including an anti-rollback assembly in accordance with a preferred embodiment of the present invention, in which the range of movement of the anti-rollback assembly between non-activated and activated positions is depicted by arrows;
FIGS. 2A and 2B are side elevational views of the wheelchair of FIG. 1 in occupied and unoccupied states, respectively;
FIG. 3 is an exploded view of mounting and brake releasing assemblies of the anti-rollback assembly of FIG. 1;
FIG. 4 is a perspective view of a bracket and brake arm supporting member of the mounting assembly of FIGS. 1 and 3;
FIG. 5 is a rear view of the bracket of the mounting assembly depicting a biasing member;
FIG. 6 is a side view of an ambulation monitor according to one embodiment of the present invention; and
FIG. 7 is an exploded view of the ambulation monitor of FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A detailed description of a conventional wheelchair structure will be discussed hereinbelow for the purposes of assisting in the detailed description of the anti-rollback assembly of the present invention and explaining the manner in which the anti-rollback assembly is operatively supported on a wheelchair. It is understood, however, the present invention is not restricted to the illustrated wheelchair or the construction and arrangement of the individual components of the illustrated wheelchair.
Referring now to the drawings, there is shown in FIGS. 1, 2 A, and 2 B a wheelchair generally designated by reference numeral 10 . The wheelchair 10 includes a frame structure 12 comprising a pair of opposing side frames 14 a and 14 b laterally spaced from and substantially parallel with one another. The opposing side frames 14 a and 14 b have respective front upright members 16 a and 16 b and respective rear upright members 18 a and 18 b. In the illustrated embodiment, the front upright member 16 a and the rear upright member 18 a of the side frame 14 a include longitudinal axes oriented substantially vertical, and are interconnected with crossbars 19 a and 20 a. The front upright member 16 b and the rear upright member 18 b of the other side frame 14 b are arranged and interconnected in a similar manner with crossbars 19 b and 20 b. Handles 22 a and 22 b are fitted onto upper ends (unnumbered) of the rear upright members 18 a and 18 b, respectively. Arm rests 24 a and 24 b are secured to upper surfaces of the crossbars 19 a and 19 b, respectively.
The wheelchair 10 further includes a flexible seat member 26 extending between the opposing side frames 14 a and 14 b and arranged in a substantially horizontal orientation so as to permit an occupant to sit thereon. A flexible back support member 28 extends between the rear upright members 18 a and 18 b and, together with the seat member 26 , define a seating area (unnumbered) for supporting the wheelchair occupant.
As shown in FIG. 1, the wheelchair 10 further includes rear drive wheel assemblies comprising two large rear drive wheels 30 a and 30 b which are manually rotatable by the occupant to rotate about hubs 32 a and 32 b, respectively. The hubs 32 a and 32 b are respectively attached to the rear upright members 18 a and 18 b with axle bolts (unnumbered) and each include a plurality of spokes (not shown) extending therefrom to interconnect the hubs 32 a and 32 b to their respective drive wheels 30 a and 30 b. Front wheel assemblies comprise small wheels 34 a and 34 b swivably connected to the front upright members 16 a and 16 b, respectively, to facilitate turning of the wheelchair 10 .
Although not shown, it is understood that in accordance with the present invention, the wheelchair 10 can include additional components, such as footrests. It is further understood that in accordance with the present invention the wheelchair can omit one or more of the components discussed above and illustrated in the drawings, so long as the wheelchair is characterized as being capable of operatively supporting the anti-rollback feature of the present invention.
One embodiment of the automatic anti-rollback assembly of the present invention, which is generally designated by reference numeral 40 , will now be described with greater specificity hereinbelow.
Referring to FIGS. 3 and 4, the illustrated automatic anti-rollback assembly 40 includes two mounting assemblies. For explanatory purposes, only one of the two mounting assemblies, which is generally designated by reference numeral 42 , will be described below.
The mounting assembly 42 includes a mounting bracket 44 with a discontinuous circular clamping end 46 , which accommodates the rear upright member 18 a. Nut-bolt combinations 48 and 50 serve to secure the mounting bracket 44 to the rear upright member 18 a. Reinforcement spacers 52 may be used in combination with the nut-bolt combinations 48 and 50 to prevent bowing of the bolts. The reinforcement spacers 52 can be made of, for example, nylon or other plastics. As shown in FIGS. 1, 2 A, and 2 B, the clamping end 46 of the mounting bracket 44 is positioned immediately above the axle bolt associated with hub 32 a.
The mounting assembly 42 further includes a movable brake-arm supporting member 54 (also referred to as a brake-member supporting member or pivotable collar), which is substantially configured as a clevis yoke. In the illustrated embodiment, the brake-arm supporting member 54 is rotatable about its longitudinal axis between first and second positions. Opposing sides of the mounting bracket 44 define aligned apertures, one of which is designated by reference numeral 56 in FIG. 4 . The apertures 56 are sized to receive a shaft 58 co-axially extending from and integral with the pivotable collar 54 . The shaft 58 is secured to the mounting bracket 44 with, for example, a lock cap 60 . As shown in FIG. 5, a torsion spring 62 is accommodated in the mounting bracket 44 and connected to the shaft 58 of the pivotable collar 54 via pin 63 to urge the pivotable collar 54 into its first position.
The opposite end (unnumbered) of the pivotable collar 54 defines a slot 66 diametrically positioned and axially extending a certain depth into pivotable collar 54 . A first bore 68 is diametrically defined within the pivotable collar 54 , and arranged orthogonally relative to the slot 66 to intersect the slot 66 . Second and third bores 70 and 72 are each diametrically disposed, arranged orthogonally relative to each other to intersect each other, and are interposed between the slot 66 and the shaft 58 . The functions of the slot 66 and the first, second, and third bores 68 , 70 , and 72 will be described below.
Still referring to FIG. 3, the automatic anti-rollback assembly 40 further includes a brake releasing assembly, which is generally designated by reference numeral 74 .
The brake releasing assembly 74 includes a substantially L-shaped actuator lever 76 , adjustor plate 78 , and connector plates 80 . For explanatory purposes, the connector plate 80 and the side of the adjustor plate 78 operatively associated with mounting assembly 42 will be described below.
The actuator lever 76 is cantilevered at a central portion (unnumbered) of the adjustor plate 78 . The end (unnumbered) of the adjustor plate 78 defines an exposed lateral port 82 , which receives a portion of the connector plate 80 . The upper region of the adjustor plate 78 has an elongated slot 84 defined therethrough in communication with the lateral port 82 . (As shown in FIG. 3, the slots 84 are located on each side of the central portion of the adjustor plate 78 .) A nut-washer combination 86 engages a first aperture 88 of the connector plate 80 and the elongated slot 84 to thereby secure the adjustor plate 78 to the connector plate 80 . The end of the connector plate 80 opposite to the first aperture 88 defines a second aperture 90 .
As shown in FIGS. 2A and 2B, when the brake releasing assembly 74 is connected to the mounting assembly 42 , the brake releasing assembly 74 is positioned immediately underneath the seat member 26 . The connection of the brake releasing assembly 74 to the mounting assembly 42 will now be described with reference to FIG. 3 .
The slot 66 of the pivotable collar 54 receives the end of the adjustor plate 78 containing the second aperture 90 so that the first bore 68 and the second aperture 90 are aligned. A quick-release pin 92 is inserted through the aligned first bore 68 and second aperture 90 to secure the brake releasing assembly 74 to the mounting assembly 42 . The provision of the quick-release pin 92 or similar connecting device facilitates the quick and easy separation and removal of the brake releasing assembly 74 . When the wheelchair 10 is of the collapsible variety, the frames 14 a and 14 b and associated wheels on either side of the seat member 26 can thereby be folded together for convenient stowage. The provision of a quick-releasing mechanism to facilitate the ability of the wheelchair 10 to be collapsed and stored represents one of the many advantages of the present invention.
Another of the advantages of the illustrated embodiment rests in the configuration of the elongated slots 84 of the adjustor plate 78 , which provides for an adjustable positional relationship with the first aperture 88 of connector plate 80 . This feature makes the illustrated anti-rollback assembly 40 adaptable and retrofittable to wheelchairs of various widths. Although not shown, it is noted that the elongated slots 84 can be replaced with, for example, a series of spaced apertures.
The anti-rollback assembly 40 also includes a brake member (or brake arm) 94 , a proximal end portion 96 of which is received in the second bore 70 of the pivotable collar 54 and secured thereto with a set screw 98 (FIG. 3 ). (The brake member 94 and mounting assembly 42 collectively form a one-way brake assembly in this embodiment.) As respectively shown in FIGS. 2A and 2B, a distal end portion 99 of the brake arm 94 either is spaced from a rear region of the drive wheel 30 a (when the wheelchair 10 is occupied) or rests on the drive wheel 30 a (when the wheelchair 10 is unoccupied or the occupant attempts to rise from or sit down into the wheelchair 10 ). As is believed evident from this description, the positional relationship of the brake arm 94 to the pivotable collar 54 can be adjusted (by loosening set screw 98 ) to make the brake arm 94 adaptable and retrofittable to wheelchairs of various drive wheel sizes.
The operational movement of the anti-rollback assembly 40 will be described below with reference to FIGS. 1, 2 A, 2 B, and 3 .
In its unoccupied state, the torsion spring 62 imparts a biasing force to urge the brake-arm supporting member 54 towards the first position, which in turn urges the seat member 26 towards its upper position and the distal end portion 99 of the brake arm 94 into the activated position. As is seen from the arrows in FIGS. 1, 2 A, and 2 B, in the illustrated embodiment the axis of the pivotal collar 54 is located higher and to the rear of the axis of the drive wheels 30 a and 30 b. As a consequence, the torsion spring 62 applies a biasing force along a non-radial direction relative to the drive wheels 30 a and 30 b. As shown by the arrows in FIGS. 1, 2 A, and 2 B, this biasing force urges the end portion 99 along a direction substantially parallel to a tangent at the point at which the brake arm end portion 99 engages the peripheral surface of the associated drive wheel. In this manner, the end portion 99 pivots upward and downward on a smaller and intersecting arc to that of the associated drive wheel. In the activated position, the distal end portion 99 of the brake arm 94 prevents the first drive wheel 30 a from rotating about a central axis thereof in a rearward direction, yet does not prevent the first drive wheel 30 a from rotating about the central axis thereof in a forward direction.
When a patient attempts to rest into the seating area of the wheelchair 10 , the weight of the patient imparts a downward force on the seat member 26 , which causes the seat member 26 to flex, bend, slide, or otherwise move in a downward direction to its lower position. The downward movement of the seat member 26 translates the downward force to the actuator lever 76 , thereby pivoting the actuator lever 76 downward as indicated by the arrow in FIG. 2 A. As the actuator lever 76 pivots, the adjustor plate 78 is rotated about its longitudinal axis to translate a corresponding rotational movement to pivotable collar 54 . As the collar 54 rotates about its axis, the brake arm 94 operatively associated therewith is pivoted about the region of its proximal end portion 96 accommodated in the second bore 70 so that the distal end portion 99 is moved substantially along the forward rotational direction from the activated position to a non-activated position. In the non-activated position, the distal end portion 99 is radially spaced from the drive wheel 30 a and, hence, does not interfere with manual operation (including both forward and rearward motion) of the wheelchair 10 .
Conversely, when an occupant of the wheelchair 10 attempts to rise from the seating area, the torsion spring 62 imparts a biasing force to urge the brake-arm supporting member 54 towards the first position, which in turn urges the seat member 26 towards its upper position and the distal end portion 99 of the brake arm 94 to move in a downward manner along an arcuate path (as shown by the arrow in FIG. 2 B), that is, substantially along a rearward rotational direction into the activated position.
In the illustrated embodiment, the arcuate path that the distal end portion 99 of the brake arm 94 follows between the activated and non-activated positions intersects the circumference of the drive wheel 30 a. Consequently, the amount of frictional force applied to the brake arm 94 by the drive wheel 30 a is proportional to the rearward force applied to the wheelchair 10 . Stated differently, when the wheelchair 10 is moved rearwardly, frictional force between the drive wheel 30 a and the brake arm 94 causes the distal end portion 99 of the brake arm 94 to move in a generally radially inward direction towards the hub 32 a, which further presses the distal end portion 99 into the drive wheel 30 a. Consequently, continued rearward motion of the wheelchair 10 has a corresponding immobilizing effect on the drive wheel 30 a of the wheelchair 10 .
Accordingly, even though the occupant of the wheelchair 10 may neglect to set a conventional parking brake (not shown), the chair 10 is automatically immobilized against backward movement by the anti-rollback device when the occupant is attempting to rise from or seat himself in the seat member 26 .
Referring now to FIGS. 6 and 7, according to another embodiment of the present invention the wheelchair is equipped with an ambulation monitor, generally designated by reference numeral 100 , for activating an alarm when the occupant of the wheelchair 10 attempts to rise from the seat member 26 .
As shown in FIG. 7, the ambulation monitor includes a housing structure 102 , which houses a horn 104 , an on/off switch 106 and a switch jack 108 electrically connected to the horn 104 , and an energy source 110 , e.g., a battery, electrically connected to the on/off switch 106 . The housing structure 102 is supported on the mounting bracket 44 with a mounting bracket 112 , a mounting bracket clamp knob 114 , and screws 116 a and 116 b.
Referring now to FIG. 6, a connector wire 120 electrically connects the switch jack 108 to a cam actuator switch 122 . A cam 124 is cooperatively associated with the pivotable collar 54 by providing the cam 124 with an eccentrically disposed aperture 126 through which a portion of the pivotable collar 54 is disposed. Accordingly, when the occupant begins to rise from the seat member 26 , the pivotable collar 54 is rotated about its longitudinal axis as described above. The cam 124 , by virtue of its cooperative association with the pivotable collar 54 , rotates to actuate the switch 122 , thereby activating the horn 104 to alert staff of the occurrence.
In its broadest aspects, several variations and modifications to the above-discussed anti-rollback assembly can be implemented without departing from the scope of the present invention. For example, the anti-rollback assembly 40 may include a separate biasing member or members, such as springs, to urge the seat member into its upper position independent of or in conjunction with the torsion spring 62 . Also, although in the illustrated embodiment each of the drive wheels 30 a and 30 b and a one-way brake assembly (that is, a mounting assembly and brake arm) associated therewith, it is understood that the anti-rollback assembly 40 may include only one mounting assembly 42 and brake arm 94 , in which case, for example, a pivotable bar (not shown) may interconnect the brake releasing assembly 74 with the side frame 14 b not associated with the mounting assembly 42 and brake arm 94 . Where the anti-rollback assembly includes one-way brake assemblies respectively associated with each of the drive wheels 30 a and 30 b (as shown in FIGS. 1, 2 A, and 2 B), a second torsion spring (not shown) may be accommodated in the mounting bracket associated with the second drive wheel 30 b; alternatively, the anti-rollback assembly 40 may include only a single torsion spring, since the pivotable collar 54 associated with the first drive wheel 30 a rotates in unison with the pivotable collar associated with the second drive wheel 30 b due to the interconnection provided by the brake releasing assembly 74 .
The one-way brake assemblies may respectively engage portions of the rear drive wheel assemblies at positions other than the rear drive wheel. For example, although not shown, the assemblies could include ratchet and pawl wheel assemblies to accomplish the anti-rollback function of the present invention.
These and other modifications to the assembly, when viewed with reference to this disclosure, are within the purview of those skilled in the art.
If desired, the automatic anti-rollback assembly 40 of the present invention may be used in conjunction with conventional supplemental braking devices well known in the art, including, for example, a manually-operated parking brake to immobilize the wheelchair from forward or rearward movement when occupied.
The foregoing detailed description of the preferred embodiments of the invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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An anti-rollback assembly adapted or adaptable for use in combination with a wheelchair. The anti-rollback assembly includes a one-way brake assembly automatically immobilizing the wheelchair against rearward movement when the occupant attempts to rise from or sit in a seat member of the wheelchair, yet at the same time does not prevent the wheelchair from moving in a forward direction. Conversely, when the occupant is fully seated in the seal member, the one-way brake assembly is disengaged so that the wheelchair can move freely in forward or rearward directions. The assembly can be retrofitted onto existing wheelchairs, and is adjustable to fit various size wheelchairs.
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BACKGROUND OF THE INVENTION
This Invention relates to a one-stage transmissible turbocharger, particularly to one transmissible from an engine, possible to increase pressure the turbocharger should have only by one stage, attaining the objective of fuel-saving by elevating horsepower of an automobile and speeding up burning of gas coming from a carburetor.
Many different turbochargers such as G style, Root style, Screw style, have been used in cars. But the most ideal condition of a turbocharger used in a car is that the engine speed (rpm) and the air pressure (bar) have effect of pressure increase from the start of the engine, and in other words, air pressure has a 45 straight line in comparison with the engine speed. But conventional turbochargers do not begin to have increased air pressure until a car speeds up to 3000 or 4000 rpm, and its pressure swiftly increases to produce instantly and substantially large thrust to the car. Then the engine speed and the air pressure may have curved graphic relation to cause danger, should a driver not know well the function of the car.
A U.S. Pat. No. 4,155,684 discloses a kind of turbocharger including a four-stage pressure increasing system, having a lower pressure stage containing a compressor wheel and a turbine wheel, and a high-pressure stage containing a compressor wheel and a turbine wheel.
But the turbocharger with four-stages of pressure increase has a flaw of a large size, and its material have to be specially treated to endure high temperature and abrasion so as to receive waste high temperature of an engine.
Then another conventional turbocharger disclosed in Taiwan patent No. 66706 (a first generation one by the applicant) includes a one-stage turbocharger and a two-stage turbocharger, a one-stage current-guider and a two-stage current-guider, a one-stage axial current-guider and a two-stage axial current-guider. Thus this mechanical turbocharger has a very complicated structure, a very long current guiding route, so it takes a very long time for pulled in wind pressure by the one stage turbocharger from an wind exit to the carburetor, so partial backwash to affect quality of air pressure. So the applicant thought out a turbocharger of a second generation wherein an axial pressure section of the one-stage and the two-stage turbo wheel having leaves moderated. However, the second generation of the turbocharger has the same flaw as the first generation, so the applicant disclosed a third generation of turbocharger in Taiwan patent of No. 102747, which diminishes its structure and also makes its flowing course shorter, the dimensions smaller and improved air pressure movement so as to attain effectual pressure increase.
The turbocharger (the first generation) of Taiwan patent of No. 66706, and that (the third generation) of No. 102747 and U.S. patent of application of Ser. No. 08/074191 (the second generation) all make use of two-stage turbine wheel to attain ideal pressure increase.
The turbocharger of the second generation uses a one-stage turbine wheel for pulling in fresh air, and a two-stage turbine wheel for reinforcing air pressure to obtain the purpose of pressure increase. A common problem is air backwash possible to happen in a housing because of a long air flowing route of the two-stage turbine wheel. Air backwash is a pressing problem worth serious consideration, and if there is any error, the air flowing route may have air turbulence owing to air backwash. Therefore, pressure increase may be offset in case of air turbulence. So in order to prevent pressure backwash and air turbulence-possibly caused by air backwash, a current-guider (or an axial current leaves) has to be added between the one-stage turbine wheel and the two-stage turbine wheel. Then the turbocharger may become larger in dimensions, not easy to fix it in the engine room already formed, only applicable to those cars having a comparatively large air exhaust, in addition to the one-stage and the two-stage turbine wheel needing comparatively large transmitting force to result in using comparatively large transmitting horsepower of the engine. These disadvantages are commonly found in the first, the second and the third generation of a turbocharger described above.
Further, The conventional turbine wheels have leaves of a centrifugal type, a 45 angle inclined type, and an axial current type for catching air and preventing pressure reversing, but those three types have a simple structure, impossible to get pressure increasing effect it should have, except increasing stages, or those three types of leaves are not proper for a single turbocharger.
SUMMARY OF THE INVENTION
The objective of the invention is to offer a one-stage transmissible turbocharger having high safety and direct proportion of air pressure increase and the engine speed so as to elevate horsepower of an automobile and to save fuel consumption.
The features of the invention are listed as follows.
1. It uses a one-stage turbocharger having small dimensions, not liable to produce air turbulence, keeping low degree of air pressure increasing and high current volume, and having real function of air pressure increase.
2. It has a one-stage turbine wheel having leaves provided with four layers of preventing backwash of air pressure, and each small leaf of the turbine wheel has a catch inlet section of 32 degrees to elevate fresh air volume caught in, and a final section formed in a current following type to let air centrifuge smoothly without backwash or reverse current.
3. The turbine wheel has leaves formed in a centrifugal turbine style for catching in and pushing air pressure for obtaining low-pressure air current and high flowing volume.
4. The turbine wheel has the leaves designed to have four layers and five-stages for preventing air pressure backwash, pulling in air volume from the catch inlet section and then pushed to flow in the axial flowing direction, reducing air pressure backwash to the minimum. Any group of the four layers consisting of four small leaves prevents air pressure backwash, with neighboring small leaves doubly organizing anti-backwash and pushing pressure. The five stages means each small leaf including five stages of the catch inlet section to the axial flowing and pushing pressure section so that air caught in is added with pressure and prevented from reversing air pressure and current.
5. The catch inlet section of each small leaf is inclined for 32 degrees to catch the largest air volume, and the axial flowing and pushing pressure section is formed to follow current direction to let air centrifuge smoothly.
6. A large gear contains a buffer spring within its shaft in order to protect a belt wheel combined with a transmitting shaft and two one-way bearings in the large gear.
7. A sleeve of the belt wheel is provided with a plurality of buffer springs for preventing the bolts from breaking by alteration of rotating speed, and excessive large torque.
BRIEF DESCRIPTION OF DRAWINGS
This invention will be well understood by referring to the accompanying drawings, wherein:
FIG. 1 is a cross-sectional view of a one-stage transmissible turbocharger in the;
FIG. 2 is a perspective view of the one-stage transmissible turbocharger in the present invention;
FIG. 3 is an exploded perspective view of the one-stage transmissible turbocharger in the present invention;
FIG. 4 is a perspective view of a turbo wheel in the present invention;
FIG. 5 is a cross-sectional view of a large gear in the present invention;
FIG. 6 is a side cross-sectional view of the large gear in the present invention;
FIG. 7 is an exploded perspective view of a belt wheel in the present invention; and,
FIG. 8 is a side cross-sectional view of the belt wheel in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A one-stage transmissible turbocharger in the present invention, as shown in FIGS. 1 and 3, includes a front current-guider 1 , a turbine wheel 2 , a rear current-guider 3 , a current-guiding disc 4 , a rear cover 5 , a transmitting shaft 6 , a belt wheel 7 and a sleeve 8 as main components combined together.
The front current-guider 1 has an intake opening 101 formed in the front center portion, an annular inner wall 100 defining the intake opening 101 , a center shaft base 12 formed in the center of the opening 101 and three ribs radially provided between the annular inner wall 100 and the center shaft base 12 , a bearing groove 120 formed in an inner wall of the center shaft base 12 for a ball bearing 13 and a shaft seal 14 to fit in. Further, the front current-guider 1 has an inner annular wall 15 shaped according to the shape of the turbine wheel 2 so as to keep the best distance to the turbine wheel 2 so that air pressure caught in by the turbine wheel 2 may not easily flow reversely. The inner annular wall 15 connects to a front wall 30 of the rear current-guider 3 , forming an air passageway 31 . The front current-guider 1 also has a plurality of threaded holes 16 provided axially in a large rear annular circumferential wall for bolts 160 to screw to combine with the rear current-guider 3 .
The turbine wheel 2 is formed integral, having at least a plurality (T 1 -T 15 ) of leaves 20 helically arranged on a surface 21 thereof, as shown in FIGS. 3 and 4. Each leaf 20 has five continual sections, namely a catch inlet section 20 A, an angle pressure increasing section 20 B, an anti-backwash section 20 C, a centrifugal pressure section 20 D and an axial pressure section 20 E. And any group of four neighboring leaves 20 form an anti-backwash layer, and forming a straight line from the axial pressure section 20 E of the first leaf T 1 to the catch inlet section 20 a of the fourth leaf T 5 . That means that air current pulled in through the catch inlet section 20 A of the first leaf T 1 passes through the four-stage anti-backwash layer to reduce air backwash possibility to the minimum and pulling-in capacity to the maximum. This invention is the fourth generation of a turbocharger, utilizing the four-layer anti-backwash function, having good advantage of pressure increasing and anti-backwash, superior to the first, the second and the third generation of a turbocharger described above. In addition, the leaves 20 make use of five stages of catching in air, pressure increasing, preventing backwash, returning pressure centrifugally, and pushing axial pressure. In this invention, the catching-in angle of the catch inlet section 20 A is changed to 32 degrees from conventional 45 degree to acquire the best result, and when passing through the four sections to the final section, the turbine wheel leaves are formed to have direction following shapes to let the centrifugal axial pressure section not liable to produce backwash. In addition, the dimensions of the product can be reduced, resulting in increasing effectiveness, possible to be applied to various automobiles having a large or a small exhausting air capacity, say 1600 CC-4000 CC. Further, the turbine wheel 2 is located inside the inner annular wall 15 of the front current-guider 1 , having a shaft hole 23 with a key groove 230 for a shaft 24 to fit through and fixed in place with a long key 230 , and rotated by the shaft 24 . The shaft 24 has male threads 241 and 242 formed respectively in a front section and a rear section and the front male threads 241 engages with nuts 250 and washers 251 to fix firmly the turbine wheel 2 to keep the same turbine wheel 2 in place.
The current-guiding disc 4 is fixed behind the turbine wheel 2 , having a curved current guiding surface 40 as shown in FIG. 1, a center shaft hole 41 for the shaft 24 to pass through, a plurality of threaded holes 42 spaced apart around the center shaft hole 41 for bolts 420 to screw with threaded holes 300 around a shaft hole 34 of the rear current-guider 3 to fix the current guiding disc 4 with the rear current-guider 3 . The shaft 24 has its end received in the shaft seal 25 and supported in the ball bearing 26 after passing through the shaft hole 41 of the current guiding disc 4 . The two ball bearings 26 are deposited in the shaft hole of the rear current-guider 3 , letting the shaft passing through the shaft hole 34 , then through a shaft sleeve 270 , and then fixed with a pinion 27 with a key groove 271 for a key 243 to combine the pinion 27 with the shaft 24 firmly. Then when the pinion 27 is rotated, it rotates the shaft 24 and the turbine wheel 2 . The male threads 242 of the shaft 24 engages with a nut 258 with a washer 280 , and a ball bearing 29 fits around the end of the shaft 24 , received in a small shaft hole 50 of the rear cover 5 .
The rear current-guider 3 has a plurality of threaded holes 301 on an annular front end surface for bolts 160 to engage with, and a plurality of threaded holes 302 in an annular rear end surface respectively facing threaded holes 51 of the rear cover 5 for bolts 52 to screw with to combine the rear current-guider 3 with the rear cover 5 . The rear current-guider 3 has an air passageway 31 and an air exit 32 for guiding increased air pressure to the intake of the carburetor, and a bearing groove 33 for a ball bearing 60 to fit therein and for the transmitting shaft 6 to pass through and also through a large gear 61 , which then engages with the pinion 27 . Further, the large gear 61 and the pinion 27 are also located in an lubricating oil chamber 35 formed in the rear current-guider 3 , and two one-way bearings 610 are deposited in a center hole of the large gear 61 , with a shaft sleeve 611 and an inner shaft sleeve 612 inside the shaft sleeve 611 sandwiched between the two one-way bearings 610 . The inner shaft sleeve 612 is firmly fixed with the transmitting shaft 6 with a key 613 , having a plurality of ratchet teeth 614 , and each ratchet tooth 614 has a spring groove in one side for a buffer spring 616 to fit therein, and a top block 617 is provided at one side of each buffer springs 616 . Then each top block 617 contacts a round post 6110 positioned in a hole 6111 of the shaft sleeve 611 . Therefore, when the engine speed alters and the transmitting shaft 6 cannot at once correspond to the speed alteration, the one-way bearings and the transmitting shaft may reduce damage. Further, the left end of the transmitting shaft fits in two ball bearings 62 and a shaft seal 63 , and the two ball bearings 62 and the shaft seal 63 are received in a large shaft hole 53 of the rear cover 5 .
The belt wheel 7 has a bush 8 fitted in a center hole and then the bush 8 together with the belt wheel 7 are fixed on a left portion of the transmitting shaft 6 protruding out of the rear cover 5 . The bush 8 has a center shaft hole 80 with a key groove 81 for a key 81 D to fit in to fix firmly the belt wheel 7 indirectly with the transmitting shaft 6 to permit the belt wheel 7 rotate the transmitting shaft 6 . The belt wheel 7 is directly rotated by the engine synchronously with the same speed as the engine, so rotating speed of the engine directly affect rotating speed of the turbine wheel 2 . So the transmitting shaft 6 may not be possible to respond to the alteration of the engine speed to result in break of the bolts 70 . In order to solve this disadvantage, the bush 8 of the belt wheel 7 has a large diameter portion 82 and a small diameter portion 87 , and the large diameter portion 82 is provided with a plurality of curved spring holes 83 arranged to space apart near an outer circumferential edge for fitting a plurality of buffer springs 84 respectively in the spring holes 83 . Further, an annular left cover 85 closes an outer end surface of the large diameter portion 82 , having a plurality of slots 850 spaced apart to face corresponding to the spring holes 83 , and a plurality of T-shaped nuts 851 respectively put to pass through the slots 850 into a large section of each spring hole 83 and also into a plurality of round holes 860 of a right annular cover 86 closing the right side of the large diameter portion 82 and also containing the left side of the belt wheel 7 . The belt wheel further 7 has its center hole fitted with an inner sleeve 71 fitting around the small diameter portion 87 of the bush 8 , and a plurality of bolt holes 72 for bolts 70 to pass through to engage with the T-shaped nuts 851 as shown in FIGS. 7 and 8. Then the resilience of the buffer springs 84 can moderate or buffer alteration of the engine speed, which is then directly transmitted to the transmitting shaft 6 . In this way, the bolts 70 are not liable to break owing to provision of the buffer springs 84 .
While the preferred embodiment of the invention has been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications that may fall within the spirit and scope of the invention.
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A one-stage transmissible turbocharger includes a turbine wheel contained in a front current-guider and a rear current-guider, increasing air pressure to elevate horsepower and speeding up burning of gas coming out of a carburetor to save fuel consumption. The turbine wheel has a plurality of leaves respectively helically formed to have 32 angles to make a catch inlet section to elevate air volume to be caught in, and a final axial pressure section for producing centrifugal current so as to give the turbine wheel functions of both axial current and centrifugal current. In addition, the turbocharger has buffer springs for protecting a belt wheel and its bolts from damaged or broken.
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CROSS-REFERENCES TO RELATED PATENT APPLICATIONS
[0001] This is a Continuation Application of application Ser. No. 12/574,255, filed Oct. 6, 2009, which is a Continuation application of 12/348,621, filed Jan. 5, 2009, issued as U.S. Pat. No. 7,616,687 on Nov. 10, 2009, which is a Continuation Application of application Ser. No. 11/873,282, filed Oct. 16, 2007; which is a Continuation Application of application Ser. No. 10/612,013, filed Jul. 3, 2003, and issued on Nov. 6, 2007, as U.S. Pat. No. 7,292,657; which is a Continuation Application of application Ser. No. 09/703,649, filed Nov. 2, 2000, and issued Jan. 20, 2004, as U.S. Pat. No. 6,680,975; which is a Continuation Application of application Ser. No. 08/024,305, filed Mar. 1, 1993, and issued on Jul. 17, 2001, as U.S. Pat. No. 6,263,026; the disclosures of which are incorporated herein by reference. One (1) Reissue application Ser. No. 10/609,438, filed on Jul. 1, 2003, of U.S. Pat. No. 6,263,026 has been abandoned. Continuation application Ser. No. 12/338,647, filed Dec. 18, 2008, Continuation application Ser. Nos. 12/343,797, 12/343,839, and 12/343,898, all filed on Dec. 24, 2008. Continuation application Ser. Nos. 12/348,510, 12/348,535, 12/348,539, 12/348,581, 12/348,590, and 12/348,621, all filed on Jan. 5, 2009, and Continuation application Ser. No. 12/497,264, filed on Jul. 2, 2009, are Continuation applications of Ser. No. 11/873,282.
FIELD OF THE INVENTION
[0002] The present invention relates to a signal compressing system. A system according to the present invention is particularly suited for compressing image signals. The present disclosure is based on the disclosure in Korean Patent Application No. 92-3398 filed Feb. 29, 1992, which disclosure is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0003] Image signals may be compressed by motion-compensated interframe discrete cosine transform (DCT) coding such as is defined by a MPEG (Moving Picture Expert Group) international standard. This form of signal compression has attracted much attention in the field of high definition television (HDTV).
[0004] FIG. 1 is a block diagram of such a conventional motion-compensated interframe DCT coder. In the shown coder, an image signal is divided into a plurality of sub-blocks. The sub-blocks are all of the same size, for example 8×8, 16×16, . . . . A motion estimator 40 produces a motion vector, defined by the difference between the current image signal and a one-frame delayed image signal, output by a frame memory 30 . The motion vector is supplied to a motion compensator 50 which compensates the delayed image signal from the frame memory 30 on the basis of the motion vector. A first adder 8 a serves to produce the difference between the present frame and the delayed, motion compensated frame. A discrete cosine transform portion 10 processes the difference signal, output by the first adder 8 a, for a sub-block. The motion estimator 40 determines the motion vector by using a block matching algorithm.
[0005] The discrete cosine transformed signal is quantized by a quantizer 20 . The image signal is scanned in a zig-zag manner to produce a runlength coded version thereof. The runlength coded signal comprises a plurality of strings which include a series of “0”s, representing the run length, and an amplitude value of any value except “0”.
[0006] The runlength coded signal is dequantized by a dequantizer 21 , inversely zig-zag scanned and inversely discrete cosine transformed by an inverse discrete cosine transforming portion 11 . The transformed image signal is added to the motion-compensated estimate error signal by a second adder 8 b. As a result the image signal is decoded into a signal corresponding to the original image signal.
[0007] Refresh switches RSW 1 , RSW 2 are arranged between the adders 8 a, 8 b and the motion compensator 40 so as to provide the original image signal free from externally induced errors.
[0008] The runlength coded signal is also supplied to a variable length coder 60 which applies a variable length coding to the runlength coded image signal. The variable length coded signal is then output through a FIFO transfer buffer 70 as a coded image signal.
[0009] In motion-compensated adaptive DCT coding, the interframe signal can be easily estimated or coded by way of motion compensation, thereby obtaining a high coding efficiency, since the image signal has a relatively high correlation along the time axis. That is, according to the afore-mentioned method, the coding efficiency is high because most of the energy of a discrete cosine transformed signal is compressed at the lower end of its spectrum, resulting in long runs of “0”s in the runlength coded signal.
[0010] However, the scanning regime of the aforementioned method does not take account of differences in the spectrum of the motion-compensated interframe DCT signal with time.
[0011] A method is known wherein one of a plurality of reference modes is previously selected on the basis of the difference between the present block and that of a previous frame and the image signal is scanned by way of a scanning pattern under the selected mode and suitably quantized. With such a method, however, three modes are employed to compute the energies of the intermediate and high frequency components of the image signal in accordance with the interframe or the intraframe modes in order to determine the appropriate mode. This mode determining procedure is undesirably complicated.
SUMMARY OF THE INVENTION
[0012] According to the present invention, there is provided a signal compressing system, comprising coding means for scanning an input signal according to a plurality of different scanning patterns to provided coded versions thereof and selection means for selecting a said scanning pattern which produces efficient coding according to a predetermined criterion and outputting a scanning pattern signal identifying the selected scanning pattern.
[0013] Preferably, the input signal is an inherently two-dimensional signal, for example, an image signal.
[0014] Preferably, the coding means codes the input signal according to a runlength coding regime.
[0015] Preferably, the system includes a variable length coder to variably length code the coded signal, produced by scanning according to the selected scanning pattern.
[0016] Preferably, the system includes discrete cosine transformer means to produce said input signal. The transformer means may be a motion-compensated interframe adaptive discrete cosine transformer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] An embodiment of the present invention will now be described, by way of example, with reference to FIGS. 2 and 3 of the accompanying drawings, in which:
[0018] FIG. 1 is a block diagram of a conventional adaptive interframe DCT coding system employing a motion compensating technique;
[0019] FIG. 2 is a block diagram of a coding system embodying the present invention;
[0020] FIGS. 3A-3H show various possible scanning patterns according to the present invention; and
[0021] FIG. 4 is a block diagram of a decoding system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring to FIG. 2 , an input signal is divided into equal-sized sub-blocks, for example, 8×8, 16×16, . . . . A motion estimator 40 determines a motion vector by comparing the current frame and a one frame delayed signal from a frame memory 30 .
[0023] The motion vector is supplied to a motion compensator 60 which, in turn, compensates the delayed frame signal for movement. A first adder 8 a produces a difference signal representing the difference between the present frame and the delayed, motion-compensated frame. A DCT coder 10 DCT-codes the difference signal. The DCT coded image signal is quantized by a quantizer 20 and then dequantized by a dequantizer 21 . The dequantized signal is supplied to a second adder 8 b, via IDCT 11 , which adds it to the output of the motion compensator 11 . This produces a signal corresponding to the original image signal.
[0024] The output of the motion compensator 50 is applied to the adders 8 a, 8 b by refresh switches RSW 2 and RSW 1 , respectively.
[0025] The quantized image signal is also supplied to a multi-scanner 80 which scans it according to a plurality of predetermined patterns.
[0026] A scanner pattern selector 90 selects the scanning pattern which produces the minimum number of bits to represent the current sub-block. The scanning pattern selector also produces selection data which identifies the selected scanning pattern.
[0027] The image signal output by the scanning pattern selector 90 is variable length coded by a variable length coder 60 . The variable length coder 60 compresses the image signal output by the scanning pattern selector 90 . The variable length coder 60 operates such that a large proportion of the data samples are each represented by a small number of bits while a small proportion of the data samples are each represented by a large number of bits.
[0028] When a discrete cosine transformed image signal is quantized and runlength coded, the number of “0”s is increased over all, while the number of “0”s decreases as the magnitude of the signal increases. Accordingly, data compression is achieved because “0” can be represented by only a few bits and “255” can be represented by a relatively large number of bits.
[0029] Both the variable length coded signal and the selection data are supplied to a multiplexer MUX 1 which multiplexes the variable length coded signal and the selection data, and optionally additional information such as teletext.
[0030] Since the variable length coded signal has data words of different lengths, a transfer buffer 70 is employed to temporarily store the multiplexed signal and output it at a constant rate.
[0031] The original image signal is reconstructed at a remote station by performing the appropriate inverse scanning of the runlength coded signal in accordance with the multiplexed scanning pattern selection data.
[0032] FIG. 4 shows a decoding system at a remote station that receives and extracts the encoded data. In FIG. 4 , demultiplexer 100 receives coded data and, in an operation inverse to that performed at the coding system, extracts the variable length encoded data, the scanning pattern information and the additional information that had been multiplexed together at the coding system. Variable length decoder 110 variable length decodes the variable length encoded data, and scanner 120 receives the variable length decoded data and reconstructs the original sub-block using a scanning pattern indicated by the extracted scanning pattern selection signal. The scanner would necessarily have to select one from a plurality pattern that was available for encoding. Using components having the same margin as dequantizers 21 and IDCT 11 in the encoder system, dequantizer 120 dequantizes the signal output from the scanner 120 , and inverse discrete cosine transformer 140 performs an inverse discrete cosine transform function on the output of dequantizer 130 , to output decoded data.
[0033] FIGS. 3A to 3H show possible scanning patterns employed by the multi-scanner 80 . Additional scanning patterns will be apparent to those skilled in the art. However, if the number of patterns becomes too large, the coding efficiency is degraded as the selection data word becomes longer.
[0034] As described above, according to the present invention, the quantized image signal is scanned according to various scanning patterns, and then the most efficient pattern is selected.
[0035] A suitable measure of efficiency is the number of bits required to runlength code the image signal.
|
A multi-scanner scans a signal according to several different patterns. A scanning pattern selector determines which scanning pattern produced the most efficient coding result, for example, for runlength coding, and outputs a coded signal, coded most efficiently, and a selection signal which identifies the scanning pattern found to be most efficient.
| 7
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/955,650 filed Mar. 19, 2014, which is expressly incorporated by reference herein.
[0002] The present invention relates to a process for preparing compound 1 that is useful as an antifungal agent. In particular, the invention seeks to provide a new methodology for preparing compound 1 and substituted derivatives thereof.
STATEMENT OF GOVERNMENT SUPPORT
[0003] This invention was created in the performance of a Cooperative Research and Development Agreement with the National Institutes of Health, an Agency of the Department of Health and Human Services. The Government of the United States has certain rights in this invention.
BACKGROUND
[0004] Living organisms have developed tightly regulated processes that specifically import metals, transport them to intracellular storage sites and ultimately transport them to sites of use. One of the most important functions of metals such as zinc and iron in biological systems is to enable the activity of metalloenzymes. Metalloenzymes are enzymes that incorporate metal ions into the enzyme active site and utilize the metal as a part of the catalytic process. More than one-third of all characterized enzymes are metalloenzymes.
[0005] The function of metalloenzymes is highly dependent on the presence of the metal ion in the active site of the enzyme. It is well recognized that agents which bind to and inactivate the active site metal ion dramatically decrease the activity of the enzyme. Nature employs this same strategy to decrease the activity of certain metalloenzymes during periods in which the enzymatic activity is undesirable. For example, the protein TIMP (tissue inhibitor of metalloproteases) binds to the zinc ion in the active site of various matrix metalloprotease enzymes and thereby arrests the enzymatic activity. The pharmaceutical industry has used the same strategy in the design of therapeutic agents. For example, the azole antifungal agents fluconazole and voriconazole contain a 1-(1,2,4-triazole) group that binds to the heme iron present in the active site of the target enzyme lanosterol demethylase and thereby inactivates the enzyme.
[0006] In the design of clinically safe and effective metalloenzyme inhibitors, use of the most appropriate metal-binding group for the particular target and clinical indication is critical. If a weakly binding metal-binding group is utilized, potency may be suboptimal. On the other hand, if a very tightly binding metal-binding group is utilized, selectivity for the target enzyme versus related metalloenzymes may be suboptimal. The lack of optimal selectivity can be a cause for clinical toxicity due to unintended inhibition of these off-target metalloenzymes. One example of such clinical toxicity is the unintended inhibition of human drug metabolizing enzymes such as CYP2C9, CYP2C19 and CYP3A4 by the currently-available azole antifungal agents such as fluconazole and voriconazole. It is believed that this off-target inhibition is caused primarily by the indiscriminate binding of the currently utilized 1-(1,2,4-triazole) to iron in the active site of CYP2C9, CYP2C19 and CYP3A4. Another example of this is the joint pain that has been observed in many clinical trials of matrix metalloproteinase inhibitors. This toxicity is considered to be related to inhibition of off-target metalloenzymes due to indiscriminate binding of the hydroxamic acid group to zinc in the off-target active sites.
[0007] Therefore, the search for metal-binding groups that can achieve a better balance of potency and selectivity remains an important goal and would be significant in the realization of therapeutic agents and methods to address currently unmet needs in treating and preventing diseases, disorders and symptoms thereof. Similarly, methods of synthesizing such therapeutic agents on the laboratory and, ultimately, commercial scale is needed. Addition of metal-based nucleophiles (Zn, Zr, Ce, Ti, Mg, Mn, Li) to azole-methyl substituted ketones have been effected in the synthesis of voriconazole (M. Butters, Org. Process Res. Dev. 2001, 5, 28-36). The nucleophile in these examples was an ethyl-pyrimidine substrate. Similarly, optically active azole-methyl epoxide has been prepared as precursor electrophile toward the synthesis of ravuconazole (A. Tsuruoka, Chem. Pharm. Bull. 1998, 46, 623-630). Despite this, the development of methodology with improved efficiency and selectivity is desirable.
BRIEF SUMMARY OF THE INVENTION
[0008] The invention is directed toward methods of synthesis of 1 or 1a. The methods can comprise the compounds herein. A first aspect of the invention relates to a process for preparing a compound of formula 1, or a pharmaceutically acceptable salt, hydrate, solvate, complex or prodrug thereof.
[0000]
[0009] The compounds herein include those wherein the compound is identified as attaining affinity, at least in part, for a metalloenzyme by formation of one or more of the following types of chemical interactions or bonds to a metal: sigma bonds, covalent bonds, coordinate-covalent bonds, ionic bonds, pi bonds, delta bonds, or backbonding interactions.
[0010] Methods for assessing metal-ligand binding interactions are known in the art as exemplified in references including, for example, “Principles of Bioinorganic Chemistry” by Lippard and Berg, University Science Books, (1994); “Mechanisms of Inorganic Reactions” by Basolo and Pearson John Wiley & Sons Inc; 2nd edition (September 1967); “Biological Inorganic Chemistry” by Ivano Bertini, Harry Gray, Ed Stiefel, Joan Valentine, University Science Books (2007); Xue et al. “Nature Chemical Biology”, vol. 4, no. 2, 107-109 (2008).
[0011] In the following aspects, reference is made to the schemes and compounds herein, including the reagents and reaction conditions delineated herein. Other aspects include any of the compounds, reagents, transformations or methods thereof delineated in the examples herein (in whole or in part), including as embodiments with single elements (e.g., compounds or transformations) or embodiments including multiple elements (e.g., compounds or transformations).
[0012] In one aspect, the invention provides a process to prepare a compound of formula II:
[0000]
[0000] comprising epoxide opening of a compound of formula I:
[0000]
[0000] to provide a compound of formula II;
wherein R is
[0000]
[0013] In another aspect, the invention provides a process to prepare amino-alcohol 1-6 or 1-7, or a mixture thereof:
[0000]
[0000] comprising arylation of substituted pyridine 4b or 4c, or a mixture thereof:
[0000]
[0000] to provide compound 1-6 or 1-7, or a mixture thereof;
[0014] wherein each R 1 is independently halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0015] In one embodiment, the invention provides a process to prepare a compound of formula IV:
[0000]
[0000] comprising olefination of a compound of formula III:
[0000]
[0000] to provide a compound of formula IV;
wherein R is
[0000]
[0016] In another embodiment, the invention provides a process to prepare a compound of formula V or Va, or a mixture thereof:
[0000]
[0000] comprising dihydroxylation of a compound of formula IV:
[0000]
[0000] to provide a compound of formula V or Va. or a mixture thereof;
wherein R is
[0000]
[0017] In another embodiment, the invention provides a process to prepare a compound of formula VI or VIa, or a mixture thereof:
[0000]
[0000] comprising activation of the primary alcohol of a compound of formula V or Va, or a mixture thereof:
[0000]
[0000] to a provide a compound of formula VI or VIa, or a mixture thereof;
[0018] wherein R is
[0000]
[0000] and
[0019] each Y is independently —OSO 2 -alkyl, —OSO 2 -substituted alkyl, —OSO 2 -aryl, —OSO 2 -substituted aryl, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, or halogen.
[0020] In another embodiment, the invention provides a process to prepare a compound of formula VII or VIIa, or a mixture thereof:
[0000]
[0000] comprising ring closure of a compound of formula VI or VIa, or a mixture thereof:
[0000]
[0000] to provide a compound of formula VII or VIIa, or a mixture thereof;
[0021] wherein R is
[0000]
[0000] and
[0022] each Y is independently —OSO 2 -alkyl, —OSO 2 -substituted alkyl, —OSO 2 -aryl, —OSO 2 -substituted aryl, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, or halogen.
[0023] In another embodiment, the invention provides a process of enriching the enantiomeric purity of an enantiomeric compound mixture, comprising:
[0024] (i) crystallizing said enantiomeric compound mixture with a chiral acid in a suitable solvent or solvent mixture, wherein:
the suitable solvent or solvent mixture is selected from acetonitrile, isopropanol, ethanol, water, methanol, or combinations thereof; and the enantiomeric compound mixture comprises
[0000]
[0000] and
[0027] (ii) isolating the enantio-enriched compound mixture
[0028] (iii) reslurrying the enantio-enriched chiral salt mixture in a slurrying solvent or slurrying solvent mixture; and
[0029] (iv) free-basing the enantio-enriched chiral salt mixture to provide the enantio-enriched compound mixture.
[0030] In another embodiment, the invention provides a process of enriching the enantiomeric purity of an enantiomeric compound mixture, comprising:
[0031] (i) crystallizing said enantiomeric compound mixture with a chiral acid in a suitable solvent or solvent mixture, wherein:
the suitable solvent or solvent mixture is selected from acetonitrile, isopropanol, ethanol, water, methanol, or combinations thereof; and the enantiomeric compound mixture comprises
[0000]
[0000] and
[0034] (ii) isolating the enantio-enriched compound mixture; and
[0035] (iii) free-basing the enantio-enriched chiral salt mixture to provide the enantio-enriched compound mixture.
[0036] In another aspect, the chiral acid from any embodiment presented herein is selected from the group consisting of tartaric acid, di-benzoyltartaric acid, malic acid, camphoric acid, camphorsulfonic acid, ascorbic acid, and di-p-toluoyltartaric acid;
[0037] In another aspect, the suitable solvent or solvent mixture from any embodiments presented herein is 1-propanol, 1-butanol, ethyl acetate, tetrahydrofuran, 2-methyltetrahydrofuran, toluene, methyl tert-butylether, diethyl ether, dichloromethane, 1,4-dioxane, 1,2-dimethoxyethane, isopropyl acetate, heptane, hexane, cyclohexane, or octane, or combinations thereof.
[0038] In another aspect, the slurrying solvent solvent or slurrying solvent mixture from any embodiments presented herein is 1-propanol, 1-butanol, ethyl acetate, tetrahydrofuran, 2-methyltetrahydrofuran, toluene, methyl tert-butylether, diethyl ether, dichloromethane, 1,4-dioxane, 1,2-dimethoxyethane, isopropyl acetate, heptane, hexane, cyclohexane, or octane, or combinations thereof.
[0039] In another aspect, the suitable solvent or solvent mixture from any embodiments presented herein is a) acetonitrile or b) a mixture of acetonitrile and isopropanol. Alternatively, another aspect is where the mixture of acetonitrile and methanol comprises 80-90% acetonitrile and 10-20% isopropanol.
[0040] In another aspect, the slurrying solvent or slurrying solvent mixture from any embodiments presented herein is a) acetonitrile or b) a mixture of acetonitrile and isopropanol. Alternatively, another aspect is where the mixture of acetonitrile and isopropanol comprises 80-90% acetonitrile and 10-20% isopropanol.
[0041] In another aspect, the invention provides a process to prepare compound 1 or 1a, or a mixture thereof:
[0000]
[0000] comprising converting amide 2c:
[0000]
[0000] to compound 1 or 1a, or mixtures thereof;
[0042] wherein R 1 is halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl;
[0043] A is N(OMe)Me, NR 8 R 9 , or
[0000]
[0044] p is 1, 2, 3, or 4;
[0045] q is 1, 2, 3, or 4;
[0046] each R 8 and R 9 are each independently H, alkyl, substituted alkyl, aryl, substituted aryl, heteroaryl, or substituted heteroaryl.
[0047] In another aspect, the invention provides a process to prepare compound 1 or 1a, or a mixture thereof:
[0000]
[0000] comprising converting amide 2c:
[0000]
[0000] to compound 1 or 1a, or mixtures thereof;
[0048] wherein R 1 is halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl;
[0049] B is N(OMe)Me, NR 8 R 9 , or
[0000]
[0050] X is O, NR 8 , or S;
[0051] r is 2, 3, or 4;
[0052] s is 2, 3, or 4;
[0053] each R 8 and R 9 are each independently H, alkyl, substituted alkyl, aryl, substituted aryl, heteroaryl, or substituted heteroaryl.
[0054] In another aspect, the invention provides a process to prepare compound 1 or 1a, or a mixture thereof:
[0000]
[0000] comprising converting morpholine amide 2b:
[0000]
[0000] to compound 1 or 1a, or mixtures thereof;
[0055] wherein R 1 is halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0056] In another aspect, the invention provides a process comprising reacting morpholine amide 2b:
[0000]
[0000] wherein M is Mg or MgX; and X is halogen;
to provide compound 1 or 1a, or a mixture thereof:
[0000]
[0057] wherein R 1 is halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0058] In another aspect, the invention provides a process comprising reacting morpholine amide 2b:
[0000]
[0000] wherein M is Mg or MgX, Li, AlX 2 ; and X is halogen, alkyl, or aryl;
to provide compound 1 or 1a, or a mixture thereof:
[0000]
[0059] wherein R 1 is halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0060] In another aspect, any of the embodiments presented herein may comprise amidation of ester 2:
[0000]
[0000] to provide morpholine amide 2b:
[0000]
[0061] wherein each R 1 is independently halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0062] In another aspect, any of the embodiments presented herein may comprise amidation of ester 2d:
[0000]
[0000] to provide morpholine amide 2b:
[0000]
[0063] wherein each R 1 is independently halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl; and
[0064] R 8 is H, alkyl, substituted alkyl, aryl, substituted aryl, heteroaryl, or substituted heteroaryl.
[0065] In another aspect, any of the embodiments presented herein may comprise reacting ester 2:
[0000]
[0000] with morpholine to provide morpholine amide 2b:
[0000]
[0066] wherein each R 1 is independently halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0067] In another aspect, the invention provides a process to prepare compound 1 or 1a, or a mixture thereof:
[0000]
[0000] comprising epoxide-opening of a compound of formula I, VII or VIIa:
[0000]
[0000] to provide a compound of formula II, VIII or VIIIa:
[0000]
[0068] wherein each R 2 is independently
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0069] In another aspect, the invention provides a process to prepare compound 1 or 1a, or mixtures thereof:
[0000]
[0000] comprising forming the tetrazole of substituted-pyridine 4d or 4e, or a mixture thereof:
[0000]
[0000] to tetrazole 6c or 6d,
[0000]
[0000] or a mixture thereof;
wherein each R 2 is independently
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0070] In another aspect, the invention provides a process to prepare compound 1 or 1a, or a mixture thereof:
[0000]
[0000] comprising the arylation of amino-alcohol 4b or 4c,
[0000]
[0000] or
[0000]
[0000] or a mixture thereof,
to amino aryl-pyridine 1-6* or 1-7*,
[0000]
[0000] or
[0000]
[0000] or a mixture thereof;
[0071] wherein each R 1 is independently halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0072] In another aspect, the invention provides a process to prepare compound 1 or 1a, or a mixture thereof:
[0000]
[0000] comprising converting a compound of formula Vb or Vc, or a mixture thereof:
[0000]
[0000] to compound 1 or 1a, or a mixture thereof;
[0073] wherein each R 2 is independently
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0074] In another aspect, the invention provides a process to prepare compound 1 or 1a, or a mixture thereof:
[0000]
[0000] comprising converting a compound of formula 15:
[0000]
[0000] to compound 1 or 1a;
[0075] wherein R 1 is halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0076] In another aspect, any of the embodiments presented herein may comprise reacting a compound of formula IVa:
[0000]
[0000] under asymmetric dihydroxylation conditions to provide a compound of formula Vb or Vc, or mixtures thereof:
[0000]
[0000] wherein the asymmetric dihydroxylation conditions comprise:
[0077] (i) AD-mix alpha or AD-mix beta; or
[0078] (ii) a first oxidant in catalytic amount, a second oxidant in stoichiometric amount, a base, and a chiral ligand; and
[0079] wherein each R 2 is independently
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0080] In another aspect, any of the embodiments presented herein may comprise a process, wherein:
[0081] (i) the first oxidant in catalytic amount is Osa t or K 2 OsO 2 (OH) 4 ;
[0082] (ii) the second oxidant in stoichiometric amount is K 3 Fe(CN) 6 or N-methylmorpholine-N-oxide;
[0083] (iii) the base is Cs 2 CO 3 , Na 2 CO 3 , K 2 CO 3 or NaHCO 3 ; and
[0084] (iv) the chiral ligand is selected from the group consisting of (DHQ) 2 PHAL, (DHQD) 2 PHAL, (DHQD) 2 AQN, (DHQ) 2 AQN, (DHQD) 2 PYR, and (DHQ) 2 PYR.
[0085] In another aspect, any of the embodiments presented herein may comprise a process, wherein the chiral ligand is selected from the group consisting of (DHQ) 2 PHAL, (DHQD) 2 PHAL, (DHQD) 2 AQN, and (DHQD) 2 PYR.
[0086] In another aspect, any of the embodiments presented herein may comprise the addition of MeSO 2 NH 2 .
[0087] In another aspect, any of the embodiments presented herein may comprise a process comprising converting a compound of formula VIb or VIc, or a mixture thereof:
[0000]
[0000] to a compound of formula VII or VIIa, or a mixture thereof:
[0000]
[0088] wherein each R 2 is independently
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl; and Y is —OSO 2 -alkyl, —OSO 2 -substituted alkyl, —OSO 2 -aryl, —OSO 2 -substituted aryl, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, or halogen.
[0089] In another aspect, any of the embodiments presented herein may comprise a process comprising:
[0090] (i) activating the primary alcohol of 2-6a or 2-6c,
[0000]
[0000] or a mixture thereof, to provide a compound of formula 2-7a or 2-7c,
[0000]
[0000] or a mixture thereof;
[0091] wherein Y is —OSO 2 -alkyl, —OSO 2 -substituted alkyl, —OSO 2 -aryl, —OSO 2 -substituted aryl, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, or halogen;
[0092] (ii) ring-closing of a compound of 2-7a or 2-7c,
[0000]
[0000] or a mixture thereof, to provide epoxide 5* or 5b*,
[0000]
[0000] or a mixture thereof;
[0093] (iii) ring-opening epoxide 5* or 5b*,
[0000]
[0000] or a mixture thereof, to provide amino-alcohol 1-6* or 1-7*,
[0000]
[0000] or a mixture thereof; and
[0094] (iv) forming the tetrazole of amino-alcohol 1-6* or 1-7*,
[0000]
[0000] to provide compound 1 or 1a,
[0000]
[0000] or a mixture thereof.
[0095] In another aspect, any of the embodiments presented herein may comprise a process comprising:
[0096] (i) activating the primary alcohol 2-6b or 2-6d,
[0000]
[0000] or a mixture thereof, to provide a compound of formula 2-7b or 2-7d,
[0000]
[0000] or a mixture thereof;
[0097] wherein each Y is independently —OSO 2 -alkyl, —OSO 2 -substituted alkyl, —OSO 2 -aryl, —OSO 2 -substituted aryl, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, or halogen;
[0098] (ii) ring-closing of compound 2-7b or 2-7d,
[0000]
[0000] or a mixture thereof, to provide epoxide 4* or 4c*,
[0000]
[0000] or a mixture thereof;
[0099] (iii) ring-opening epoxide 4* or 4c*,
[0000]
[0000] or a mixture thereof, to provide amino-alcohol 4b or 4c,
[0000]
[0000] or a mixture thereof;
[0100] (iv) arylating amino-alcohol 4b or 4c,
[0000]
[0000] or a mixture thereof, to provide aryl-pyridine 1-6* or 1-7*,
[0000]
[0000] or a mixture thereof; and
[0101] (v) forming the tetrazole of amino-alcohol 1-6* or 1-7*,
[0000]
[0000] or a mixture thereof, to provide compound 1 or 1a,
[0000]
[0000] or a mixture thereof;
[0102] wherein each R 1 is independently halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0103] In another aspect, the invention provides a compound of formula IVb:
[0000]
[0104] wherein R is
[0000]
[0000] and
[0105] each R 12 is independently H, optionally substituted alkyl, optionally substituted alkenyl, optionally substituted aryl, optionally substituted heteroaryl, optionally substituted cycloalkyl, or optionally substituted hetrocyclyl.
[0000] In another aspect, the invention provides a compound of formula VI* or VIa*, or a mixture thereof:
[0000]
[0000] wherein R is
[0000]
[0106] each Y 1 is independently OH, —OSO 2 -alkyl, —OSO 2 -substituted alkyl, —OSO 2 -aryl, —OSO 2 -substituted aryl, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, or halogen; and
[0107] each R 12 is independently H, optionally substituted alkyl, optionally substituted alkenyl, optionally substituted aryl, optionally substituted heteroaryl, optionally substituted cycloalkyl, or optionally substituted heterocyclyl.
[0108] In another aspect, the invention provides a process to prepare a compound of formula IX or IXa, or a mixture thereof, comprising:
[0000]
[0109] (i) combining compound 1 or 1a,
[0000]
[0000] or a mixture thereof, a sulfonic acid
[0000]
[0110] and a crystallization solvent or crystallization solvent mixture;
[0111] (ii) diluting the mixture from step (i) with a crystallization co-solvent or crystallization co-solvent mixture; and
[0112] (iii) isolating a compound of formula IX or IXa, or a mixture thereof;
[0113] wherein each Z is independently aryl, substituted aryl, alkyl, or substituted alkyl.
[0114] In another aspect, the invention provides a process to prepare a compound of formula 5* or 5b*,
[0000]
[0000] or a mixture thereof, the method comprising converting a compound of formula IVa,
[0000]
[0115] wherein R 2 is
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0116] In another aspect, any of the embodiments presented herein may comprise reacting a compound of formula IVa:
[0000]
[0000] under asymmetric dihydroxylation conditions to provide a compound of formula Vb or Vc, or mixtures thereof:
[0000]
[0000] wherein the asymmetric dihydroxylation conditions comprise:
[0117] (i) AD-mix alpha or AD-mix beta; or
[0118] (ii) a first oxidant in catalytic amount, a second oxidant in stoichiometric amount, a base, and a chiral ligand; and
[0000]
[0119] wherein each R 2 is independently halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)-O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)-O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0120] In another aspect, any of the embodiments presented herein may comprise converting a compound of formula Vb or Vc, or a mixture thereof:
[0000]
[0000] to provide a compound of formula of 5* or 5b*,
[0000]
[0000] or a mixture thereof:
[0121] wherein each R 2 is independently
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0122] In another aspect, any of the embodiments presented herein may further comprise:
[0123] (i) arylating a compound of formula IVa,
[0000]
[0000] to afford a compound of formula IV,
[0000]
[0124] (ii) dihydroxylating IV,
[0000]
[0000] to afford a compound of formula V or Va,
[0000]
[0000] or a mixture thereof;
[0125] (iii) activating the primary alcohol of a compound of formula V or Va,
[0000]
[0000] or a mixture thereof, to provide a compound of formula 2-7a or 2-7c,
[0000]
[0000] or a mixture thereof; and
[0126] (iv) ring-closing of a compound of formula 2-7a or 2-7c,
[0000]
[0000] or a mixture thereof, to afford a compound of formula of 5* or 5b*,
[0000]
[0000] or a mixture thereof;
[0127] wherein R is
[0000]
[0128] each R 2 is independently
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl; and
[0129] each Y is independently OSO 2 -alkyl, OSO 2 -substituted alkyl, —OSO 2 -aryl, —OSO 2 -substituted aryl, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, or halogen.
[0130] In another aspect, Z from any of the embodiments presented herein is phenyl, p-tolyl, methyl, or ethyl.
[0131] In another aspect, any of the embodiments presented herein may further comprise:
[0132] (i) dihydroxylating a compound of formula IVa,
[0000]
[0000] to afford a compound of formula Vb or Vc,
[0000]
[0000] or a mixture thereof;
[0133] (ii) arylating a compound of formula Vb or Vc,
[0000]
[0000] or a mixture thereof, to afford a compound of formula V or Va,
[0000]
[0000] or a mixture thereof;
[0134] (iii) activating the primary alcohol of a compound of formula V or Va,
[0000]
[0000] or a mixture thereof, to provide a compound of formula 2-7a or 2-7c,
[0000]
[0000] or a mixture thereof; and
[0135] (iv) ring-closing of a compound of formula 2-7a or 2-7c.
[0000]
[0000] or a mixture thereof, to afford a compound of formula of 5* or 5b*,
[0000]
[0000] or a mixture thereof;
[0000]
[0136] wherein R is
[0137] each R 2 is independently
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl; and
each Y is independently —OSO 2 -alkyl, OSO 2 -substituted alkyl, —OSO 2 -aryl, —OSO 2 -substituted aryl, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, or halogen.
[0139] In another aspect, any of the embodiments presented herein may further comprise:
[0140] (i) dihydroxylating a compound of formula IVa,
[0000]
[0000] to afford a compound of formula Vb or Vc,
[0000]
[0000] or a mixture thereof;
[0141] (ii) activating the primary alcohol of a compound of formula Vb or Vc,
[0000]
[0000] or a mixture thereof, to afford a compound of formula VIb or VIc,
[0000]
[0000] or a mixture thereof;
[0142] (iii) ring-closing of a compound of formula VIb or VIc,
[0000]
[0000] or a mixture thereof, to provide a compound of formula VII or VIIa,
[0000]
[0000] or a mixture thereof; and
[0143] (iv) arylating a compound of formula VII or VIIa,
[0000]
[0000] or a mixture thereof, to afford a compound of formula 5* or 5b*,
[0000]
[0000] or a mixture thereof;
[0144] wherein each R 2 is independently
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)-O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl; and each Y is independently OSO 2 -alkyl, —OSO 2 -substituted alkyl, —OSO 2 -aryl, —OSO 2 -substituted aryl, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, or halogen.
[0145] In another aspect, any of the embodiments presented herein may further comprise:
[0146] (i) ring opening of a compound of formula VII or VIIa,
[0000]
[0000] or a mixture thereof, to afford 1-6* or 1-7*,
[0000]
[0000] or a mixture thereof;
[0147] wherein each R 2 is independently
[0000]
[0000] halo, —O(C═O)-alkyl, —O(C═O)-substituted alkyl, —O(C═O)-aryl, —O(C═O)-substituted aryl, —O(C═O)—O-alkyl, —O(C═O)—O-substituted alkyl, —O(C═O)—O-aryl, —O(C═O)—O-substituted aryl, —O(SO 2 )-alkyl, —O(SO 2 )-substituted alkyl, —O(SO 2 )-aryl, or —O(SO 2 )-substituted aryl.
[0148] In another aspect, any of the embodiments presented herein may further comprise:
[0149] (i) forming the tetrazole of 1-6* or 1-7*,
[0000]
[0000] or a mixture thereof to afford compound 1 or 1a, or a mixture thereof:
[0000]
[0150] In another aspect, the crystalization solvent or crystallization solvent mixture from any of the embodiments presented herein is ethyl acetate, isopropyl acetate, ethanol, methanol, or acetonitrile, or combinations thereof.
[0151] In another aspect, the crystallization co-solvent or crystallization co-solvent mixture from any of the embodiments presented herein is pentane, methyl t-butylether, hexane, heptane, or toluene, or combinations thereof.
[0152] In another aspect, any of the embodiments presented herein may comprise repeating the enantio-enrichment step(s) until desired level of enantio-enrichment is attained.
[0153] In another aspect, Y in any of the embodiments presented herein may be mesylate or tosylate.
[0154] In another aspect, any of the embodiments presented herein may comprise substituting morpholine-amide 2b with amide 2c.
[0155] In another aspect, any of the embodiments presented herein may comprise substituting ethyl ester 2 with ester 2d. In other aspects, the invention provides a compound of any of the formulae herein, wherein the compound inhibits (or is identified to inhibit) lanosterol demethylase (CYP51).
[0156] In another aspect, the invention provides a pharmaceutical composition comprising a compound of any formulae herein and a pharmaceutically acceptable carrier.
[0157] In other aspects, the invention provides a method of modulating metalloenzyme activity in a subject, comprising contacting the subject with a compound of any formulae herein, in an amount and under conditions sufficient to modulate metalloenzyme activity.
[0158] In one aspect, the invention provides a method of treating a subject suffering from or susceptible to a metalloenzyme-related disorder or disease, comprising administering to the subject an effective amount of a compound or pharmaceutical composition of any formulae herein.
[0159] In another aspect, the invention provides a method of treating a subject suffering from or susceptible to a metalloenzyme-related disorder or disease, wherein the subject has been identified as in need of treatment for a metalloenzyme-related disorder or disease, comprising administering to said subject in need thereof, an effective amount of a compound or pharmaceutical composition of any formulae herein, such that said subject is treated for said disorder.
[0160] In another aspect, the invention provides a method of treating a subject suffering from or susceptible to a metalloenzyme-mediated disorder or disease, wherein the subject has been identified as in need of treatment for a metalloenzyme-mediated disorder or disease, comprising administering to said subject in need thereof, an effective amount of a compound or pharmaceutical composition of any formulae herein, such that metalloenzyme activity in said subject is modulated (e.g., down regulated, inhibited). In another aspect, the compounds delineated herein preferentially target cancer cells over nontransformed cells.
DETAILED DESCRIPTION
Definitions
[0161] The term “chiral” refers to molecules which have the property of non-superimposability of the mirror image partner, while the term “achiral” refers to molecules which are superimposable on their mirror image partner.
[0162] The term “diastereomers” refers to stereoisomers with two or more centers of dissymmetry and whose molecules are not minor images of one another.
[0163] The term “enantiomers” refers to two stereoisomers of a compound which are non-superimposable minor images of one another. An equimolar mixture of two enantiomers is called a “racemic mixture” or a “racemate.”
[0164] The term “isomers” or “stereoisomers” refers to compounds which have identical chemical constitution, but differ with regard to the arrangement of the atoms or groups in space.
[0165] The term “prodrug” includes compounds with moieties which can be metabolized in vivo. Generally, the prodrugs are metabolized in vivo by esterases or by other mechanisms to active drugs. Examples of prodrugs and their uses are well known in the art (See, e.g., Berge et al. (1977) “Pharmaceutical Salts”, J. Pharm. Sci. 66:1-19). The prodrugs can be prepared in situ during the final isolation and purification of the compounds, or by separately reacting the purified compound in its free acid form or hydroxyl with a suitable esterifying agent. Hydroxyl groups can be converted into esters via treatment with a carboxylic acid. Examples of prodrug moieties include substituted and unsubstituted, branch or unbranched lower alkyl ester moieties, (e.g., propionoic acid esters), lower alkenyl esters, di-lower alkyl-amino lower-alkyl esters (e.g., dimethylaminoethyl ester), acylamino lower alkyl esters (e.g., acetyloxymethyl ester), acyloxy lower alkyl esters (e.g., pivaloyloxymethyl ester), aryl esters (phenyl ester), aryl-lower alkyl esters (e.g., benzyl ester), substituted (e.g., with methyl, halo, or methoxy substituents) aryl and aryl-lower alkyl esters, amides, lower-alkyl amides, di-lower alkyl amides, and hydroxy amides. Preferred prodrug moieties are propionoic acid esters and acyl esters. Prodrugs which are converted to active forms through other mechanisms in vivo are also included. In aspects, the compounds of the invention are prodrugs of any of the formulae herein.
[0166] The term “subject” refers to animals such as mammals, including, but not limited to, primates (e.g., humans), cows, sheep, goats, horses, dogs, cats, rabbits, rats, mice and the like. In certain embodiments, the subject is a human.
[0167] The terms “a,” “an,” and “the” refer to “one or more” when used in this application, including the claims. Thus, for example, reference to “a sample” includes a plurality of samples, unless the context clearly is to the contrary (e.g., a plurality of samples), and so forth.
[0168] Throughout this specification and the claims, the words “comprise,” “comprises,” and “comprising” are used in a non-exclusive sense, except where the context requires otherwise.
[0169] As used herein, the term “about,” when referring to a value is meant to encompass variations of, in some embodiments ±20%, in some embodiments ±10%, in some embodiments ±5%, in some embodiments ±1%, in some embodiments ±0.5%, and in some embodiments ±0.1% from the specified amount, as such variations are appropriate to perform the disclosed methods or employ the disclosed compositions.
[0170] Use of the word “inhibitor” herein is meant to mean a molecule that exhibits activity for inhibiting a metalloenzyme . By “inhibit” herein is meant to decrease the activity of metalloenzyme , as compared to the activity of metalloenzyme in the absence of the inhibitor. In some embodiments, the term “inhibit” means a decrease in metalloenzyme activity of at least about 5%, at least about 10%, at least about 20%, at least about 25%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95%. In other embodiments, inhibit means a decrease in metalloenzyme activity of about 5% to about 25%, about 25% to about 50%, about 50% to about 75%, or about 75% to 100%. In some embodiments, inhibit means a decrease in metalloenzyme activity of about 95% to 100%, e.g., a decrease in activity of 95%, 96%, 97%, 98%, 99%, or 100%. Such decreases can be measured using a variety of techniques that would be recognizable by one of skill in the art. Particular assays for measuring individual activity are described below.
[0171] Furthermore the compounds of the invention include olefins having either geometry:
[0172] “Z” refers to what is referred to as a “cis” (same side) configuration whereas “E” refers to what is referred to as a “trans” (opposite side) configuration. With respect to the nomenclature of a chiral center, the terms “d” and “1” configuration are as defined by the IUPAC Recommendations. As to the use of the terms, diastereomer, racemate, epimer and enantiomer, these will be used in their normal context to describe the stereochemistry of preparations.
[0173] As used herein, the term “alkyl” refers to a straight-chained or branched hydrocarbon group containing 1 to 12 carbon atoms. The term “lower alkyl” refers to a C1-C6 alkyl chain. Examples of alkyl groups include methyl, ethyl, n-propyl, isopropyl, tert-butyl, and n-pentyl. Alkyl groups may be optionally substituted with one or more substituents.
[0174] The term “alkenyl” refers to an unsaturated hydrocarbon chain that may be a straight chain or branched chain, containing 2 to 12 carbon atoms and at least one carbon-carbon double bond. Alkenyl groups may be optionally substituted with one or more substituents.
[0175] The term “alkynyl” refers to an unsaturated hydrocarbon chain that may be a straight chain or branched chain, containing the 2 to 12 carbon atoms and at least one carbon-carbon triple bond. Alkynyl groups may be optionally substituted with one or more substituents.
[0176] The sp 2 or sp carbons of an alkenyl group and an alkynyl group, respectively, may optionally be the point of attachment of the alkenyl or alkynyl groups.
[0177] The term “alkoxy” refers to an —O-alkyl radical.
[0178] As used herein, the term “halogen”, “hal” or “halo” means —F, —Cl, —Br or —I.
[0179] The term “haloalkoxy” refers to an -O-alkyl radical that is substituted by one or more halo substituents. Examples of haloalkoxy groups include trifluoromethoxy, and 2,2,2-trifluoroethoxy.
[0180] The term “cycloalkyl” refers to a hydrocarbon 3-8 membered monocyclic or 7-14 membered bicyclic ring system having at least one saturated ring or having at least one non-aromatic ring, wherein the non-aromatic ring may have some degree of unsaturation. Cycloalkyl groups may be optionally substituted with one or more substituents. In one embodiment, 0, 1, 2, 3, or 4 atoms of each ring of a cycloalkyl group may be substituted by a substituent. Representative examples of cycloalkyl group include cyclopropyl, cyclopentyl, cyclohexyl, cyclobutyl, cycloheptyl, cyclopentenyl, cyclopentadienyl, cyclohexenyl, cyclohexadienyl, and the like.
[0181] The term “aryl” refers to a hydrocarbon monocyclic, bicyclic or tricyclic aromatic ring system. Aryl groups may be optionally substituted with one or more substituents. In one embodiment, 0, 1, 2, 3, 4, 5 or 6 atoms of each ring of an aryl group may be substituted by a substituent. Examples of aryl groups include phenyl, naphthyl, anthracenyl, fluorenyl, indenyl, azulenyl, and the like.
[0182] The term “heteroaryl” refers to an aromatic 5-8 membered monocyclic, 8-12 membered bicyclic, or 11-14 membered tricyclic ring system having 1-4 ring heteroatoms if monocyclic, 1-6 heteroatoms if bicyclic, or 1-9 heteroatoms if tricyclic, said heteroatoms selected from O, N, or S, and the remainder ring atoms being carbon (with appropriate hydrogen atoms unless otherwise indicated). Heteroaryl groups may be optionally substituted with one or more substituents. In one embodiment, 0, 1, 2, 3, or 4 atoms of each ring of a heteroaryl group may be substituted by a substituent. Examples of heteroaryl groups include pyridyl, furanyl, thienyl, pyrrolyl, oxazolyl, oxadiazolyl, imidazolyl thiazolyl, isoxazolyl, quinolinyl, pyrazolyl, isothiazolyl, pyridazinyl, pyrimidinyl, pyrazinyl, triazinyl, isoquinolinyl, indazolyl, and the like.
[0183] The term “nitrogen-containing heteroaryl” refers to a heteroaryl group having 1-4 ring nitrogen heteroatoms if monocyclic, 1-6 ring nitrogen heteroatoms if bicyclic, or 1-9 ring nitrogen heteroatoms if tricyclic.
[0184] The term “heterocycloalkyl” refers to a nonaromatic 3-8 membered monocyclic, 7-12 membered bicyclic, or 10-14 membered tricyclic ring system comprising 1-3 heteroatoms if monocyclic, 1-6 heteroatoms if bicyclic, or 1-9 heteroatoms if tricyclic, said heteroatoms selected from O, N, S, B, P or Si, wherein the nonaromatic ring system is completely saturated. Heterocycloalkyl groups may be optionally substituted with one or more substituents. In one embodiment, 0, 1, 2, 3, or 4 atoms of each ring of a heterocycloalkyl group may be substituted by a substituent. Representative heterocycloalkyl groups include piperidinyl, piperazinyl, tetrahydropyranyl, morpholinyl, thiomorpholinyl, 1,3-dioxolane, tetrahydrofuranyl, tetrahydrothienyl, thiirenyl, and the like.
[0185] The term “alkylamino” refers to an amino substituent which is further substituted with one or two alkyl groups. The term “aminoalkyl” refers to an alkyl substituent which is further substituted with one or more amino groups. The term “hydroxyalkyl” or “hydroxylalkyl” refers to an alkyl substituent which is further substituted with one or more hydroxyl groups. The alkyl or aryl portion of alkylamino, aminoalkyl, mercaptoalkyl, hydroxyalkyl, mercaptoalkoxy, sulfonylalkyl, sulfonylaryl, alkylcarbonyl, and alkylcarbonylalkyl may be optionally substituted with one or more substituents.
[0186] Acids and bases useful in the methods herein are known in the art. Acid catalysts are any acidic chemical, which can be inorganic (e.g., hydrochloric, sulfuric, nitric acids, aluminum trichloride) or organic (e.g., camphorsulfonic acid, p-toluenesulfonic acid, acetic acid, ytterbium triflate) in nature. Acids are useful in either catalytic or stoichiometric amounts to facilitate chemical reactions. Bases are any basic chemical, which can be inorganic (e.g., sodium bicarbonate, potassium hydroxide) or organic (e.g., triethylamine, pyridine) in nature. Bases are useful in either catalytic or stoichiometric amounts to facilitate chemical reactions.
[0187] Alkylating agents are any reagent that is capable of effecting the alkylation of the functional group at issue (e.g., oxygen atom of an alcohol, nitrogen atom of an amino group). Alkylating agents are known in the art, including in the references cited herein, and include alkyl halides (e.g., methyl iodide, benzyl bromide or chloride), alkyl sulfates (e.g., methyl sulfate), or other alkyl group-leaving group combinations known in the art. Leaving groups are any stable species that can detach from a molecule during a reaction (e.g., elimination reaction, substitution reaction) and are known in the art, including in the references cited herein, and include halides (e.g., I—, Cl—, Br—, F—), hydroxy, alkoxy (e.g., —OMe, —O-t-Bu), acyloxy anions (e.g., —OAc, —OC(O)CF 3 ), sulfonates (e.g., mesyl, tosyl), acetamides (e.g., —NHC(O)Me), carbamates (e.g., N(Me)C(O)Ot-Bu), phosphonates (e.g., —OP(O)(OEt) 2 ), water or alcohols (protic conditions), and the like.
[0188] In certain embodiments, substituents on any group (such as, for example, alkyl, alkenyl, alkynyl, aryl, aralkyl, heteroaryl, heteroaralkyl, cycloalkyl, heterocycloalkyl) can be at any atom of that group, wherein any group that can be substituted (such as, for example, alkyl, alkenyl, alkynyl, aryl, aralkyl, heteroaryl, heteroaralkyl, cycloalkyl, heterocycloalkyl) can be optionally substituted with one or more substituents (which may be the same or different), each replacing a hydrogen atom. Examples of suitable substituents include, but are not limited to alkyl, alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aralkyl, heteroaralkyl, aryl, heteroaryl, halogen, haloalkyl, cyano, nitro, alkoxy, aryloxy, hydroxyl, hydroxylalkyl, oxo (i.e., carbonyl), carboxyl, formyl, alkylcarbonyl, alkylcarbonylalkyl, alkoxycarbonyl, alkylcarbonyloxy, aryloxycarbonyl, heteroaryloxy, heteroaryloxycarbonyl, thio, mercapto, mercaptoalkyl, arylsulfonyl, amino, aminoalkyl, dialkylamino, alkylcarbonylamino, alkylaminocarbonyl, alkoxycarbonylamino, alkylamino, arylamino, diarylamino, alkylcarbonyl, or arylamino-substituted aryl; arylalkylamino, aralkylaminocarbonyl, amido, alkylaminosulfonyl, arylaminosulfonyl, dialkylaminosulfonyl, alkylsulfonylamino, arylsulfonylamino, imino, carbamido, carbamyl, thioureido, thiocyanato, sulfoamido, sulfonylalkyl, sulfonylaryl, mercaptoalkoxy, N-hydroxyamidinyl, or N′-aryl, N″-hydroxyamidinyl.
[0189] Compounds of the invention can be made by means known in the art of organic synthesis. Methods for optimizing reaction conditions, if necessary minimizing competing by-products, are known in the art. Reaction optimization and scale-up may advantageously utilize high-speed parallel synthesis equipment and computer-controlled microreactors (e.g. Design And Optimization in Organic Synthesis, 2 nd Edition, Carlson R, Ed, 2005; Elsevier Science Ltd ; Jähnisch, K et al, Angew. Chem. Int. Ed. Engl. 2004 43: 406; and references therein). Additional reaction schemes and protocols may be determined by the skilled artesian by use of commercially available structure-searchable database software, for instance,
[0190] SciFinder® (CAS division of the American Chemical Society) and CrossFire Beilstein® (Elsevier MDL), or by appropriate keyword searching using an internet search engine such as Google® or keyword databases such as the US Patent and Trademark Office text database. The invention includes the intermediate compounds used in making the compounds of the formulae herein as well as methods of making such compounds and intermediates, including without limitation those as specifically described in the examples herein.
[0191] The compounds herein may also contain linkages (e.g., carbon-carbon bonds) wherein bond rotation is restricted about that particular linkage, e.g. restriction resulting from the presence of a ring or double bond. Accordingly, all cis/trans and E/Z isomers are expressly included in the present invention. The compounds herein may also be represented in multiple tautomeric forms, in such instances, the invention expressly includes all tautomeric forms of the compounds described herein, even though only a single tautomeric form may be represented. All such isomeric forms of such compounds herein are expressly included in the present invention. All crystal forms and polymorphs of the compounds described herein are expressly included in the present invention. Also embodied are extracts and fractions comprising compounds of the invention. The term isomers is intended to include diastereoisomers, enantiomers, regioisomers, structural isomers, rotational isomers, tautomers, and the like. For compounds which contain one or more stereogenic centers, e.g., chiral compounds, the methods of the invention may be carried out with an enantiomerically enriched compound, a racemate, or a mixture of diastereomers.
[0192] Preferred enantiomerically enriched compounds have an enantiomeric excess of 50% or more, more preferably the compound has an enantiomeric excess of 60%, 70%, 80%, 90%, 95%, 98%, or 99% or more. In preferred embodiments, only one enantiomer or diastereomer of a chiral compound of the invention is administered to cells or a subject.
Pharmaceutical Compositions
[0193] In one aspect, the invention provides a pharmaceutical composition comprising a compound of any formulae herein and a pharmaceutically acceptable carrier.
[0194] In another embodiment, the invention provides a pharmaceutical composition further comprising an additional therapeutic agent. In a further embodiment, the additional therapeutic agent is an anti-cancer agent, antifungal agent, cardiovascular agent, antiinflammatory agent, chemotherapeutic agent, an anti-angiogenesis agent, cytotoxic agent, an anti-proliferation agent, metabolic disease agent, opthalmologic disease agent, central nervous system (CNS) disease agent, urologic disease agent, or gastrointestinal disease agent.
[0195] In one aspect, the invention provides a kit comprising an effective amount of a compound of any formulae herein, in unit dosage form, together with instructions for administering the compound to a subject suffering from or susceptible to a metalloenzyme-mediated disease or disorder, including cancer, solid tumor, cardiovascular disease, inflammatory disease, infectious disease. In other embodiments the disease, disorder or symptom thereof is metabolic disease, opthalmologic disease, central nervous system (CNS) disease, urologic disease, or gastrointestinal disease.
[0196] The term “pharmaceutically acceptable salts” or “pharmaceutically acceptable carrier” is meant to include salts of the active compounds which are prepared with relatively nontoxic acids or bases, depending on the particular substituents found on the compounds described herein. When compounds of the present invention contain relatively acidic functionalities, base addition salts can be obtained by contacting the neutral form of such compounds with a sufficient amount of the desired base, either neat or in a suitable inert solvent. Examples of pharmaceutically acceptable base addition salts include sodium, potassium, calcium, ammonium, organic amino, or magnesium salt, or a similar salt. When compounds of the present invention contain relatively basic functionalities, acid addition salts can be obtained by contacting the neutral form of such compounds with a sufficient amount of the desired acid, either neat or in a suitable inert solvent. Examples of pharmaceutically acceptable acid addition salts include those derived from inorganic acids like hydrochloric, hydrobromic, nitric, carbonic, monohydrogencarbonic, phosphoric, monohydrogenphosphoric, dihydrogenphosphoric, sulfuric, monohydrogensulfuric, hydroiodic, or phosphorous acids and the like, as well as the salts derived from relatively nontoxic organic acids like acetic, propionic, isobutyric, maleic, malonic, benzoic, succinic, suberic, fumaric, lactic, mandelic, phthalic, benzenesulfonic, p-tolylsulfonic, citric, tartaric, methanesulfonic, and the like. Also included are salts of amino acids such as arginate and the like, and salts of organic acids like glucuronic or galactunoric acids and the like (see, e.g., Berge et al., Journal of Pharmaceutical Science 66:1-19 (1977)). Certain specific compounds of the present invention contain both basic and acidic functionalities that allow the compounds to be converted into either base or acid addition salts. Other pharmaceutically acceptable carriers known to those of skill in the art are suitable for the present invention.
[0197] The neutral forms of the compounds may be regenerated by contacting the salt with a base or acid and isolating the parent compound in the conventional manner. The parent form of the compound differs from the various salt forms in certain physical properties, such as solubility in polar solvents, but otherwise the salts are equivalent to the parent form of the compound for the purposes of the present invention.
[0198] In addition to salt forms, the present invention provides compounds which are in a prodrug form. Prodrugs of the compounds described herein are those compounds that readily undergo chemical changes under physiological conditions to provide the compounds of the present invention. Additionally, prodrugs can be converted to the compounds of the present invention by chemical or biochemical methods in an ex vivo environment. For example, prodrugs can be slowly converted to the compounds of the present invention when placed in a transdermal patch reservoir with a suitable enzyme or chemical reagent.
[0199] Certain compounds of the present invention can exist in unsolvated forms as well as solvated forms, including hydrated forms. In general, the solvated forms are equivalent to unsolvated forms and are intended to be encompassed within the scope of the present invention. Certain compounds of the present invention may exist in multiple crystalline or amorphous forms. In general, all physical forms are equivalent for the uses contemplated by the present invention and are intended to be within the scope of the present invention.
[0200] The invention also provides a pharmaceutical composition, comprising an effective amount a compound described herein and a pharmaceutically acceptable carrier. In an embodiment, compound is administered to the subject using a pharmaceutically-acceptable formulation, e.g., a pharmaceutically-acceptable formulation that provides sustained delivery of the compound to a subject for at least 12 hours, 24 hours, 36 hours, 48 hours, one week, two weeks, three weeks, or four weeks after the pharmaceutically-acceptable formulation is administered to the subject.
[0201] Actual dosage levels and time course of administration of the active ingredients in the pharmaceutical compositions of this invention may be varied so as to obtain an amount of the active ingredient which is effective to achieve the desired therapeutic response for a particular patient, composition, and mode of administration, without being toxic (or unacceptably toxic) to the patient.
[0202] In use, at least one compound according to the present invention is administered in a pharmaceutically effective amount to a subject in need thereof in a pharmaceutical carrier by intravenous, intramuscular, subcutaneous, or intracerebro ventricular injection or by oral administration or topical application. In accordance with the present invention, a compound of the invention may be administered alone or in conjunction with a second, different therapeutic.
[0203] By “in conjunction with” is meant together, substantially simultaneously or sequentially. In one embodiment, a compound of the invention is administered acutely. The compound of the invention may therefore be administered for a short course of treatment, such as for about 1 day to about 1 week. In another embodiment, the compound of the invention may be administered over a longer period of time to ameliorate chronic disorders, such as, for example, for about one week to several months depending upon the condition to be treated.
[0204] By “pharmaceutically effective amount” as used herein is meant an amount of a compound of the invention, high enough to significantly positively modify the condition to be treated but low enough to avoid serious side effects (at a reasonable benefit/risk ratio), within the scope of sound medical judgment. A pharmaceutically effective amount of a compound of the invention will vary with the particular goal to be achieved, the age and physical condition of the patient being treated, the severity of the underlying disease, the duration of treatment, the nature of concurrent therapy and the specific compound employed. For example, a therapeutically effective amount of a compound of the invention administered to a child or a neonate will be reduced proportionately in accordance with sound medical judgment. The effective amount of a compound of the invention will thus be the minimum amount which will provide the desired effect.
[0205] A decided practical advantage of the present invention is that the compound may be administered in a convenient manner such as by intravenous, intramuscular, subcutaneous, oral or intra-cerebroventricular injection routes or by topical application, such as in creams or gels. Depending on the route of administration, the active ingredients which comprise a compound of the invention may be required to be coated in a material to protect the compound from the action of enzymes, acids and other natural conditions which may inactivate the compound. In order to administer a compound of the invention by other than parenteral administration, the compound can be coated by, or administered with, a material to prevent inactivation.
[0206] The compound may be administered parenterally or intraperitoneally. Dispersions can also be prepared, for example, in glycerol, liquid polyethylene glycols, and mixtures thereof, and in oils.
[0207] Some examples of substances which can serve as pharmaceutical carriers are sugars, such as lactose, glucose and sucrose; starches such as corn starch and potato starch; cellulose and its derivatives such as sodium carboxymethycellulose, ethylcellulose and cellulose acetates; powdered tragancanth; malt; gelatin; talc; stearic acids; magnesium stearate; calcium sulfate; vegetable oils, such as peanut oils, cotton seed oil, sesame oil, olive oil, corn oil and oil of theobroma; polyols such as propylene glycol, glycerine, sorbitol, manitol, and polyethylene glycol; agar; alginic acids; pyrogen-free water; isotonic saline; and phosphate buffer solution; skim milk powder; as well as other non-toxic compatible substances used in pharmaceutical formulations such as Vitamin C, estrogen and echinacea, for example. Wetting agents and lubricants such as sodium lauryl sulfate, as well as coloring agents, flavoring agents, lubricants, excipients, tableting agents, stabilizers, anti-oxidants and preservatives, can also be present. Solubilizing agents, including for example, cremaphore and beta-cyclodextrins can also used in the pharmaceutical compositions herein.
[0208] Pharmaceutical compositions comprising the active compounds of the presently disclosed subject matter (or prodrugs thereof) can be manufactured by means of conventional mixing, dissolving, granulating, dragee-making levigating, emulsifying, encapsulating, entrapping or lyophilization processes. The compositions can be formulated in conventional manner using one or more physiologically acceptable carriers, diluents, excipients or auxiliaries which facilitate processing of the active compounds into preparations which can be used pharmaceutically.
[0209] Pharmaceutical compositions of the presently disclosed subject matter can take a form suitable for virtually any mode of administration, including, for example, topical, ocular, oral, buccal, systemic, nasal, injection, transdermal, rectal, vaginal, and the like, or a form suitable for administration by inhalation or insufflation.
[0210] For topical administration, the active compound(s) or prodrug(s) can be formulated as solutions, gels, ointments, creams, suspensions, and the like.
[0211] Systemic formulations include those designed for administration by injection, e.g., subcutaneous, intravenous, intramuscular, intrathecal or intraperitoneal injection, as well as those designed for transdermal, transmucosal, oral, or pulmonary administration.
[0212] Useful injectable preparations include sterile suspensions, solutions or emulsions of the active compound(s) in aqueous or oily vehicles. The compositions also can contain formulating agents, such as suspending, stabilizing and/or dispersing agent. The formulations for injection can be presented in unit dosage form (e.g., in ampules or in multidose containers) and can contain added preservatives.
[0213] Alternatively, the injectable formulation can be provided in powder form for reconstitution with a suitable vehicle, including but not limited to sterile pyrogen free water, buffer, dextrose solution, and the like, before use. To this end, the active compound(s) can be dried by any art-known technique, such as lyophilization, and reconstituted prior to use.
[0214] For transmucosal administration, penetrants appropriate to the barrier to be permeated are used in the formulation. Such penetrants are known in the art.
[0215] For oral administration, the pharmaceutical compositions can take the form of, for example, lozenges, tablets or capsules prepared by conventional means with pharmaceutically acceptable excipients such as binding agents (e.g., pregelatinized maize starch, polyvinylpyrrolidone or hydroxypropyl methylcellulose); fillers (e.g., lactose, microcrystalline cellulose or calcium hydrogen phosphate); lubricants (e.g., magnesium stearate, talc or silica); disintegrants (e.g., potato starch or sodium starch glycolate); or wetting agents (e.g., sodium lauryl sulfate). The tablets can be coated by methods well known in the art with, for example, sugars or enteric coatings.
[0216] Liquid preparations for oral administration can take the form of, for example, elixirs, solutions, syrups or suspensions, or they can be presented as a dry product for constitution with water or other suitable vehicle before use. Such liquid preparations can be prepared by conventional means with pharmaceutically acceptable additives such as suspending agents (e.g., sorbitol syrup, cellulose derivatives or hydrogenated edible fats); emulsifying agents (e.g., lecithin or acacia); non aqueous vehicles (e.g., almond oil, oily esters, ethyl alcohol or fractionated vegetable oils); and preservatives (e.g., methyl or propyl p-hydroxybenzoates or sorbic acid). The preparations also can contain buffer salts, preservatives, flavoring, coloring and sweetening agents as appropriate.
[0217] Preparations for oral administration can be suitably formulated to give controlled release of the active compound or prodrug, as is well known.
[0218] For buccal administration, the compositions can take the form of tablets or lozenges formulated in a conventional manner.
[0219] For rectal and vaginal routes of administration, the active compound(s) can be formulated as solutions (for retention enemas), suppositories, or ointments containing conventional suppository bases, such as cocoa butter or other glycerides.
[0220] For nasal administration or administration by inhalation or insufflation, the active compound(s) or prodrug(s) can be conveniently delivered in the form of an aerosol spray from pressurized packs or a nebulizer with the use of a suitable propellant, e.g., dichlorodifluoromethane, trichlorofluoromethane, dichlorotetrafluoroethane, fluorocarbons, carbon dioxide or other suitable gas. In the case of a pressurized aerosol, the dosage unit can be determined by providing a valve to deliver a metered amount. Capsules and cartridges for use in an inhaler or insufflator (for example capsules and cartridges comprised of gelatin) can be formulated containing a powder mix of the compound and a suitable powder base such as lactose or starch.
[0221] A specific example of an aqueous suspension formulation suitable for nasal administration using commercially-available nasal spray devices includes the following ingredients: active compound or prodrug (0.5-20 mg/ml); benzalkonium chloride (0.1-0.2 mg/mL); polysorbate 80 (TWEEN® 80; 0.5-5 mg/ml); carboxymethylcellulose sodium or microcrystalline cellulose (1-15 mg/ml); phenylethanol (1-4 mg/ml); and dextrose (20-50 mg/ml). The pH of the final suspension can be adjusted to range from about pH5 to pH7, with a pH of about pH 5.5 being typical.
[0222] For prolonged delivery, the active compound(s) or prodrug(s) can be formulated as a depot preparation for administration by implantation or intramuscular injection. The active ingredient can be formulated with suitable polymeric or hydrophobic materials (e.g., as an emulsion in an acceptable oil) or ion exchange resins, or as sparingly soluble derivatives, e.g., as a sparingly soluble salt. Alternatively, transdermal delivery systems manufactured as an adhesive disc or patch which slowly releases the active compound(s) for percutaneous absorption can be used. To this end, permeation enhancers can be used to facilitate transdermal penetration of the active compound(s). Suitable transdermal patches are described in for example, U.S. Pat. No. 5,407,713; U.S. Pat. No. 5,352,456; U.S. Pat. No. 5,332,213; U.S. Pat. No. 5,336,168; U.S. Pat. No. 5,290,561; U.S. Pat. No. 5,254,346; U.S. Pat. No. 5,164,189; U.S. Pat. No. 5,163,899; U.S. Pat. No. 5,088,977; U.S. Pat. No. 5,087,240; U.S. Pat. No. 5,008,110; and U.S. Pat. No. 4,921,475, each of which is incorporated herein by reference in its entirety.
[0223] Alternatively, other pharmaceutical delivery systems can be employed. Liposomes and emulsions are well-known examples of delivery vehicles that can be used to deliver active compound(s) or prodrug(s). Certain organic solvents such as dimethylsulfoxide (DMSO) also can be employed.
[0224] The pharmaceutical compositions can, if desired, be presented in a pack or dispenser device which can contain one or more unit dosage forms containing the active compound(s). The pack can, for example, comprise metal or plastic foil, such as a blister pack. The pack or dispenser device can be accompanied by instructions for administration.
[0225] The active compound(s) or prodrug(s) of the presently disclosed subject matter, or compositions thereof, will generally be used in an amount effective to achieve the intended result, for example in an amount effective to treat or prevent the particular disease being treated. The compound(s) can be administered therapeutically to achieve therapeutic benefit or prophylactically to achieve prophylactic benefit. By therapeutic benefit is meant eradication or amelioration of the underlying disorder being treated and/or eradication or amelioration of one or more of the symptoms associated with the underlying disorder such that the patient reports an improvement in feeling or condition, notwithstanding that the patient can still be afflicted with the underlying disorder. For example, administration of a compound to a patient suffering from an allergy provides therapeutic benefit not only when the underlying allergic response is eradicated or ameliorated, but also when the patient reports a decrease in the severity or duration of the symptoms associated with the allergy following exposure to the allergen. As another example, therapeutic benefit in the context of asthma includes an improvement in respiration following the onset of an asthmatic attack, or a reduction in the frequency or severity of asthmatic episodes. Therapeutic benefit also includes halting or slowing the progression of the disease, regardless of whether improvement is realized.
[0226] For prophylactic administration, the compound can be administered to a patient at risk of developing one of the previously described diseases. A patient at risk of developing a disease can be a patient having characteristics placing the patient in a designated group of at risk patients, as defined by an appropriate medical professional or group. A patient at risk may also be a patient that is commonly or routinely in a setting where development of the underlying disease that may be treated by administration of a metalloenzyme inhibitor according to the invention could occur. In other words, the at risk patient is one who is commonly or routinely exposed to the disease or illness causing conditions or may be acutely exposed for a limited time. Alternatively, prophylactic administration can be applied to avoid the onset of symptoms in a patient diagnosed with the underlying disorder.
[0227] The amount of compound administered will depend upon a variety of factors, including, for example, the particular indication being treated, the mode of administration, whether the desired benefit is prophylactic or therapeutic, the severity of the indication being treated and the age and weight of the patient, the bioavailability of the particular active compound, and the like. Determination of an effective dosage is well within the capabilities of those skilled in the art.
[0228] Effective dosages can be estimated initially from in vitro assays. For example, an initial dosage for use in animals can be formulated to achieve a circulating blood or serum concentration of active compound that is at or above an IC50 of the particular compound as measured in as in vitro assay, such as the in vitro fungal MIC or MFC and other in vitro assays described in the Examples section. Calculating dosages to achieve such circulating blood or serum concentrations taking into account the bioavailability of the particular compound is well within the capabilities of skilled artisans. For guidance, see Fingl & Woodbury, “General Principles,” In: Goodman and Gilman's The Pharmaceutical Basis of Therapeutics, Chapter 1, pp. 1-46, latest edition, Pagamonon Press, and the references cited therein, which are incorporated herein by reference.
[0229] Initial dosages also can be estimated from in vivo data, such as animal models. Animal models useful for testing the efficacy of compounds to treat or prevent the various diseases described above are well-known in the art.
[0230] Dosage amounts will typically be in the range of from about 0.0001 or 0.001 or 0.01 mg/kg/day to about 100 mg/kg/day, but can be higher or lower, depending upon, among other factors, the activity of the compound, its bioavailability, the mode of administration, and various factors discussed above. Dosage amount and interval can be adjusted individually to provide plasma levels of the compound(s) which are sufficient to maintain therapeutic or prophylactic effect. In cases of local administration or selective uptake, such as local topical administration, the effective local concentration of active compound(s) cannot be related to plasma concentration. Skilled artisans will be able to optimize effective local dosages without undue experimentation.
[0231] The compound(s) can be administered once per day, a few or several times per day, or even multiple times per day, depending upon, among other things, the indication being treated and the judgment of the prescribing physician.
[0232] Preferably, the compound(s) will provide therapeutic or prophylactic benefit without causing substantial toxicity. Toxicity of the compound(s) can be determined using standard pharmaceutical procedures. The dose ratio between toxic and therapeutic (or prophylactic) effect is the therapeutic index. Compounds(s) that exhibit high therapeutic indices are preferred.
[0233] The recitation of a listing of chemical groups in any definition of a variable herein includes definitions of that variable as any single group or combination of listed groups. The recitation of an embodiment for a variable herein includes that embodiment as any single embodiment or in combination with any other embodiments or portions thereof. The recitation of an embodiment herein includes that embodiment as any single embodiment or in combination with any other embodiments or portions thereof.
[0234] Another object of the present invention is the use of a compound as described herein (e.g., of any formulae herein) in the manufacture of a medicament for use in the treatment of a metalloenzyme-mediated disorder or disease. Another object of the present invention is the use of a compound as described herein (e.g., of any formulae herein) for use in the treatment of a metalloenzyme-mediated disorder or disease. Another object of the present invention is the use of a compound as described herein (e.g., of any formulae herein) in the manufacture of an agricultural composition for use in the treatment or prevention of a metalloenzyme-mediated disorder or disease in agricultural or agrarian settings.
Agricultural Applications
[0235] The compounds and compositions herein can be used in methods of modulating metalloenzyme activity in a microorganism on a plant comprising contacting a compound (or composition) herein with the plant (e.g., seed, seedling, grass, weed, grain). The compounds and compositions herein can be used to treat a plant, field or other agricultural area (e.g., as herbicides, pesticides, growth regulators, etc.) by administering the compound or composition (e.g., contacting, applying, spraying, atomizing, dusting, etc.) to the subject plant, field or other agricultural area. The administration can be either pre- or post-emergence. The administration can be either as a treatment or preventative regimen.
Examples
[0236] The present invention will now be demonstrated using specific examples that are not to be construed as limiting.
General Experimental Procedures
[0237] Definitions of variables in the structures in schemes herein are commensurate with those of corresponding positions in the formulae delineated herein.
Synthesis of 1 or 1a
[0238]
[0239] A process to prepare enantiopure compound 1 or la is disclosed. Syntheses of for la may be accomplished using the example syntheses that are shown below (Schemes 1-4). The preparation of precursor ketone 3-Br is performed starting with reaction of 2,5-dibromo-pyridine with ethyl 2-bromo-difluoroacetate to produce ester 2-Br. This ester can be reacted with morpholine to furnish morpholine amide 2b-Br, followed by arylation to provide ketone 3-Br. Alternatively, ketone 3-Br can be afforded directly from ester 2-Br as shown in Scheme 1.
[0000]
[0240] Ketone 3 may be prepared in an analogous fashion as described in Scheme 1 starting from corresponding substituted 2-bromo-pyridines, which can be prepared according to synthetic transformations known in the art and contained in the references cited herein (Scheme 2).
[0000]
[0241] Alternatively, compound 1 can be prepared according to Scheme 3 utilizing diols 2-6b (or 2-6d, the enantiomer of 2-6b, or mixtures thereof) or 2-6a (or 2-6c, the enantiomer of 2-6a, or mixtures thereof). Olefins 2-5a and 2-5 can be prepared by reacting ketones 3 and 1-4 under Wittig olefination conditions (e.g., Ph 3 PCH 3 Br and BuLi). Also, as indicated in Scheme 5, any of pyridine compounds, 3, 2-5a, 2-6b, 2-7b, 4*, 4b, or 6 can be converted to the corresponding 4-CF 3 CH 2 O—Ph analogs (e.g., 1-4, 2-5, 2-6a, 2-7a, 5*, 1-6*, or 1 or the corresponding enantiomers, or mixtures thereof) by cross-coupling with 4,4,5,5-tetramethyl-2-(4-(2,2,2-trifluoroethoxy)phenyl)-1,3,2-dioxaborolane (or the corresponding alkyl boronates or boronic acid or the like), in a suitable solvent system (e.g., an organic-aqueous solvent mixture), in the presence of a transition metal catalyst (e.g., (dppf)PdC1 2 ), and in the presence of a base (e.g., KHCO 3 , K 2 CO 3 , Cs 2 CO 3 , or Na 2 CO 3 , or the like). Olefins 2-5a and 2-5 can be transformed to the corresponding chiral diols, 2-6b (or 2-6d, the enantiomer of 2-6b, or mixtures thereof) or 2-6a (or 2-6c, the enantiomer of 2-6a, or mixtures thereof), through exposure to Sharpless asymmetric dihydroxylation conditions: 1) commercially available AD-mix alpha or AD-mix beta with or without additional osmium oxidant and methanesulfonamide, 2) combination of a catalytic osmium oxidant (e.g., OsO 4 or K 2 OsO 2 (OH) 4 ), a stoichiometric iron oxidant (e.g., K 3 Fe(CN) 6 ), a base (e.g., KHCO 3 , K 2 CO 3 , Cs 2 CO 3 , or Na 2 CO 3 , or the like), and a chiral ligand (e.g., (DHQ) 2 PHAL, (DHQD) 2 PHAL, (DHQD) 2 AQN, (DHQ)2AQN, (DHQD) 2 PYR, or (DHQ)2PYR; preferably (DHQ)2PHAL,
[0242] (DHQD) 2 PHAL, (DHQD) 2 AQN, and (DHQD) 2 PYR), or 3) option 2) with methanesulfonamide. The primary alcohol of the resultant chiral diols, 2-6b (or 2-6d, the enantiomer of 2-6b, or mixtures thereof) or 2-6a (or 2-6c, the enantiomer of 2-6a, or mixtures thereof), can then be activated to afford compounds 2-7b (or 2-7d, the enantiomer of 2-7b, or mixtures thereof) or 2-7a (or 2-7c, the enantiomer of 2-7a, or mixtures thereof). For example, the mesylates can be prepared by exposing chiral diols, 2-6b (or 2-6d, the enantiomer of 2-6b, or mixtures thereof) or 2-6a (or 2-6c, the enantiomer of 2-6a, or mixtures thereof), to methanesulfonyl chloride and a base. Epoxide formation can be affected by the base-mediated (e.g., KHCO 3 , K 2 CO 3 , Cs 2 CO 3 , or Na 2 CO 3 , or the like) ring closure of compounds 2-7b (or 2-7d, the enantiomer of 2-7b, or mixtures thereof) or 2-7a (or 2-7c, the enantiomer of 2-7a, or mixtures thereof) to provide epoxides 4* (or 4c*, the enantiomer of 4*, or mixtures thereof) and 5* (or 5-b*, the enantiomer of 5*, or mixtures thereof). The epoxides can then be converted into amino-alcohols 4b (or 4c, the enantiomer of 4b, or mixtures thereof) and 1-6* (or 1-7*, the enantiomer of 1-6*, or mixtures thereof) through ammonia-mediated epoxide opening using ammonia in a suitable solvent (e.g., MeOH, EtOH, or water). Subsequent treatment with TMS-azide in the presence of trimethylorthoformate and sodium acetate in acetic acid would yield compounds 6 (or 6a, the enantiomer of 6, or mixtures thereof) or 1 (or 1a, the enantiomer of 1, or mixtures thereof) (U.S. Pat. No. 4,426,531).
[0000]
[0243] Compound 1 (or 1a, the enantiomer of 1, or mixtures thereof) prepared by any of the methods presented herein can be converted to a sulfonic salt of formula IX (or IXa, the enantiomer of IX, or mixtures thereof), as shown in Scheme 4. This can be accomplished by a) combining compound 1 (or 1a, the enantiomer of 1, or mixtures thereof), a crystallization solvent or crystallization solvent mixture (e.g., EtOAc, iPrOAc, EtOH, MeOH, or acetonitrile, or combinations thereof), and a sulfonic acid
[0000]
[0000] (e.g., Z═Ph, p-tolyl, Me, or Et), b) diluting the mixture with an appropriate crystallization co-solvent or crystallization co-solvent mixture (e.g., pentane, methyl t-butylether, hexane, heptane, or toluene, or combinations thereof), and c) filtering the mixture to obtain a sulfonic acid salt of formula IX (or IXa, the enantiomer of IX, or mixtures thereof).
[0000]
[0244] The following describes the HPLC method used in assessing HPLC purity of the examples and intermediates presented below:
[0245] Column: Waters XBridge Shield RP18, 4.6×150 mm, 3.5 μm
[0246] Mobile Phase: A=0.05% TFA/H 2 O, B=0.05% TFA/ACN
[0247] Autosampler flush: 1:1 ACN/H 2 O
[0248] Diluent: 1:1 ACN/H 2 O
[0249] Flow Rate: 1.0 ml/min
[0250] Temperature: 45° C.
[0251] Detector: UV 275 nm
[0000]
Pump Parameters
Step
Segment Time
A
B
Curve
0
0.5
80.0
20.0
0
1
15.0
60.0
40.0
1
2
10.0
15.0
85.0
1
3
5.0
0.0
100.0
1
4
2.0
0.0
100.0
0
5
8.0
80.0
20.0
0
EXAMPLE 1
Preparation of ethyl 2-(5-bromopyridin-2-yl)-2,2-difluoroacetate (2-Br)
[0252]
[0253] In a clean multi-neck round bottom flask, copper powder (274.7 g, 2.05 eq) was suspended in dimethyl sulfoxide (3.5 L, 7 vol) at 20-35° C. Ethyl bromodifluoroacetate (449 g, 1.05 eq) was slowly added to the reaction mixture at 20-25° C. and stirred for 1-2 h. 2, 5-dibromopyridine (500 g, 1 eq) was added to the reaction mixture and the temperature was increased to 35-40 ° C. The reaction mixture was maintained at this temperature for 18-24 h and the reaction progress was monitored by GC.
[0254] After the completion of the reaction, ethyl acetate (7 L, 14 vol) was added to the reaction mixture and stirring was continued for 60-90 min at 20-35° C. The reaction mixture was filtered through a Celite bed (100 g; 0.2 times w/w Celite and 1L; 2 vol ethyl acetate). The reactor was washed with ethyl acetate (6 L, 12 vol) and the washings were filtered through a
[0255] Celite bed. The Celite bed was finally washed with ethyl acetate (1 L, 2 vol) and all the filtered mother liquors were combined. The pooled ethyl acetate solution was cooled to 8-10° C., washed with the buffer solution (5 L, 10 vol) below 15° C. (Note: The addition of buffer solution was exothermic in nature. Controlled addition of buffer was required to maintain the reaction mixture temperature below 15° C.). The ethyl acetate layer was washed again with the buffer solution until (7.5 L; 3×5 vol) the aqueous layer remained colorless. The organic layer was washed with a 1:1 solution of 10% w/w aqueous sodium chloride and the buffer solution (2.5 L; 5 vol). The organic layer was then transferred into a dry reactor and the ethyl acetate was distilled under reduced pressure to get crude 2-Br.
[0256] The crude 2-Br was purified by high vacuum fractional distillation and the distilled fractions having 2-Br purity greater than 93% (with the dialkylated not more than 2% and starting material less than 0.5%) were pooled together to afford 2-Br.
[0257] Yield after distillation: 47.7% with >93% purity by GC (pale yellow liquid). Another 10% yield was obtained by re-distillation of impure fractions resulting in overall yield of ˜55-60%.
[0258] 1 H NMR: δ values with respect to TMS (DMSO-d 6 ; 400 MHz): 8.85; (1H, d, 1.6 Hz), 8.34; (1H, dd, J=2.0 Hz, 6.8 Hz), 7.83; (1H, d, J=6.8 Hz), 4.33; (2H, q, J=6.0 Hz), 1.22; (3H, t, J=6.0 Hz). 13 C NMR: 162.22 (t, —C═O), 150.40 (Ar—C—), 149.35; (t, Ar—C), 140.52; (Ar—C), 123.01; (Ar—C), 122.07; (Ar—C), 111.80; (t, —CF 2 ), 63.23; (—OCH 2 —), 13.45; (—CH 2 CH 3 ).
EXAMPLE 2
Preparation of 2-(5-bromopyridin-2-yl)-1-(2,4-difluorophenyl)-2,2-difluoroethanone (3-Br)
A. One-Step Method
[0259]
[0260] 1-Bromo-2,4-difluorobenzene (268.7 g; 1.3 eq) was dissolved in methyl tert butyl ether (MTBE, 3.78 L, 12.6 vol) at 20-35° C. and the reaction mixture was cooled to −70 to −65° C. using acetone/dry ice bath. n-Butyl lithium (689 mL, 1.3 eq; 2.5 M) was then added to the reaction mixture maintaining the reaction temperature below −65° C. (Note: Controlled addition of the n-Butyl Lithium to the reaction mixture was needed to maintain the reaction mixture temperature below −65° C.). After maintaining the reaction mixture at this temperature for 30-45 min, 2-Br (300 g, 1 eq) dissolved in MTBE (900 mL, 3 vol) was added to the reaction mixture below −65° C. The reaction mixture was continued to stir at this temperature for 60-90 min and the reaction progress was monitored by GC. The reaction was quenched by slow addition of 20% w/w ammonium chloride solution (750 mL, 2.5 vol) below −65° C. The reaction mixture was gradually warmed to 20-35° C. and an additional amount of 20% w/w ammonium chloride solution (750 mL, 2.5 vol) was added. The aqueous layer was separated, the organic layer was washed with a 10% w/w sodium bicarbonate solution (600 mL, 2 vol) followed by a 5% sodium chloride wash (600 mL, 2 vol). The organic layer was dried over sodium sulfate (60 g; 0.2 times w/w), filtered and the sodium sulfate was washed with MTBE (300 mL, 1 vol). The organic layer along with washings was distilled below 45° C. under reduced pressure until no more solvent was collected in the receiver. The distillation temperature was increased to 55-60° C., maintained under vacuum for 3-4 h and cooled to 20-35° C. to afford 275 g (73.6% yield, 72.71% purity by HPLC) of 3-Br as a pale yellow liquid.
[0261] 1 H NMR: δ values with respect to TMS (DMSO-d 6 ; 400 MHz):8.63; (1H, d, 1.6 Hz, Ar—H), 8.07-8.01; (2H, m, 2 x Ar—H), 7.72; (1H, d, J=6.8 Hz, Ar—H), 7.07-6.82; (1H, m, Ar—H), 6.81-6.80; (1H, m, Ar—H). 13 C NMR:185.60; (t, —C═O), 166.42; (dd, Ar—C—), 162.24; (dd, Ar—C), 150.80; (Ar—C), 150.35; (Ar—C), 140.02; (Ar—C), 133.82; (Ar—C), 123.06; (Ar—C), 1122.33; (Ar—C), 118.44; (Ar—C), 114.07; (—CF 2 —), 122.07; (Ar—C), 105.09; (Ar—C).
B. Two-Step Method via 2b-Br
[0262]
[0263] 2-Br (147.0 g) was dissolved in n-heptane (1.21 L) and transferred to a 5-L reactor equipped with overhead stirrer, thermocouple, condenser and addition funnel. Morpholine (202 ml) was added. The solution was heated to 60° C. and stirred overnight. The reaction was complete by HPLC analysis (0.2% 2-Br; 94.7% 2b-Br). The reaction was cooled to room temperature and 1.21 L of MTBE was added. The solution was cooled to ˜4° C. and quenched by slow addition of 30% citric acid (563 ml) to maintain the internal temperature <15° C. After stirring for one hour the layers were allowed to settle and were separated (Aq. pH=5). The organic layer was washed with 30% citric acid (322 ml) and 9% NaHCO 3 (322 ml, aq. pH 7+ after separation). The organic layer was concentrated on the rotary evaporator (Note 1) to 454 g (some precipitation started immediately and increased during concentration). After stirring at room temperature the suspension was filtered and the product cake was washed with n-heptane (200 ml). The solid was dried in a vacuum oven at room temperature to provide 129.2 g (77%) dense powder. The purity was 96.5% by HPLC analysis.
[0264] To a 1-L flask equipped with overhead stirring, thermocouple, condenser and addition funnel was added magnesium turnings (14.65 g), THF (580 ml) and 1-bromo-2,4-difluorobenzene (30.2 g, 0.39 equiv). The mixture was stirred until the reaction initiated and self-heating brought the reaction temperature to 44° C. The temperature was controlled with a cooling bath as the remaining 1-bromo-2,4-difluorobenzene (86.1 g, 1.11 equiv) was added over about 30 min. at an internal temperature of 35-40° C. The reaction was stirred for 2 hours while gradually cooling to room temperature. The dark yellow solution was further cooled to 12° C.
[0265] During the Grignard formation, a jacketed 2-L flask equipped with overhead stirring, thermocouple, and addition funnel was charged with morpholine amide 2b-Br (129.0 g) and THF (645 ml). The mixture was stirred at room temperature until the solid dissolved, and then the solution was cooled to −8.7° C. The Grignard solution was added via addition funnel over about 30 min at a temperature of −5 to 0° C. The reaction was stirred at 0° C. for 1 hour and endpointed by HPLC analysis. The reaction mixture was cooled to −5° C. and quenched by slow addition of 2N HCl over 1 hour at ≦10° C. The mixture was stirred for 0.5 h then the layers were allowed to settle and were separated. The aqueous layer was extracted with MTBE (280 ml). The combined organic layers were washed with 9% NaHCO 3 (263 g) and 20% NaCl (258 ml). The organic layer was concentrated on the rotary evaporator with THF rinses to transfer all the solution to the distillation flask. Additional THF (100 ml) and toluene (3×100 ml) were added and distilled to remove residual water from the product. After drying under vacuum, the residue was 159.8 g of a dark brown waxy solid (>theory). The purity was approximately 93% by HPLC analysis.
EXAMPLE 3
Preparation of 3-amino-1-(5-bromopyridin-2-yl)-2-(2,4-difluorophenyl)-1,1-difluoropropan-2-ol (±4b-Br)
[0266]
[0267] 4-Br (200 g, 1 eq) was added into methanolic ammonia (8.0 L; 40 vol; ammonia content: 15-20% w/v) in an autoclave at 10-20° C. The reaction mixture was gradually heated to 60-65° C. and at 3-4 kg/cm 2 under sealed conditions for 10-12 h. The reaction progress was monitored by GC. After completion of the reaction, the reaction mixture was cooled to 20-30° C. and released the pressure gradually. The solvent was distilled under reduced pressure below 50° C. and the crude obtained was azeotroped with methanol (2×600 mL, 6 vol) followed by with isopropanol (600 mL, 2 vol) to afford 203 g (96.98% yield, purity by HPLC: 94.04%) of ±4b-Br.
EXAMPLE 4
Preparation of 3-amino-1-(5-bromopyridin-2-yl)-2-(2,4-difluorophenyl)-1,1-difluoropropan-2-ol (4b-Br or 2c-Br)
[0268]
[0269] Amino alcohol ±4b-Br (150 g, 1 eq) was dissolved in an isopropanol /acetonitrile mixture (1.5L, 8:2 ratio, 10 vol) and Di-p-toluoyl-L-tartaric acid (L-DPTTA) (84.05 g, 0.55 eq) was added into the reactor at 20-30 ° C. The reaction mixture was heated to 45-50° C. for 1 1.5 h (Note: The reaction mixture becomes clear and then became heterogeneous). The reaction mixture was gradually cooled to 20-30° C. and stirred for 16-18 h. The progress of the resolution was monitored by chiral HPLC analysis.
[0270] After the completion of the resolution, the reaction mixture was gradually cooled to 20-35° C. The reaction mixture was filtered and the filtered solid was washed with a mixture of acetonitrile and isopropanol (8:2 mixture, 300 mL, 2 vol) and dried to afford 75 g of the L-DPTTA salt (95.37% ee). The L-DPTTA salt obtained was chirally enriched by suspending the salt in isopropanol/acetonitrile (8:2 mixture; 750 mL, 5 vol) at 45-50° C. for 24-48 h. The chiral enhancement was monitored by chiral HPLC; the solution was gradually cooled to 20-25° C., filtered and washed with an isoporpanol/acetonitrile mixture (8:2 mixture; 1 vol). The purification process was repeated and after filtration, the salt resulted in chiral purity greater than 96% ee. The filtered compound was dried under reduced pressure at 35-40° C. to afford 62 g of the enantio-enriched L-DPPTA salt with 97.12% ee as an off-white solid. The enantio-enriched L-DPTTA salt (50 g, 1 eq) was dissolved in methanol (150 mL, 3 vol) at 20-30° C. and a potassium carbonate solution (18.05 g K 2 CO 3 in 150 mL water) was slowly added at 20-30° C. under stirring. The reaction mixture was maintained at this temperature for 2-3 h (pH of the solution at was maintained at 9). Water (600 mL, 12 vol) was added into the reaction mixture through an additional funnel and the reaction mixture was stirred for 2-3 h at 20-30° C. The solids were filtered; washed with water (150 mL, 3 vol) and dried under vacuum at 40-45° C. to afford 26.5 g of amino alcohol 4b-Br or 4c-Br with 99.54% chemical purity, 99.28% ee as an off-white solid. (Water content of the chiral amino alcohol is below 0.10% w/w).
[0271] 1 H NMR: δ values with respect to TMS (DMSO-d 6 ; 400 MHz):8.68; (1H, d, J=2.0 Hz, Ar—H), 8.16; (1H, dd, J=8.0 Hz, 2.0 Hz, Ar—H), 7.49-7.43; (1H, m, Ar—H), 7.40; (1H, d, J=8 Hz, Ar—H), 7.16-7.11; (1H, m, Ar—H), 7.11-6.99; (1H, m, Ar—H), 3.39-3.36; (1H, m, —OCH A H B —), 3.25-3.22; (1H, m, —OCH A H B —). 13 C NMR:163.87-158.52; (dd, 2 x Ar—C—), 150.88; (Ar—C), 149.16; (Ar—C), 139.21; (Ar—C), 132.39; (Ar—C), 124.49; (Ar—C), 122.17; (Ar—C), 121.87; (d, Ar—C), 119.91; (t, —CF 2 —), 110.68; (Ar—C), 103.97; (t, Ar—C), 77.41; (t,-C-OH), 44.17; (—CH 2 —NH 2 ).
EXAMPLE 5
Preparation of 1-(5-bromopyridin-2-yl)-2-(2,4-difluorophenyl)-1,1-difluoro-3-(1H-tetrazol-1-yl)propan-2-ol (1-6*-Br or 1-7*-Br)
[0272]
[0273] 4b-Br or 4c-Br (20.0 g, 1 eq.) was added to acetic acid (50 mL, 2.5 vol) at 25-35° C. followed by the addition of anhydrous sodium acetate (4.32 g, 1 eq), trimethyl orthoformate (15.08 g, 2.7 eq). The reaction mixture was stirred for 15-20 min at this temperature and trimethylsilyl azide (12.74 g, 2.1 eq) was added to the reaction mixture (Chilled water was circulated through the condenser to minimize the loss of trimethylsilyl azide from the reaction mixture by evaporation). The reaction mixture was then heated to 70-75° C. and maintained at this temperature for 2-3 h. The reaction progress was monitored by HPLC. Once the reaction was complete, the reaction mixture was cooled to 25-35° C. and water (200 mL, 10 vol) was added. The reaction mixture was extracted with ethyl acetate (400 mL, 20 vol) and the aqueous layer was back extracted with ethyl acetate (100 mL, 5 vol). The combined organic layers were washed with 10% potassium carbonate solution (3×200 mL; 3×10 vol) followed by a 10% NaCl wash (1×200 mL, 10 vol). The organic layer was distilled under reduced pressure below 45° C. The crude obtained was azeotroped with heptanes (3×200 mL) to get 21.5g (94% yield, 99.26 5 purity) of tetrazole 1-6* or 1-7* compound as pale brown solid (low melting solid).
[0274] 1 H NMR: δ values with respect to TMS (DMSO-d 6 ; 400 MHz NMR instrument):9.13; (1H, Ar—H), 8.74; (1H, Ar—H), 8.22-8.20; (1H, m, Ar—H), 7.44; (1H, d, J=7.2 Hz, Ar—H), 7.29; (1H Ar—H), 7.23-7.17; (1H, m, Ar—H), 6.92-6.88; (1H, Ar—H), 5.61; (1H, d, J=11.2 Hz, —OCH A H B —), 5.08; (1H, d, J=5.6 Hz, —OCH A H B —). 13 C NMR:163.67-161.59; (dd, Ar—C—), 160.60-158.50; (dd, Ar—C—), 149.65; (Ar—C), 144.99; (Ar—C), 139.75; (Ar—C), 131.65; (Ar—C), 124.26; (Ar—C), 122.32; (d, Ar—C), 119.16; (t, —CF 2 —), 118.70; (d, Ar—C), 111.05; (d, Ar—C) 104.29; (t, Ar—C), 76.79; (t,—C—OH), 59.72; (Ar—C), 50.23; (—OCH 2 N—).
EXAMPLE 6
Preparation of 2-(2,4-difluorophenyl)-1,1-difluoro-3-(1H-tetrazol-1-yl)-1-(5-(4-(2,2,2-trifluoroethoxy)phenyl)pyridin-2-yl)propan-2-ol (1 or 1a)
A. Preparation of 1 or 1a via 1-6*-Br or 1-7*-Br
[0275]
[0276] Synthesis of 4,4,5,5-tetramethyl-2-(4-(2,2,2-trifluoroethoxy)phenyl)-1,3,2-dioxaborolane Potassium carbonate (59.7 g, 2.2 eq.) was added to a slurry of DMF (190 mL, 3.8 Vol.), 4-Bromo phenol (37.4g, 1.1 eq.) and 2,2,2-trifluroethyl tosylate (50.0 g, 1.0 eq.) at 20-35° C. under an inert atmosphere. The reaction mixture was heated to 115-120° C. and maintained at this temperature for 15-18 h. The reaction progress was monitored by GC. The reaction mixture was then cooled to 20-35° C., toluene (200 mL, 4.0 vol.) and water (365 mL, 7. 3 vol.) were added at the same temperature, stirred for 10-15 minutes and separated the layers.
[0277] The aqueous layer was extracted with toluene (200 mL, 4.0 vol.). The organic layers were combined and washed with a 2M sodium hydroxide solution (175 mL, 3.5 vol.) followed by a 20% sodium chloride solution (175 mL, 3.5 vol.). The organic layer was then dried over anhydrous sodium sulfate and filtered. The toluene layer was transferred into clean reactor, spurged with argon gas for not less than 1 h. Bis(Pinacolato) diborane (47 g, 1.1 eq.), potassium acetate (49.6 g, 3.0 eq.) and 1,4-dioxane (430 mL, 10 vol.) were added at 20-35° C., and spurged the reaction mixture with argon gas for at least 1 h. Pd(dppf)Cl 2 (6.88 g, 0.05 eq) was added to the reaction mixture and continued the argon spurging for 10-15 minutes. The reaction mixture temperature was increased to 70-75° C., maintained the temperature under argon atmosphere for 15-35 h and monitored the reaction progress by GC. The reaction mixture was cooled to 20-35° C., filtered the reaction mixture through a Celite pad, and washed with ethyl acetate (86 mL, 2 vol.). The filtrate was washed with water (430 mL, 10 vol.). The aqueous layer was extracted with ethyl acetate (258 mL, 6 vol.) and washed the combined organic layers with a 10% sodium chloride solution (215 mL, 5 vol.). The organic layer was dried over anhydrous sodium sulfate (43 g, 1 time w/w), filtered and concentrated under reduced pressure below 45° C. to afford crude 4,4,5,5-tetramethyl-2-(4-(2,2,2-trifluoroethoxy)phenyl)-1,3,2-dioxaborolane (65 g; 71% yield with the purity of 85.18% by GC). The crude 4,4,5,5-tetramethyl-2-(4-(2,2,2-trifluoroethoxy)phenyl)-1,3,2-dioxaborolane (65 g, 1 eq.) was dissolved in 10% ethyl acetate—n-Heptane (455 mL, 7 vol.) and stirred for 30-50 minutes at 20-35° C. The solution was filtered through a Celite bed and washed with 10% ethyl acetate in n-Heptane (195 mL, 3 vol.). The filtrate and washings were pooled together, concentrated under vacuum below 45° C. to afford 4,4,5,5-tetramethyl-2-(4-(2,2,2-trifluoroethoxy)phenyl)-1,3,2-dioxaborolane as a thick syrup (45.5 g; 70% recovery). This was then dissolved in 3% ethyl acetate-n-heptane (4 vol.) and adsorbed on 100-200 M silica gel (2 times), eluted through silica (4 times) using 3% ethyl acetate—n-heptane. The product rich fractions were pooled together and concentrated under vacuum. The column purified fractions (>85% pure) were transferred into a round bottom flask equipped with a distillation set-up. The compound was distilled under high vacuum below 180° C. and collected into multiple fractions. The purity of fractions was analyzed by GC (should be >98% with single max impurity <1.0%). The less pure fractions (>85% and <98% pure fraction) were pooled together and the distillation was repeated to get 19g (32% yield) of 4,4,5,5-tetramethyl-2-(4-(2,2,2-trifluoroethoxy)phenyl)-1,3,2-dioxaborolane as a pale yellow liquid.
[0278] 1 H NMR: δ values with respect to TMS (DMSO-d 6 ; 400 MHz):7.64; (2H, d, 6.8 Hz), 7.06; (2H, d, J=6.4 Hz), 4.79; (2H, q, J=6.8 Hz), 1.28; (12H, s).
[0279] 13 C NMR: 159.46; (Ar—C—O—), 136.24; (2 x Ar—C—), 127.77-120.9; (q, —CF 3 ), 122.0; (Ar—C—B), 114.22; (2 x Ar—C—), 64.75; (q, J=27.5 Hz).
Synthesis of 2-(2,4-difluorophenyl)-1,1-difluoro-3-(1H-tetrazol-1-yl)-1-(5-(4-(2,2,2-trifluoroethoxy)phenyl)pyridin-2-yl)propan-2-ol (1 or 1a)
[0280] 1-6*-Br or 1-7*-Br (14 g, 0.03 mol, 1 eq) was added to tetrahydrofuran (168 mL, 12 vol) at 25-35° C. and the resulting solution was heated to 40-45° C. The reaction mixture was maintained at this temperature for 20-30 min under argon bubbling. Sodium carbonate (8.59 g, 0.08 mol, 2.5 eq) and water (21 mL, 1.5 vol) were added into the reaction mixture and the bubbling of argon was continued for another 20 30 min. 4,4,5,5-tetramethyl-2-(4-(2,2,2-trifluoroethoxy)phenyl)-1,3,2-dioxaborolane (10.76 g, 1.1 eq) dissolved in tetrahydrofuran (42 mL, 3 vol) was added into the reaction mixture and argon bubbling was continued for 20-30 min. Pd(dppf)Cl 2 (2.65 g, 0.1 eq) was added to the reaction mixture under argon bubbling and stirred for 20-30 min (Reaction mixture turned into dark red color). The reaction mixture was heated to 65-70° C. and maintained at this temperature for 3-4 h. The reaction progress was monitored by HPLC. The reaction mixture was cooled to 40-45° C. and the solvent was distilled under reduced pressure. Toluene (350 mL, 25 vol.) was added to the reaction mixture and stirred for 10-15 min followed by the addition of water (140 mL, 10 vol). The reaction mixture was filtered through Hyflo (42 g, 3 times), the layers were separated and the organic layer was washed with water (70 mL, 5 vol) and a 20% w/w sodium chloride solution (140 mL, 10 vol). The organic layer was treated with charcoal (5.6 g, 0.4 times, neutral chalrcoal), filtered through Hyflo. (1S)-10-Camphor sulfonic acid (7.2 g, 1 eq.) was added to the toluene layer and the resulting mixture was heated to 70-75° C. for 2-3 h. The reaction mixture was gradually cooled to 25-35° C. and stirred for 1-2 h. The solids were filtered, washed with toluene (2×5 vol.) and then dried under vacuum below 45° C. to afford 18.0 g of an off white solid. The solids (13.5 g, 1 eq.) were suspended in toluene (135 mL, 10 vol) and neutralized by adding 1M NaOH solution (1.48 vol, 1.1 eq) at 25-35° C. and stirred for 20-30 min Water (67.5 mL, 5 vol) was added to the reaction mixture and stirred for 10-15 min, and then the layers were separated. The organic layer was washed with water (67.5 mL, 5 vol) to remove the traces of CSA. The toluene was removed under reduced pressure below 45° C. to afford crude 1 or 1a. Traces of toluene were removed by azeotroping with ethanol (3×10 vol), after which light brown solid of crude 1 or 1a (7.5 g, 80% yield) was obtained. The crude 1 or 1a (5 g) was dissolved in ethanol (90 mL, 18 vol.) at 20-35° C., and heated to 40-45° C. Water (14 vol) was added to the solution at 40-45° C., the solution was maintained at this temperature for 30-45 min and then gradually cooled to 20-35° C. The resulting suspension was continued to stir for 16-18 h at 20-35° C., an additional amount of water (4 vol.) was added and the stirring continued for 3-4 h. The solids were filtered to afford 4.0 g (80% recovery) of 1 or 1a (HPLC purity >98%) as an off-white solid.
[0281] 1 H NMR: δ values with respect to TMS (DMSO-d 6 ; 400 MHz):9.15; (1H, s, Ar—H), 8.93; (1H, d, J=0.8 Hz, Ar—H), .8.22-8.20; (1H, m, Ar—H), 7.80; (2H, d, J=6.8 Hz, Ar—H), 7.52; (1H, d, J=6.8 Hz, Ar—H), 7.29; (1H, d,J=3.2 Hz, Ar—H), 7.27-7.21; (1H, m, Ar—H), 7.23-7.21; (2H, d, J=6.8 Hz, Ar—H), 7.19; (1H, d, J=6.8 Hz, Ar—H), 6.93-6.89; (1H, m, Ar—H), 5.68; (1H, J=12 Hz, —CH A H B ), 5.12; (2H, d, J=11.6 Hz, —CH A H B ), 4.85; (2H, q, J=7.6 Hz).
[0282] 13 C NMR: 163.93-158.33; (m, 2 x Ar—C), 157.56; (Ar—C), 149.32; (t, Ar—C), 146.40; (Ar—C), 145.02; (Ar—C), 136.20; (Ar-C), 134.26; (2 x Ar—C), 131.88-131.74; (m, AR—C), 129.72; (Ar—C), 128.47; (2 x Ar—C), 123.97; (q, —CF 2 —), 122.41; (Ar—C), 119.30; (—CF 3 ), 118.99; (Ar—C), 115.65; (2 x Ar—C), 110.99; (d, Ar—C), 104.22; (t, Ar—C), 77.41-76.80; (m, Ar—C), 64.72; (q, —OCH 2 —CF 3 ), 50.54; (—CH 2 —N—).
B. Preparation of 1 or 1a via 4b-Br or 4c-Br
[0283]
[0284] Synthesis of 3 -amino-2-(2,4-difluorophenyl)-1,1 -difluoro-1-(5 -(4-(2,2,2-trifluoroethoxy)phenyl)pyridin-2-yl)propan-2-ol (8a or 8b) Potassium carbonate (30.4 g) and water (53.3 g) were charged to a 1-L flask equipped with overhead stirring, thermocouple, and nitrogen/vacuum inlet valve, and stirred until dissolved. The boronic acid (19.37 g), a solution of 4b-Br or 4c-Br in 2-butanol (103.5 g, 27.8 g theoretical 4b-Br or 4c-Br)) and 2-BuOH (147.1 g) were added and stirred to form a clear mixture. The flask was evacuated and refilled with nitrogen 3 times. Pd(dppf) 2 Cl 2 (0.30 g) was added and stirred to form a light orange solution. The flask was evacuated and refilled with nitrogen 4 times. The mixture was heated to 85° C. and stirred overnight and endpointed by HPLC analysis. The reaction mixture was cooled to 60° C. and the layers were allowed to settle. The aqueous layer was separated. The organic layer was washed with 5% NaCl solution (5×100 ml) at 30-40° C. The organic layer was filtered and transferred to a clean flask with rinses of 2-BuOH. The combined solution was 309.7 g, water content 13.6 wt % by KF analysis. The solution was diluted with 2-BuOH (189 g) and water (10 g). Theoretically the solution contained 34.8 g product, 522 ml (15 volumes) of 2-BuOH, and 52.2 ml (1.5 volumes) of water. L-Tartaric acid (13.25 g) was added and the mixture was heated to a target temperature of 70-75° C. During the heat-up, a thick suspension formed. After about 15 minutes at 70-72° C. the suspension became fluid and easily stirred. The suspension was cooled at a rate of 10° C./hour to 25° C. then stirred at 25° C. for about 10 hours. The product was collected on a vacuum filter and washed with 10:1 (v/v) 2-BuOH/water (50 ml) and 2-butanol (40 ml). The salt was dried in a vacuum oven at 60° C. with a nitrogen purge for 2 days. The yield was 40.08 g of 8a or 8b as a fluffy, grayish-white solid. The water content was 0.13 wt % by KF analysis. The yield was 87.3% with an HPLC purity of 99.48%.
Synthesis of 2-(2,4-difluorophenyl)-1,1-difluoro-3-(1H-tetrazol-1-yl)-1-(5-(4-(2,2,2-trifluoroethoxy)phenyl)pyridin-2-yl)propan-2-ol (1 or 1a)
[0285] To a 350 ml pressure bottle were charged acetic acid (73 ml), 8a or 8b (34.8 g), sodium acetate (4.58 g) and trimethylorthoformate (16.0 g). The mixture was stirred for 18 min at room temperature until a uniform suspension was obtained. Azidotrimethylsilane (8.88 g) was added and the bottle was sealed. The bottle was immersed in an oil bath and magnetically stirred. The oil bath was at 52° C. initially, and was warmed to 62-64° C. over about ½ hour. The suspension was stirred at 62-64° C. overnight. After 20.5 hours the suspension was cooled to room temperature and sampled. The reaction was complete by HPLC analysis. The reaction was combined with three other reactions that used the same raw material lots and general procedure (total of 3.0 g additional starting material). The combined reactions were diluted with ethyl acetate (370 ml) and water (368 ml) and stirred for about ½ hour at room temperature. The layers were settled and separated. The organic layer was washed with 10% K 2 CO 3 solution (370 ml/397 g) and 20% NaCl solution (370 ml/424 g). The organic layer (319 g) was concentrated, diluted with ethanol (202 g) and filtered, rinsed with ethanol (83 g).
[0286] The combined filtrate was concentrated to 74 g of amber solution.
[0287] The crude 1 or 1a solution in ethanol (74 g solution, containing theoretically 31.9 g 1 or 1a) was transferred to a 2-L flask equipped with overhead stifling, thermocouple, and addition funnel. Ethanol (335 g) was added including that used to complete the transfer of the 1 or 1a solution. The solution was heated to nominally 50° C. and water (392 g) was added over 12 minutes. The resulting hazy solution was seeded with 1 or 1a crystals and stirred at 50° C. After about 1/2 hour the mixture was allowed to cool to 40° C. over about ½ hour during which time crystallization started. Some darker colored chunky solid separated out from the main suspension. The pH of the crystallizing mixture was adjusted from 4.5 to 6 using 41% KOH (1.7 g). After about 1 hour a good suspension had formed. Additional water (191 g) was added slowly over ½ hour. The suspension was heated to 50° C. and cooled at 5° C./min to room temperature. After stirring overnight the suspension was cooled in a water bath to 16° C. and filtered after 1 hour. The wet cake was washed with 55:45 (v/v) water/ethanol (2×50 ml) and air-dried on the vacuum filter funnel overnight. Further drying at 40° C. in a vacuum oven with a nitrogen bleed resulted in no additional weight loss. The yield was 30.2 g of off-white fine powder plus some darker granular material. By in-process HPLC analysis there was no difference in the chemical purity of the darker and lighter materials. The purity was 99.4%. The water content was 2.16 wt % by KF analysis. The residual ethanol was 1.7 wt % estimated by 1 H NMR analysis. The corrected yield was 29.0 g, 91.0% overall yield for tetrazole formation and crystallization. The melting point was 65° C. by DSC analysis.
Incorporation by Reference
[0288] The contents of all references (including literature references, issued patents, published patent applications, and co-pending patent applications) cited throughout this application are hereby expressly incorporated herein in their entireties by reference.
Equivalents
[0289] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents of the specific embodiments of the invention described herein. Such equivalents are intended with be encompassed by the following claims.
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The present invention relates to a process for preparing compound 1 that is useful as an antifungal agent. In particular, the invention seeks to provide new methodology for preparing compound 1 and substituted derivatives thereof.
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BACKGROUND OF THE INVENTION
In a concurrently filed commonly assigned application entitled, "Substituted α-[2'-Tricyclo]3.3.1.1 3 ,7 ]decylidene benzeneacetonitrile Derivatives", whose teachings are hereby incorporated by reference, substituted α-[2'tricyclo [3.3.1.1 3 ,7 ]decylidene]benzeneacetonitrile derivatives which have antihypoxia activity are described. We have prepared related benzeneacetic acid derivatives which possess antihypoxia, antiparkinson and/or anticonvulsant activities, that is they either protect warm-blooded animals from the effects of oxygen deprivation, reduce pentylenete-trazole- or electric shock induced seizures, or reduce N-carbamoyl-2-(2,6-dichlorophenyl)acetamide hydrochloride-induced tremors.
BRIEF SUMMARY OF THE INVENTION
In accordance with this invention there are provided compounds of the formula: ##STR2## where the R 1 , R 2 and R 3 substituents are independently selected from hydrogen, lower alkyl, lower alkoxy, halogen and trifluoromethane provided that at least one of such substituents is hydrogen.
DETAILED DESCRIPTION
As used herein the terms "lower alkyl" and "lower alkoxy" refer to straight and branched chain alkylene groups having 1 to 4 carbons and "halogen" refers to chlorine, bromine, iodine and fluorine (preferably chlorine).
As described in the following Examples, the compounds of the invention can be prepared from the corresponding α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetonitrile derivatives 3 which are described in the above mentioned copending application and which can be obtained by the condensation of 2-adamantanone 1 with the appropriate phenylacetonitrile 2 in tetrahydrofuran solution and in the presence of potassium tert-butoxide. Sequential treatment of the benzeneacetonitrile derivatives with diisobutylaluminum hydride to provide the aldehyde 4, and then with sulfamic acid-sodium chlorite provides the title α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetic acids 5. The reaction scheme is as follows: ##STR3##
EXAMPLE 1
α-[2'-Tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetic Acid
A solution of 10.0 g (0.04 mol) of α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetonitrile (3, R 1 ═R 2 ═R 3 ═H) in 50 ml methylene chloride was added over 30 min to 55 ml of a 1M solution of diisobutylaluminum hydride in methylene chloride under a nitrogen atmosphere. The reaction was stirred for 3 hours, then cooled in an ice bath and quenched by dropwise addition of 60 ml of 6N sulfuric acid, followed by addition of water and methylene chloride. The organic layer was washed sequentially with water, saturated aqueous sodium bicarbonate, and saturated aqueous sodium chloride, then dried over magnesium sulfate. Removal of the solvent in vacuo yielded the corresponding aldehyde (4, R 1 ═R 2 ═R 3 ═H) as an unstable oil. Without further purification, the latter was dissolved in 30 ml of tetrahydrofuran and 400 ml of potassium biphthalate buffer (pH 4.0) was added with vigorous stirring followed by 5.04 g (1.3 equivalent) of sulfamic acid and 6.68 g (1.3 equivalent) of sodium chlorite dihydrate. The yellow reaction mixture was stirred for 2 hours at room temperature, then water and ether were added and the two layers were separated. The organic extract was washed with saturated aqueous sodium chloride and dried over magnesium sulfate. Crystallization from ethyl acetate provided 8.57 g of the product acid (5, R 1 ═R 2 ═R 3 ═H). Mp 182°-186° C. Anal. Calcd. for C 18 H 20 O 2 ; C, 80.56; H. 7.51. Found: C, 80.18; H, 7.38.
EXAMPLE 2
3-Chloro-α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetic Acid
The title compound (5, R 1 ═R 3 ═H, R 2 ═Cl) was prepared by a method similar to that described in Example 1 from 3-chloro-α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetonitrile (3, R 1 ═R 3 ═H, R 2 ═Cl) via the corresponding aldehyde (4, R 1 ═R 3 ═H, R 2 ═Cl). The product acid has a melting point of 185° C. (methanol). Anal. Calcd. for C 18 H 19 ClO 2 : C, 71.40; H, 6.32; Cl, 11.71. Found: C, 71.00; H, 6.33; Cl, 11.64.
EXAMPLE 3
4-Methyl-α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetic Acid
The title compound (5, R 1 ═CH 3 , R 2 ═R 3 ═H) was prepared by a method similar to that described in Example 1 from 4-methyl-α-[2'-tricyclo-[3.3.1.1 3 ,7 ]decylidene]benzeneacetonitrile (3, R 1 ═CH 3 , R 2 ═R 3 ═H), via the corresponding aldehyde (4, R 1 ═CH 3 , R 2 ═R 3 ═H). The product acid has a melting point of 201°-202° C. (methanol). Anal. Calcd. for C 19 H 22 O 2 : C, 80.82; H, 7.85. Found: C, 81.02; H, 7.81.
EXAMPLE 4
2-Methyl-α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetic Acid
The title compound (5, R 1 ═R 2 ═H, R 3 ═CH 3 ) was prepared by a method similar to that described in Example 1 from 2-methyl-α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetonitrile (3, R 1 ═R 2 ═H, R 3 ═CH 3 ) via the corresponding aldehyde (4, R 1 ═R 2 ═H, R 3 ═CH 3 ). The product acid has a melting point of 120° C. (methanol). Anal. Calcd. for C 19 H 22 O 2 : C, 80.82; H, 7.85. Found: C, 80.82: H, 7.87.
EXAMPLE 5
3-Trifluoromethyl-α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetic Acid
The title compound (5, R 1 ═R 3 ═H, R 2 ═CF 3 ) was prepared by a method similar to that described in Example 1 from 3-trifluoromethyl-α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetonitrile (3, R 1 ═R 3 ═H, R 2 ═CF 3 ) via the corresponding aldehyde (4, R 1 ═R 3 ═H, R 2 ═CF 3 ). The product acid has a melting point of 198°-200° C. (methanol). Anal. Calcd. for C 19 H 19 F 3 O 2 : C. 67.85; H, 5.69; F, 16.95. Found: C, 67.90; H, 5.93; F, 16.79.
EXAMPLE 6
4-Chloro-α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetic Acid
The title compound (5, R 1 ═Cl, R 2 ═R 3 ═H) was prepared by a method similar to that described in Example 1 from 4-chloro-α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]benzeneacetonitrile (3, R 1 ═Cl, R 2 ═R 3 ═H). The product has a melting point of 218°-219° C. (methanol). Anal. Calcd. for C 18 H 19 ClO 2 : C, 71.40; H, 6.32; Cl, 11.71. Found: C, 71.19; H, 6.53; Cl, 11.18.
Compounds possessing useful antihypoxia activity extend the lifetime of animals exposed to a hypoxic environment. This activity is conveniently measured in mice. Groups of mice are tested at various times after the intraperitoneal administration of the test compound dissolved in saline in dosages of 1 to 100 mg/kg of mouse weight. The animals' survival time in a hypoxic environment (96% nitrogen and 4% oxygen) is recorded. A statistical comparison (Wilcoxon Rank sum) is made between coincident vehicle treated animals and the experimental group. The compounds of Examples 1, and 4 to 6 were tested at the 100 mg/kg dosage level and were found active.
The evaluation of the anti-convulsant activity of drugs is based mainly on their ability to block the pentylenetetrazole(PTZ)- and/or electric shock-induced convulsions. In general, compounds which protect animals against pentylenetetrazole-induced seizures are useful in the treatment of petit mal epilepsy, and drugs which protect animals against electric shock-induced convulsions are effective in the treatment of grand mal and focal seizures. Compounds possessing broader activity which protect animals against both forms of induced seizures may be useful in the treatment of adult petit mal and psychomotor epilepsies.
In the PTZ-induced seizure test two groups of 5 mice each are administered the test compound at 1/4 of the LD50 dose or vehicle intraperitonially (i.p.). Thirty minutes later each mouse is administered PTZ, 150 mg/kg i.p. The mice are housed by groups in plastic cages. The animals are observed for 15 minutes immediately following PTZ administration. Alternation of the convulsive pattern such as delayed onset of convulsions, changes in the type of convulsions and prevention of convulsions are noted. The number of survivors 15 minutes after PTZ administration is recorded.
The dose of PTZ used as a convulsive challenge is higher than the LD100 dose, therefore, the number of surviving mice 15 minutes post PTZ can be used as an index of anticonvulsive activity. Active compounds are considered as those that protect 3 or more mice. Most compounds which afford protection against death also delay and moderate or prevent PTZ-induced seizures. The seizure pattern of untreated mice (controls) is: (1) initial twitching, (2) a more severe generalized jerking of the body usually accompanied by a squeak which is followed immediately by (3) frank clonic convulsion which lead to tonic convulsions with tonic extension of the hind limbs. The compounds of Examples 1 to 3 were found active at a dosages 225, 250 and 350 mg/kg of mouse weight respectively.
In the electric shock test, mice are subjected to a shock of 50 mA for 0.2 seconds applied through saline-wetted corneal electrodes. The control group is tested similarly. Untreated mice subjected to electric shock exhibit a typical seizure pattern. Tonic flexion occurs immediately after shock. This changes to tonic extension (hind limb) with 0.5 to 2 seconds and then into generalized clonic convulsions, followed by depression and recovery. The criterion for drug activity is prevention of hind limb tonic extension in 3 or more mice. Some compounds will prevent the tonic phase of the seizure entirely (flexion and extension). The compound of Example 6 was found to be active at a dosage of 350 mg/kg of mouse weight.
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Substituted α-[2'-tricyclo[3.3.1.1 3 ,7 ]decylidene]-benzeneacetic acid derivatives of the formula: ##STR1## where the R 1 , R 2 and R 3 substituents are independently selected from hydrogen, lower alkyl, lower alkoxy, halogen and trifluoromethane, provided that at least one of such substituents is hydrogen have antihypoxia, anticonvulsant and/or antiparkinson activities.
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BACKGROUND OF THE INVENTION
Vibration dampers have been utilized for many years in torsional couplings, such as in the clutch driven member for an automotive vehicle power train to control engine induced torsional vibration in the connected elements of the power train. The vibration damper assembly is interposed in the clutch driven member ahead of a manually operated transmission to neutralize the torsional vibrations emanating from the vehicle engine, which vibrations would otherwise cause disturbing impact loads, pulsations and noises in the transmission and driveline. A vibration damper may also be utilized for a lock-up clutch inserted into a torque converter for an automatic transmission where the vibrations in the direct drive mode as a result of the lock-up between the torque input and the drive shaft would not be hydraulically dampened by the torque converter vibration damping characteristics.
A conventional vibration damper assembly consists of a clutch hub splined to the output shaft leading to the vehicle transmission and having an integral radial flange, a clutch plate and a spring retainer plate sandwiching the hub flange, and a plurality of compression springs received in circumferentially spaced axially aligned sets of openings in the plates and hub flange. The clutch plate and spring retainer plate are rigidly secured together and have limited rotation relative to the hub and flange, and annular friction pads are carried on the opposite surfaces of the clutch plate radially outwardly of the hub flange.
However, special circumstances may occur which will dictate a vibration damper having unusual characteristics so as to control objectionable vibration and/or gear rattle in a transmission which may occur during idling or under full engine load. Obviously, a conventional vibration damper will not be able to handle such special circumstances, but the present invention has such capabilities to overcome these problems.
SUMMARY OF THE INVENTION
The present invention comprehends the provision of a novel vibration damper assembly for use in a torsional coupling or automotive vehicle clutch which provides a multi-stage damping operation. The lowest spring rate stage acts to dampen gear rattle in the transmission at idle when the clutch is engaged and the transmission is in neutral. This rattle is caused by unevenness in the power supplied by the engine at low rpms. The higher stage or stages in the damper acts to cushion vibrations at higher engine speeds or loads.
The present invention also comprehends the provision of a novel multi-stage vibration damper assembly utilizing a two-part hub assembly having an inner hub and an outer hub yieldably connected by low rate compression springs. To provide a two-stage damper, the springs connecting the inner and outer hubs work simultaneously, while to produce a three-stage damper, one spring or spring set connecting the hubs provides a reaction force as soon as the hubs rotate in relation to each other and, after several degrees of rotation, a second spring or spring set contact both the hubs to supply an additional reaction force at a higher rate than the first stage. In all instances, the springs connecting the outer hub with the clutch plates provide the final damping stage.
The present invention further comprehends a novel multi-stage vibration damper assembly wherein the inner hub has an outer contour that is symmetrical about its centerline but consists of slightly converging edges beyond the hub barrel joined at each end by an arcuate segment. The opening in the outer hub is slightly larger than the inner hub contour with its contour consisting of parallel walls or edges joined by arcuate segments at the ends. The arcuate segments on the outer contour of the inner hub and the inner periphery of the outer hub are provided with complementary spring pockets to receive the lower rate compression springs utilized for the first stage or stages of damping action.
Another object of the present invention is the provision of a novel multi-stage vibration damper assembly having inner and outer hubs wherein the inner hub pilots in the outer hub along the major and minor diameters of the cam shape of the inner hub, and piloting is no longer done between the hub and the driving plate. Therefore, the clearance between the two hubs can be increased or decreased allowing the driving member to compensate for out of squareness between the flywheel and the transmission input shaft. The outer hub is piloted in the driving member by the springs of the final stage inserted in the aligned windows formed in the clutch plate, spring retainer plate and the outer hub.
A further object of the present invention is the provision of a novel multi-stage vibration damper assembly having inner and outer hubs wherein the area of contact between the hubs is larger than that for a splined connection and therefore the compressive stresses are reduced. Also, the tolerance requirements to achieve uniform contact of the mating surfaces between the hubs during engagement are not as stringent as with mating splines. Further, the spring pockets between the hubs allow for fewer springs than designs requiring separate springs for the coast and drive directions.
Further objects are to provide a construction of maximum simplicity, efficiency, economy and ease of assembly and operation, and such further objects, advantages and capabilities as will later more fully appear and are inherently possessed thereby.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial rear elevational view of one embodiment of vibration damper providing a two-stage operation.
FIG. 2 is a cross sectional view taken on the irregular line 2--2 of FIG. 1.
FIG. 3 is a partial rear elevational view showing the hubs in their engaged drive position.
FIG. 4 is a rear elevational view of the inner hub.
FIG. 5 is a cross sectional view through the inner hub taken on the irregular line 5--5 of FIG. 4.
FIG. 6 is a rear elevational view of the outer hub.
FIG. 7 is a cross sectional view taken on the irregular line 7--7 of FIG. 6.
FIG. 8 is a partial rear elevational view of a second embodiment of vibration damper having a hub providing different travel in the drive and coast directions.
FIG. 9 is a rear elevational view of the inner hub of FIG. 8.
FIG. 10 is a partial rear elevational view of a third embodiment of vibration damper providing a three-stage operation.
FIG. 11 is a rear elevational view of the inner hub of FIG. 10.
FIG. 12 is a partial rear elevational view of the outer hub of FIG. 10.
FIG. 13 is a partial rear elevational view of a fourth embodiment of vibration damper providing a three-stage operation.
FIG. 14 is a rear elevational view of the inner hub of FIG. 13.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to the disclosure in the drawings wherein are shown illustrative embodiments of the present invention, FIGS. 1 and 2 disclose a clutch plate assembly embodying one form of vibration damper 10 where the clutch plate assembly is adapted to be mounted on a driven shaft 11 and positioned between a flywheel and a pressure plate of a vehicle clutch (not shown). The clutch plate assembly incorporating the vibration damper 10 includes a clutch or driving plate 12 having annular friction facings 13, 13 secured to the opposite surfaces of the plate adjacent the outer periphery 14 thereof by suitable securing means, such as rivets 15. The plate 12 has a laterally offset inner periphery 16 defining a central opening 17 to be journalled on a hub barrel 33. A plurality of circumferentially spaced spring windows 18 are formed in the plate and connected by arcuate concave portions 19, and a plurality of openings 21 receive the reduced ends of shoulder rivets 22 to connect this plate with a spring retainer plate 23.
The spring retainer plate 23 also has a laterally offset inner periphery 24 defining a central opening 25; the offset peripheries 16 and 24 extending inward towards each other. This plate has spring windows 26 connected by arcuate concave portions 27 and openings 28 to receive the opposite ends of the rivets 22. The rivets 22 may have washers 29 at the opposite ends to support and space the plates 12 and 23 in the assembly.
A hub assembly 31 for the vibration damper 10 comprises an inner hub 32 having a hub barrel 33 with an internally splined opening 34 receiving the driven shaft 11 therein and a generally rectangular flange formed of opposed portions 35, 35; and an outer hub 36 having a slightly larger generally rectangular central opening 37 to operatively receive the flange portions 35, 35, a plurality of circumferentially spaced spring windows 38 adapted to be axially aligned with the windows 18 and 26 in the plates 12 and 23, respectively, and a plurality of elongated notches 39 formed in the outer periphery 41 of the outer hub and adapted to receive the rivets 22. Slightly concave arcuate grooves 42 form a circle on each side of the flange joining the spring windows 38.
The central opening 37 is formed with a pair of parallel elongated sides 43, 43 and a pair of slightly curved edges 44, 44, each end edge having a centrally located notch 45 formed therein. The distance between the sides 43, 43 of opening 37 is slightly greater than the diameter of the hub barrel 33. With respect to the flange on the hub barrel 33, the flange portions 35 extend from diametrically opposite sides of the barrel, with each portion having slightly converging edges 46, 46 tangentially intersecting the barrel 33 and terminating in a slightly curved end edge 47 complementary to the end 44 of the opening 37. Each end edge 47 is formed with a notch 48 substantially identical to and normally opposite the notch 45 in the end edge 44. Each edge 46 is located at an angle of approximately 9° with respect to the longitudinal center line through the inner hub 32.
FIGS. 1 and 2 show the damper assembly 10 with a pair of small compression springs 51 in the spring pockets formed by the aligned pairs of notches 45, 48, and a spring 52 or concentric springs 52, 53 are provided for each axially aligned set of spring windows 18, 38, 26. The hub barrel 33 and flange portions 35, 35 are piloted in the outer hub 36 along the major diameter defined as the distance between the arcs of end edges 44, 44 and the minor diameter defined as the distance between the parallel sides 43, 43. The outer hub 36 is piloted in the driving member assembly by the springs 52, 53 positioned in the windows of the clutch plate 12, spring retainer plate 23 and outer hub 36. Thus, there is no piloting between the inner hub 32 and the clutch plate 12, and the clearance between the inner hub 32 and the outer hub 36 can be increased or decreased allowing the driven member to compensate for any out-of-squareness between the flywheel and the transmission input shaft 11.
As seen in FIGS. 1 and 3, the clutch plate 12 and spring retainer plate 23 and the outer hub 36 can rotate relative to the inner hub 32 as limited by the angle between the edges 46, 46 and the parallel sides 43, 43; relative movement being yieldably opposed by the compression springs 51. Thus, there is travel of approximately 8° in either the drive or coast directions before the inner and outer hubs engage. Once this degree of travel has been achieved (see FIG. 3) any additional torque is damped by the springs 52, 53 in the spring windows.
The lowest rate stage governed by the springs 51 dampens gear rattle in the transmission at idle when the clutch is engaged and the transmission is in neutral. This rattle is caused by unevenness in the power supplied by the engine at low rpm's. As an example, engaging an air conditioning unit will decrease the engine rpm and increase the resulting rattle.
Although this embodiment of damper provides approximately 8° of arcuate movement between the inner and outer hubs, the amount of arcuate movement can be decreased to 6° or 4° as desired. Also, the degree of movement in the coast direction can be less than the degree of movement in the drive direction. Considering the embodiment shown in FIGS. 8 and 9, like parts will have the same reference numeral with the addition of a script a. This damper assembly 10a includes a clutch plate 12a with friction facings 13a, a spring retainer plate 23a secured to the plate 12a by shoulder rivets 22a, aligned spring windows to receive concentric springs 52a, 53a, and a hub assembly 31a comprising an inner hub 32a with a barrel 33a and opposed flange portions 35a, 35a and an outer hub 36a having a central opening 37a.
The opening 37a is identical to the opening 37 in the embodiment of FIGS. 1 through 7 with parallel sides 43a and curved end edges 44a having notches 45a, except that the notches 45a, 45a are slightly offset from a longitudinal centerline through the opening. As seen in FIG. 9, the inner hub 32a has flange portions 35a with one side edge 54 at an approximately 6° angle and the opposite edge 55 at an approximately 2° angle from the longitudinal centerline of the inner hub. The edges 54, 54 of the flange portions are positioned on diagonally opposite sides of the inner hub as are the edges 55, 55. Thus, this embodiment will provide a 6° movement in the drive direction and a 2° movement in the coast direction. Also, the notches 48a, 48a are slightly offset from the longitudinal centerline of the inner hub; the notches being offset in opposite directions. The operation of this embodiment is substantially identical to that of the embodiment of FIGS. 1-7 except for the difference of angular motion between the inner and outer hubs for the drive and coast directions.
FIGS. 10 through 12 disclose a third embodiment of vibration damper assembly 10b wherein like parts will have the same reference numeral with the addition of a script b. This embodiment of damper provides for a three-stage version of the damper having a low rate intermediate stage, and includes a clutch plate 12b and spring retainer plate 23b secured together by shoulder rivets 22b, friction facings 13b mounted on the plate 12b, aligned spring windows in the plates for concentric springs 52b, 53b and a hub assembly 31b. The hub assembly includes an inner hub 32b having a barrel 33b and oppositely disposed flange portions 56 and 57, and an outer hub 36b having a central opening 37b. Each flange portion 56 or 57 has slightly converging edges 58 joined by a curved end 59 or 61, respectively; the curved end 59 having a central notch 62 while the curved end 61 has an enlarged central notch 63.
The central opening 37b of the outer hub 36b is defined by a pair of parallel sides 43b, 43b and a pair of curved ends 64, 65. The end 64 has a central notch 66 opposite to the notch 62 to form a spring pocket for a small compression spring 68, and the end 65 has an enlarged central notch 67 opposite to the notch 63 to form an enlarged spring pocket for a larger compression spring 69. As seen in FIG. 10, the notch 67 is greater in length than the notch 63.
This assembly provides a three-stage damping action with the initial and intermediate stages occurring between the inner and outer hubs; the intermediate stage reducing the velocity of the inner hub relative to the outer hub prior to metal-to-metal contact between the edges 58 and the sides 43b. In operation, when engagement of the clutch plate 12b is initiated, the lowest rate spring 68 begins to supply a reaction force as soon as the hubs start to rotate in relation to each other. After several degrees of rotation wherein the longer notch 67 provides a limited lost motion with respect to the intermediate rate spring 69, the spring 69 contacts both the inner and outer hubs and supplies an additional reaction force at a higher rate than the first stage. The intermediate stage spring 69 is intended to eliminate the "klunk" sound resulting from the engagement of the inner and outer hubs as the edges 58 contact the sides 43b.
Depending on the rate of the intermediate stage spring 69, the final stage may or may not begin to compress its springs 52b, 53b before the inner hub 32b contacts the outer hub 36b. Once the inner and outer hubs are in metal-to-metal contact, then the third stage springs 52b, 53b become the sole damping force.
FIGS. 13 and 14 disclose a fourth embodiment of vibration damper having a high rate intermediate stage wherein like parts have the same reference numerals with a script c. The damper assembly 10c includes a clutch plate 12c and a spring retainer plate 23c joined by shoulder rivets 22c, friction facings 13c secured to the outer periphery of the plate 12c, aligned spring windows in the plates to receive concentric springs 52c, 53c, and a hub assembly 31c. The hub assembly includes an inner hub 32c having a barrel 33c and oppositely disposed flange portions 71, 71, and an outer hub 36c having a central opening 37c to receive the inner hub. Each flange portion 71 has slightly converging edges 72 tangentially intersecting the barrel 33c and joined by curved ends 73; each end having an enlarged central notch 74 formed therein.
The central opening 37c of the outer hub 36c has a pair of parallel sides 43c, 43c joined by a pair of curved ends 44c, 44c; each end being formed with an enlarged notch 75 cooperating with a facing notch 74 in portion 71 to form a spring pocket. Each of the oppositely positioned spring pockets houses an outer low rate compression spring 76 and a higher rate concentric inner compression spring 77. As seen in FIG. 13, the outer spring 76 is of a length to be conformably received in the facing notches 74, 75 while the inner spring 77 has an expanded length that is shorter than the length of the notches 74, 75.
This damper assembly 10c provides for a three-stage damping function having a high rate intermediate stage. In operation, as engagement of the clutch plate 12c is initiated, rotation of the plates 12c and 23c and the outer hub 36c, connected by the concentric spring sets 52c, 53c, relative to the inner hub 32c acts to first compress the outer springs 76 to provide the initial reaction force. As the length of each spring 77 is less than the length of the associated notch, compression of springs 76 does not act to compress springs 77 until several degrees of relative rotation occur between the inner and outer hubs. After the several degrees of rotation, the edges of the notches 74, 75, engage the inner springs 77 to provide an intermediate stage of damping at a relatively high spring rate. This intermediate stage slows the contact of and will eliminate any "klunk" sound as the edges 72 and 43c of the inner and outer hubs, respectively, engage. Once the inner and outer hubs engage to act as a unit, the springs 52c, 53c in the aligned openings in the plates and the outer hub provide the third stage of damper action.
In each of the above embodiments, the areas of contact between the hubs is larger than in a splined engagement, and therefore compressive stresses are reduced. The configuration of the hubs has no sharp corners or stress risers, the parts are simpler to manufacture and the tolerance requirements to achieve uniform contact of the mating surfaces during engagement are not as stringent as with mating splines. The inner hub has a much greater shear strength and, in the event of a failure in the inner hub, the resulting broken pieces will not be able to turn freely inside the outer hub as would be the case if the teeth were broken off a splined design. Also, the spring pockets allow for the use of fewer springs than designs which require separate springs for the coast and drive directions.
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A multiple stage damper for the driven member of a vehicle clutch which eliminates objectionable vibration during both engine idle and while the vehicle is in motion. The damper comprises inner and outer hubs with springs therebetween and additional damper springs between the outer hub and the clutch and spring retainer plates to provide two or more damping stages. A two stage damper results when the springs connecting the inner and outer hubs work simultaneously, while a three stage damper results when a first spring or springs are actuated prior to a second spring or springs providing a sequential damping action.
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TECHNICAL FIELD
The present invention relates generally to the control of a selectable one-way clutch, and in particular to a selectable one-way clutch having three operational modes for use within a hybrid transmission having a motor controller and a transmission controller, wherein clutch speed synchronization is controlled by the motor controller and clutch actuation and release are controlled by the transmission controller.
BACKGROUND OF THE INVENTION
In a vehicle having a gasoline/electric hybrid transmission, the vehicle may be powered alternately by a gasoline-powered internal combustion engine or an electric motor to thereby optimize fuel efficiency while reducing vehicle emissions. Hybrid vehicles achieve their relatively high fuel efficiency in large part by alternating between the gasoline-powered engine and the electric motor when one power source is better suited than the other for a specific vehicle operating condition. For example, a gasoline-powered engine is known to be more efficient than an electric motor during periods of constant or relatively non-variable vehicle speed, such as while cruising at a sustained rate of speed, while an electric motor is generally better suited than a gasoline engine for use when the vehicle power requirements are highly variable, such as during starting or stopping of the vehicle.
Vehicles having either conventional internal combustion or hybrid gasoline/electric transmissions typically utilize a torque-transmitting device known as a friction clutch or clutch pack for smoothly engaging or coupling two rotating bodies or shafts to transmit torque therebetween. Likewise, the same clutch pack is used to subsequently disengage the coupled shafts to interrupt the power transfer and permit, for example, a smooth shifting between the various gears of a planetary gear set and/or decoupling of one or more motor/generators. Hybrid vehicles in particular generally shift gears in a more controlled and synchronous manner relative to conventional gas engines, due in part to the unique configuration and integrated hybrid motor and transmission controls. However, even within the more synchronous shifting mechanism of a hybrid transmission, conventional clutch packs tend to require a higher hydraulic pump pressure to quickly and fully actuate the conventional clutch-apply mechanism, which may in turn lead to higher losses within the hydraulic circuit and/or spin losses at or along the clutch plate interface.
SUMMARY OF THE INVENTION
Accordingly, a hybrid gasoline/electric transmission having a motor controller and a transmission controller is provided comprising a controllable three-mode, selectable one-way clutch with an outer race, an inner race, a pair of actuators, and two selector plates that are slidingly engageable within the outer race, the transmission controller being configured to select between the three operating modes and the motor controller being configured to synchronize the clutch speed to facilitate mode selection.
In one aspect of the invention, the three operational modes comprise freewheeling in two clutch rotational directions, torque holding in one rotational direction, and torque holding in two rotational directions.
In another aspect of the invention, a method is provided for controlling a selectable one-way clutch within a hybrid transmission having a motor controller and a transmission controller. The method includes detecting the speed difference across the selectable one-way clutch using a speed sensor, communicating the detected speed difference from the speed sensor to the transmission controller, synchronizing the clutch speed using the motor controller, and selecting between one of three clutch operational modes in response to a speed difference signal from the transmission controller.
The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic plan view of a controllable, selectable one-way clutch having three operational modes according to the invention;
FIG. 1B is a schematic plan view of an outer race and dual-selector plates of a controllable, selectable one-way clutch according to the invention;
FIG. 1C is a schematic plan view of an inner race of a controllable, selectable one-way clutch according to the invention;
FIG. 2A is a table describing three clutch operational modes according to the invention;
FIG. 2B is a schematic fragmentary cross sectional side view of an outer and inner race of a controllable, selectable one-way clutch having two selector plates showing a first operational mode according to the invention;
FIG. 2C is a schematic fragmentary cross sectional side view of an outer and inner race of a controllable, selectable one-way clutch having two selector plates showing a second operational mode according to the invention;
FIG. 2D is a schematic fragmentary cross sectional view of an outer and inner race of a controllable, selectable one-way clutch having two selector plates showing a third operational mode according to the invention;
FIG. 3A is a graphical illustration of differential clutch speed versus three clutch operating modes during application of a selectable one-way clutch according to the invention;
FIG. 3B is a graphical illustration of differential clutch speed versus three clutch operating modes during release of a controllable, selectable one-way clutch according to the invention;
FIG. 4A is a lever diagram of a representative hybrid transmission having a controllable, selectable one-way clutch in “released” mode; and
FIG. 4B is a lever diagram of a representative hybrid transmission having a controllable, selectable one-way clutch in “applied” mode.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings wherein like reference numbers correspond to like or similar components throughout the several figures, there is shown in FIG. 1A a portion of a hybrid transmission 10 having a controllable, selectable one-way clutch 18 , hereinafter referred to as clutch 18 . Clutch 18 is preferably a mechanical diode-type selectable one-way clutch, but may also take the form of, for example, a sprag clutch, roller clutch, or other selectable one-way clutch. Clutch 18 has mating concentric inner and outer races 20 , 22 , respectively. As shown in FIG. 1C , inner race 20 has an outer wall 39 , a plurality of angled wells 36 as will be described later hereinbelow, and a plurality of radially-inward projecting teeth or splines 24 that are configured to engage or mate with slots or grooves of a rotatable body, such as a drive or crank shaft (not shown). Likewise, as shown in FIG. 1A , outer race 22 has an outer wall 35 having a plurality of outwardly-projecting teeth or splines 26 that are configured to mate with slots or grooves of a preferably stationary or grounded clutch hub (not shown).
Hybrid transmission 10 has a speed sensor 11 , a motor controller 16 , and a transmission controller 14 . Speed sensor 11 is preferably an input/output-type speed sensor of the type known in the art, and is configured to deliver a speed sensor signal to the transmission controller 14 . The motor controller 16 is configured to control the operation of at least one and preferably two motor/generators 82 , 84 , labeled M/G 1 and M/G 2, respectively, as well as to synchronize the rotational speeds of the inner and outer races 20 , 22 , as described later herein. The transmission controller 14 is configured to control the operation and/or functionality of the non-motor components of the hybrid transmission 10 , and is configured to receive a signal from the speed sensor 11 for actuation (i.e. apply and release) of the clutch 18 . A first and second projection or arm 12 A and 12 B are each operatively and respectively connected to a first and second selector plate 50 , 52 of the clutch 18 , with each selector plate 50 , 52 shown in more detail in FIG. 1B .
FIG. 1B , which is a plan view depicting clutch 18 with inner race 20 removed to show the internal detail of clutch 18 , shows the outer race 22 with a preferably continuous circumferential groove 56 that is sized and shaped to guide or direct selector plates 50 , 52 , each of which are at least partially slidably moveable or repositionable within the groove 56 . Selector plates 50 , 52 each have a plurality of preferably identical and equally spaced openings or windows 51 . Also, a plurality of substantially identical strut wells or pockets 32 A, 32 B are arranged around the outer wall 35 of outer race 22 , preferably with approximately equal spacing within each set of pockets. Pockets 32 A and 32 B are substantially identical, preferably differing only in orientation to facilitate actuation of clutch 18 . Specifically, each of pockets 32 A are preferably oriented in one direction, while each of pockets 32 B are preferably oriented approximately 180° opposite the orientation of pockets 32 A.
Additionally, each of the pockets 32 A, 32 B are configured and sized to receive a mating strut 34 A, 34 B, with each strut 34 A, 34 B being configured and/or shaped to engage and/or disengage with an angled well 36 (see FIG. 1C ) or similar recess within the inner race 20 as required to respectively allow rotation of the inner race 20 in either one or both directions, as well as to lock or hold torque in both directions. First and second arms 12 A, 12 B are operatively attached to the first and second selector plates 50 , 52 , respectively, providing a projection on which a force external to the outer race 22 may be exerted or directed for moving the selector plates 50 , 52 to bring the windows 51 into engagement with the struts 34 A, 34 B, alternately depressing and releasing the struts 34 A, 34 B as needed. When actuated by arms 12 A, 12 B, respectively, the selector plates 50 , 52 each slide or move along the circumferential groove 56 of outer race 22 , with each of the arms 12 A, 12 B protruding through an opening or slot 55 in outer wall 35 . The first arm 12 A is actuated by a first actuator 42 . Likewise, the second selector plate is actuated by a second actuator 43 , with the motion of the arms 12 A, 12 B represented by the arrows in FIG. 1B . The actuators 42 , 43 are controlled by the transmission controller 14 and are preferably slide valves of the type known in the art. However, those skilled in the art will recognize that any mechanism suitable for repositioning first and second selector plates 50 , 52 respectively, along or within circumferential groove 56 may be used, such as, for example, a piston or motor.
Turning to the table of FIG. 2A , three operational modes are shown for clutch 18 (see FIGS. 1A-C ), with each clutch operational mode defining the direction of torque holding within the clutch 18 . In Mode 1 the clutch 18 is allowed to “freewheel”, i.e. torque is not held in either rotational direction, and permitting for example inner race 20 to rotate or spin unimpeded within a stationary outer race 22 . In Mode 2 , torque is locked or held in one rotational direction. For example, inner race 20 would be permitted to freewheel or rotate unimpeded in a clockwise direction, and lock or be held from rotating in the counter-clockwise direction. Finally, in Mode 3 the clutch 18 is locked, i.e. torque is held in both rotational directions. Each of the three operational modes described generally above as applied to clutch 18 are shown in detail in the fragmentary cross-sectional side views of FIGS. 2B , 2 C, and 2 D, respectively.
In each of FIGS. 2B , 2 C, and 2 D, wells 32 A, 32 B are shown with a substantially vertical locking surface 40 and a sloped surface 41 . Vertical locking surface 40 is configured and/or shaped to oppose a strut 34 A, 34 B to thereby prevent rotation in one direction when Modes 2 or 3 are selected (see FIG. 2A ), while sloped surface 41 is configured and/or shaped to allow a strut 34 A, 34 B to be depressed into a mating pocket 32 A, 32 B as required and thereby permits relative rotation of the races 20 , 22 in at least one direction, i.e. Modes 1 or 2 (see FIG. 2A ). As shown in FIGS. 2B , 2 C, and 2 D, outer race 22 is grounded to the transmission case 70 and inner race 20 is rotating, inner race 20 being connected to motor/generator 84 , which is in communication with the motor controller 16 . Motor controller 16 , as previously described, is configured to synchronize the rotational speeds of the inner and outer races 20 , 22 to facilitate actuation of the clutch 18 . However, in the event outer race 22 is not grounded and therefore is also rotating, the motor/generator 82 would be likewise connected to the outer race 22 and in communication with motor controller 16 , as shown by the dotted line connection.
In FIG. 2B , representing Mode 1 or “freewheeling”, first and second selection plates 50 , 52 are positioned by actuators 42 , 43 , respectively, in response to a control signal from the transmission controller 14 . When repositioned as shown, first and second selector plates 50 , 52 depress each of the required number of struts 34 A, 34 B into a respective mating well 32 A, 32 B, with each strut 34 A, 34 B compressing a biasing spring 37 to thereby allow inner race 20 to freely rotate or freewheel in either rotational direction, as represented by arrows 1 and 2 . Likewise, in FIG. 2C , representing Mode 2 or torque-holding in a single direction, the first selector plate 50 is positioned in response to a signal from the transmission controller 14 . Biasing springs 37 return any depressed strut 34 A to its initial position, thus engaging the strut 34 A with a vertical locking surface 40 . Torque is held in one direction by preventing the inner race 20 from rotating in the direction of arrow 1 due to the obstructing presence of the strut 34 A. The second selector plate 52 continues to depress strut 34 B, allowing inner race 20 to continue to freely rotate in the direction of arrow 2 . Finally, in FIG. 2D both first and second selector plates 50 , 52 are repositioned to allow biasing springs 37 to uncompress and return struts 34 A, 34 B to their initial, non-depressed state, thereby locking the inner race 20 in both rotational directions (arrows 1 and 2 ). While a single strut 34 A, 34 B is shown in FIGS. 2B , 2 C, and 2 D for illustrative simplicity, for optimal control and performance of clutch 18 , a plurality of struts 34 A, 34 B is preferred, such as shown in FIG. 1B .
Turning to FIG. 3A , a curve is shown plotting differential clutch speed (Δ S ) versus the three clutch operating modes (see FIG. 2A ) during application of clutch 18 (see FIGS. 1A , 1 B, and 1 C). The three operational modes are arranged sequentially along the X axis, while the Y axis describes the speed differential Δ S as measured across the disparately rotating inner and outer races 20 , 22 (see FIGS. 1A , 1 B, and 1 C). According to the invention, each of the three operational modes, i.e. Mode 1 , Mode 2 , and Mode 3 , are selected from according to a measured or otherwise determined speed differential Δ S determined by speed sensor 11 (see FIG. 1A ), with Δ S also having a positive or negative rotational direction value defined by the relative rotational direction of the inner and outer races 20 , 22 .
As shown in FIG. 3A , while in Mode 1 , i.e. “freewheeling”, to apply the clutch 18 the motor controller 16 (see FIGS. 2A , 2 B, and 2 C) cycles or synchronizes the outer and inner races 20 , 22 of the clutch 18 so that Δ S approaches approximately zero revolution per minute, as represented by point 61 . The signal communicated at point 61 precipitates a change from Mode 1 to Mode 2 when the speed sensor 11 detects that the direction of Δ S reaches a non-negative quantity, i.e. at point 64 , at which point the transmission controller 14 signals the clutch 18 to change to Mode 2 and thereby hold torque in one rotational direction. Because of the time delay in making the physical shift by actuation of the required selector plates 50 , 52 (see FIG. 2C ), a slight time lag Δt occurs before Mode 2 is fully realized at point 65 . While the direction of Δ S is positive, the clutch 18 continues freewheeling. While in Mode 2 , when the direction of Δ S turns negative, i.e. at point 68 , the clutch 18 locks. When the speed sensor 11 detects zero differential clutch speed and zero speed change, the transmission controller 14 signals the clutch 18 to change to Mode 3 so that rotational motion is prevented in both directions, as shown in FIG. 2D , thereby freeing or releasing the motor/generators 82 , 84 (see FIG. 1A ) to change speeds as necessary. Because of the time delay in making the physical shift by actuation of the required selector plates 50 , 52 (see FIG. 2D ), a slight time lag Δt occurs before Mode 3 is fully realized at point 69 .
Turning to FIG. 3B , a similar speed curve is shown describing the release of the clutch 18 , beginning with dual-directional torque holding or Mode 3 . To initiate the release of the clutch 18 , the transmission controller 14 (see FIGS. 1A and 1B ) commands or signals a mode change from Mode 3 to Mode 2 at point 71 . Prior to a mode change to Mode 2 , the motor controller 16 commands or signals the motor to load the clutch 18 in the direction opposite that of the impending clutch release, then in Mode 2 the motor controller 16 unloads the clutch 18 so that the clutch 18 may be easily released (i.e. the struts 34 B may be more easily disengaged in FIG. 2C ) in the opposite direction. When the speed sensor 11 (see FIG. 1A ) detects that the quantity Δ S is positive, the transmission controller 14 changes the operating mode to “freewheel in both directions”, i.e. Mode 1 , which is the initial state of FIG. 3A as previously described hereinabove. The actuation cycle then repeats as previously described hereinabove for FIG. 3A .
Turning now to FIG. 4A , a lever diagram is shown for a representative hybrid transmission 110 having a selectable one-way clutch 180 as previously described herewithin for clutch 18 , the clutch 180 shown in a released or unapplied state (i.e. Mode 1 ). The hybrid transmission 110 has a first and second motor/generator, 182 , 184 , respectively, an engine 186 , and a first and second planetary gear set 190 , 192 , respectively. The first and second motor/generators 182 and 184 are controlled by a motor controller 16 (see FIGS. 1 A and 2 A-D) as previously described hereinabove. First planetary gear set 190 comprises a carrier (node C 1 ), a ring gear (node R 1 ), and a sun gear (node S 1 ). Likewise, second planetary gear set 192 comprises a carrier (node C 2 ), a ring gear (node R 2 ), and a sun gear (node S 2 ). A second clutch 181 , which may allow for different gear connections, is shown in an applied state. First motor/generator 182 is operatively connected to carrier C 1 of first planetary gear set 190 , which is in turn connected to the sun gear S 2 of the secondary planetary gear set 192 . Second motor/generator 184 is connected to the sun gear S 1 , which is in turn connected to the ring gear R 2 through the second applied clutch 181 . Engine 186 is connected to the ring gear R 1 , while the carrier C 2 is connected to the clutch output 198 . Clutch 180 of the present invention is shown in the disengaged or unapplied state.
Dotted lines 200 , 201 , 202 and 204 , 205 , and 206 represent various speed ratios in the unapplied mode, i.e. a range of speed ratios determined by motor/generator 182 . When clutch 180 is applied as previously described hereinabove, motor/generator 182 cycles or synchronizes the speed across clutch 180 to approximately zero rpm to provide a single fixed speed ratio, as represented by dotted lines 207 and 208 . As shown in FIG. 4B , torque is held in both directions, i.e. clutch 180 is fully applied. While the hybrid transmission 110 shown in FIGS. 4A and 4B is one example, those skilled in the art will recognize that various other hybrid transmission configurations and designs would be operable within the scope of the invention.
While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
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A controllable selectable one-way clutch is provided for use within a hybrid transmission. The clutch comprises an outer and inner race, and a first and second selector plate. A transmission motor controller synchronizes the speeds of the races to facilitate application and release of the clutch, and a transmission controller communicates a signal to the clutch for re-positioning of the plates to apply and release the clutch. The clutch has three operational modes, including freewheeling and holding torque in one direction or both directions. A method is also provided for applying a selectable one-way clutch in a vehicle having a hybrid transmission with a motor controller and a transmission controller, including synchronizing the clutch speed using the motor controller, detecting the direction of the race speed difference, communicating the race speed difference to the transmission controller, and selecting between the clutch operational modes in response to the detected speed difference.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 14/160,316, filed Jan. 21, 2014, titled PATIENT MONITOR FOR DETERMINING MICROCIRCULATION STATE, which is a continuation of U.S. patent application Ser. No. 13/101,093, filed May 4, 2011, titled PATIENT MONITOR FOR DETERMINING MICROCIRCULATION STATE, which claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/332,155, filed May 6, 2010, titled PATIENT MONITOR FOR DETERMINING MICROCIRCULATION STATE, the entire contents of each of which are hereby incorporated by reference herein in their entireties.
FIELD OF THE DISCLOSURE
The present disclosure relates to medical sensors and specifically to a medical sensor and/or monitor for determining the circulation state in blood vessels.
BACKGROUND OF THE DISCLOSURE
Patient monitoring of various physiological parameters of a patient is important to a wide range of medical applications. Oximetry is one of the techniques that has developed to accomplish the monitoring of some of these physiological characteristics. It was developed to study and to measure, among other things, the oxygen status of blood. Pulse oximetry—a noninvasive, widely accepted form of oximetry—relies on a sensor attached externally to a patient to output signals indicative of various physiological parameters, such as a patient's constituents and/or analytes, including for example a percent value for arterial oxygen saturation, carbon monoxide saturation, methemoglobin saturation, fractional saturations, total hematocrit, bilirubins, perfusion quality, or the like. A pulse oximetry system generally includes a patient monitor, a communications medium such as a cable, and/or a physiological sensor having light emitters and a detector, such as one or more LEDs and a photodetector. The sensor is attached to a tissue site, such as a finger, toe, ear lobe, nose, hand, foot, or other site having pulsatile blood flow which can be penetrated by light from the emitters. The detector is responsive to the emitted light after attenuation by pulsatile blood flowing in the tissue site. The detector outputs a detector signal to the monitor over the communication medium, which processes the signal to provide a numerical readout of physiological parameters such as oxygen saturation (SpO2) and/or pulse rate.
High fidelity pulse oximeters capable of reading through motion induced noise are disclosed in U.S. Pat. Nos. 7,096,054, 6,813,511, 6,792,300, 6,770,028, 6,658,276, 6,157,850, 6,002,952 5,769,785, and 5,758,644, which are assigned to Masimo Corporation of Irvine, Calif. (“Masimo Corp.”) and are incorporated by reference herein. Advanced physiological monitoring systems can incorporate pulse oximetry in addition to advanced features for the calculation and display of other blood parameters, such as carboxyhemoglobin (HbCO), methemoglobin (HbMet), total hemoglobin (Hbt), total Hematocrit (Hct), oxygen concentrations, glucose concentrations, blood pressure, electrocardiogram data, temperature, and/or respiratory rate as a few examples. Typically, the physiological monitoring system provides a numerical readout of and/or waveform of the measured parameter. Advanced physiological monitors and multiple wavelength optical sensors capable of measuring parameters in addition to SpO2, such as HbCO, HbMet and/or Hbt are described in at least U.S. patent application Ser. No. 11/367,013, filed Mar. 1, 2006, titled Multiple Wavelength Sensor Emitters and U.S. patent application Ser. No. 11/366,208, filed Mar. 1, 2006, titled Noninvasive Multi-Parameter Patient Monitor, assigned to Masimo Laboratories, Inc. and incorporated by reference herein. Further, noninvasive blood parameter monitors and optical sensors including Rainbow™ adhesive and reusable sensors and RAD-57™ and Radical-7™ monitors capable of measuring SpO2, pulse rate, perfusion index (PI), signal quality (SiQ), pulse variability index (PVI), HbCO and/or HbMet, among other parameters, are also commercially available from Masimo Corp.
During blood circulation, arteries carry blood away from the heart in high volume and under high pressure. Arteries branch off into smaller blood vessels, called arterioles. Arterioles are well innervated, surrounded by smooth muscle cells, and are about 10-100 μm in diameter. Arterioles carry the blood to the capillaries, which are the smallest blood vessels, which are not innervated, have no smooth muscle, and are about 5-8 μm in diameter. Blood flows out of the capillaries into the venules, which have little smooth muscle and are about 10-200 μm in diameter. The blood flows from venules into the veins, which carry blood back to the heart.
Microcirculation generally refers to the vascular network lying between the arterioles and the venules, including the capillaries, as well as the flow of blood through this network. These small vessels can be found in the vasculature which are embedded within organs and are responsible for the distribution of blood within tissues as opposed to larger vessels in the macrocirculation which transport blood to and from the organs. One of the functions of microcirculation is to deliver oxygen and other nutrients to tissue. Sometimes, microcirculation in these small vessels can become blocked, interfering with the delivery of oxygen to the tissue.
SUMMARY OF THE DISCLOSURE
As placement of a physiological monitoring sensor is typically at a sensor site located at an extremity of the body, the state of microcirculation, such as whether vessels are blocked or open, can have a significant effect on the readings at the sensor site. It is therefore desirable to provide a patient monitor and/or physiological monitoring sensor capable of distinguishing the microcirculation state of blood vessels. In some embodiments, the patient monitor and/or sensor provide a warning and/or compensates a measurement based on the microcirculation state. In some embodiments, a microcirculation determination process implementable by the patient monitor and/or sensor is used to determine the state of microcirculation of the patient.
BRIEF DESCRIPTION OF THE DRAWINGS
Throughout the drawings, reference numbers may be re-used to indicate correspondence between referenced elements. The drawings are provided to illustrate embodiments of the disclosure described herein and not to limit the scope thereof.
FIG. 1 illustrates a block diagram of a patient monitor, such as a pulse oximeter, and associated sensor;
FIG. 2 illustrates an example graph depicting the optical absorption characteristic of normal blood and plasma;
FIGS. 3A and 3B illustrate graphs of oxygen saturation values for a normal microcirculation state data set;
FIGS. 4A and 4B illustrate graphs of oxygen saturation values for another normal microcirculation state data set;
FIGS. 5A and 5B illustrate graphs of oxygen saturation values for an anomalous microcirculation state data set;
FIG. 6 illustrates a flow diagram for a process for determining the state of microcirculation usable by a pulse oximeter; and
FIG. 7 illustrates a flow diagram for a process for determining the state of microcirculation wherein multiple data points are collected.
DETAILED DESCRIPTION
FIG. 1 illustrates a block diagram of a patient monitor 100 , such as a pulse oximeter, and associated sensor 110 . Generally, in the case of a pulse oximeter, the sensor 110 has LED emitters 112 , generally one at a red wavelength and one at an infrared wavelength, and a photodiode detector 114 . The sensor 110 is generally attached to an adult patient's finger or an infant patient's foot. For a finger, the sensor 110 is configured so that the emitters 112 project light through the fingernail and through the blood vessels and capillaries underneath. The LED emitters 112 are activated by drive signals 122 from the pulse oximeter 100 . The detector 114 is positioned at the fingertip opposite the fingernail so as to detect the LED emitted light as it emerges from the finger tissues. The photodiode generated signal 124 is relayed by a cable to the pulse oximeter 100 .
A pulse oximeter 100 determines oxygen saturation (SpO2) by computing the differential absorption by arterial blood of the two wavelengths emitted by the sensor 110 . A typical pulse oximeter 100 contains a sensor interface 120 , one or more processors 130 , such as a SpO2 processor, an instrument manager 140 , a display 150 , an audible indicator (tone generator) 160 , and a keypad 170 . The sensor interface 120 provides LED drive current 122 which alternately activates the sensor's red and infrared LED emitters 112 . The sensor interface 120 also has input circuitry for amplification and filtering of the signal 124 generated by the photodiode detector 114 , which corresponds to the red and infrared light energy attenuated from transmission through the patient tissue site. The SpO2 processor 130 calculates a ratio of detected red and infrared intensities, and an arterial oxygen saturation value is empirically determined based on that ratio. The instrument manager 140 provides hardware and software interfaces for managing the display 150 , audible indicator 160 , and keypad 170 . The display 150 shows the computed oxygen saturation status, as described above. Similarly, other patient parameters including HbCO, HbMet, Hbt, Hct, oxygen concentrations, glucose concentrations, pulse rate, PI, SiQ, and/or PVI can be computed. The audible indicator 160 provides the pulse beep as well as alarms indicating desaturation events. The keypad 170 provides a user interface for such things as alarm thresholds, alarm enablement, and/or display options.
Computation of SpO2 relies on the differential light absorption of oxygenated hemoglobin, HbO 2 , and deoxygenated hemoglobin, Hb, to determine their respective concentrations in the arterial blood. Specifically, pulse oximetry measurements are made at red (R) and infrared (IR) wavelengths chosen such that deoxygenated hemoglobin absorbs more red light than oxygenated hemoglobin, and, conversely, oxygenated hemoglobin absorbs more infrared light than deoxygenated hemoglobin, for example 660 nm (R) and 905 nm (IR).
To distinguish between tissue absorption at the two wavelengths, the red and infrared emitters 112 are provided drive current 122 so that only one is emitting light at a given time. For example, the emitters 112 can be cycled on and off alternately, in sequence, with each only active for a quarter cycle and with a quarter cycle separating the active times. This allows for separation of red and infrared signals and removal of ambient light levels by downstream signal processing. Because only a single detector 114 is used, it responds to both the red and infrared emitted light and generates a time-division-multiplexed (“modulated”) output signal 124 . This modulated signal 124 is coupled to the input of the sensor interface 120 .
In addition to the differential absorption of hemoglobin derivatives, pulse oximetry relies on the pulsatile nature of arterial blood to differentiate hemoglobin absorption from absorption of other constituents in the surrounding tissues. Light absorption between systole and diastole varies due to the blood volume change from the inflow and outflow of arterial blood at a peripheral tissue site. This tissue site might also comprise skin, muscle, bone, venous blood, fat, pigment, and/or the like, each of which absorbs light. It is assumed that the background absorption due to these surrounding tissues is invariant and can be ignored. Thus, blood oxygen saturation measurements are based upon a ratio of the time-varying or AC portion of the detected red and infrared signals with respect to the time-invariant or DC portion: R/IR=(Red AC /Red DC )/(IR AC /IR DC ).
The desired SpO2 measurement is then computed from this ratio. The relationship between R/IR and SpO2 can be determined by statistical regression of experimental measurements obtained from human volunteers and calibrated measurements of oxygen saturation. In a pulse oximeter device, this empirical relationship can be stored as a “calibration curve” in a read-only memory (ROM) look-up table so that SpO2 can be directly read-out of the memory in response to input R/IR measurements.
The pulse oximeter 100 can also measure perfusion index, PI, which is a numerical value that indicates the strength of the IR signal returned from a monitoring site and provides a relative assessment of the pulse strength at the monitoring site. The perfusion index can be defined as follows: PI=(IR max −IR min )/IR DC , where IR max is the maximum value, IR min is the minimum value, and IR DC is the average value of the invariant portion. As the light absorption characteristic of blood is typically “flatter” or less sensitive to oxygen saturation around the infrared wavelength, the infrared signal from a sensor is influenced primarily by the amount of the blood at the monitoring site, not by the level of oxygenation in the blood. Accordingly, the perfusion index, which is a numerical value that indicates the strength of the IR signal returned from a monitoring site, provides a relative assessment of the pulse strength at the monitoring site. PI values generally range from 0.02% (very weak pulse strength) to 20% (very strong pulse strength). In some embodiments, PI can be measured using other wavelengths. For example, red, near red, near IR, as well as other wavelengths can be used.
In an embodiment, the sensor 110 also includes a memory device 116 . The memory 116 can include any one or more of a wide variety of memory devices known to an artisan from the disclosure herein, including erasable programmable read only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory, other non-volatile memory, a combination of the same or the like. The memory 116 can include read-only memory such as read-only memory (ROM), a read and write device such as a random-access memory (RAM), combinations of the same, or the like. The remainder of the present disclosure will refer to such combination as simply EPROM for ease of disclosure; however, an artisan will recognize from the disclosure herein that the memory can include ROM, RAM, single wire memory, other types of memory, combinations of the same, or the like.
The memory device 116 can advantageously store some or all of a wide variety of data and information, including, for example, information on the type or operation of the sensor, type of patient or body tissue, buyer or manufacturer information, sensor characteristics including the number of wavelengths capable of being emitted, emitter specifications, emitter drive requirements, demodulation data, calculation mode data, calibration data, software such as scripts, executable code, or the like, sensor electronic elements, sensor life data indicating whether some or all sensor components have expired and should be replaced, encryption information, monitor or algorithm upgrade instructions or data, or the like. In an embodiment, the memory device can also include oxygen saturation to perfusion index and R/IR ratio to perfusion index ratios and/or data.
In certain situations, pulse oximetry sensors may produce anomalous readings, such as when a patient suffers from cyanosis. In a patient suffering from cyanosis, blood cells are uncharacteristically low on oxygen, leading to oxygen deficiency and giving the patient's skin a bluish-hue. One potential cause is that the patient's body produces too much hemoglobin, making the blood “thicker” or slower flowing, making microcirculation vessels more prone to blockage. Thus, a “blocked” microcirculation state can indicate cyanosis.
A “blocked” microcirculation state can also indicate other medical conditions, such as sepsis, systemic inflammatory response syndrome (SIRS), or septicemia. Sepsis is a potentially deadly medical condition that is characterized by a whole-body inflammatory state (called SIRS) and the presence of a known or suspected infection. The body may develop this inflammatory response by the immune system to microbes in the blood, urine, lungs, skin, or other tissue. Septicemia is a related medical term referring to the presence of pathogenic organisms in the bloodstream, which can lead to sepsis. Sepsis can also be referred to as blood poisoning. During sepsis or SIRS, inflammation in the body can cause constriction in blood vessels, leading to low blood pressure or insufficient blood flow.
During a “blocked” microcirculation state, blood cells can get blocked in the microcirculation vessels, such as the arterioles and capillaries. Blood cells can clump together or otherwise catch against the wall of blood vessels, creating a blockage that prevents blood cells, including red blood cells carrying hemoglobin, from passing through the blockage. However, plasma, which is composed of mostly water and in which the blood cells are suspended, is generally able to flow through passages in the blockage. In some situations, some blood vessels at the monitoring site may continue to have normal flow while some vessels are blocked. Thus, a “blocked” microcirculation state can indicate that some microcirculation vessels in an area are blocked and not necessarily all vessels in the area are blocked.
With the blockage preventing most or all the red blood cells from passing a blood vessel, at most only a limited amount of hemoglobin passes through a blocked blood vessel. In some situations, the blood vessel may only be partially blocked, where some hemoglobin passes through but less than when the blood vessel is unblocked. Normally, blood is made up of about 40-50% of red blood cells, of which about 95% is hemoglobin. Plasma, which is about 95% water, normally constitutes about 55% of the blood's volume.
Accordingly, a pulse oximeter placed on a tissue site experiencing blockage in microcirculation vessels may detect mostly plasma passing through with no or only a small percentage of red blood cells, at least at part of the monitoring site. The resulting change in the normal composition of blood can cause anomalous readings in the pulse oximetry monitor. As plasma has generally different absorption characteristics for red and infrared wavelengths than normal blood, pulse oximetry readings may become skewed. Red AC and/or IR AC can be affected, causing measured R/IR ratio to change. For example, if Red AC rises or IR AC drops, the R/IR ratio increases. Alternatively, if Red AC drops or IR AC rises, the R/IR ratio decreases. Thus, the value of R/IR can change due to a change in the light absorption of blood even if the underlying oxygen saturation of the blood remains the same.
However, by comparing oxygen saturation and PI for normal microcirculation to the oxygen saturation and PI for blocked microcirculation, such as by calculating and comparing ratios, the monitor can determine the existence of an abnormal situation. Typically, SpO2 is mostly independent of PI, with SpO2 varying minimally as PI increases. However, SpO2 varying by more than normal as PI increases can indicate an anomalous microcirculation state, such as a blockage. In one embodiment, by analyzing the measured ratios, the pulse oximeter 100 can determine the microcirculation state, such as whether a blocked vessel exists in the microcirculation vessels.
FIG. 2 illustrates an example graph depicting the optical absorption characteristic of normal blood and plasma. The graph depicts sampling wavelengths at 660 nm 220 and at 905 nm 225 . As illustrated, IR absorption for plasma at a frequency of 905 nm is on a “steeper” section of the curve compared to the “flatter” section of the curve for normal blood. This can imply that readings for IR for plasma would be more sensitive to changes in the absorption quality of the blood. In contrast, the IR measurement for normal blood, for example at 905 nm, is usually insensitive to a change in oxygenation of normal blood, but more affected by change in the amount of blood. As illustrated in the graph, plasma can have a “flatter” section in its absorption curve at a different wavelength, for example at 970 nm 230 .
FIGS. 3A and 3B illustrate graphs of oxygen saturation values for a normal microcirculation state data set. FIG. 3A has an y-axis 305 corresponding to the measured ratio, R/IR, and a x-axis 310 corresponding to perfusion index, PI. FIG. 3B has a y-axis 320 corresponding to measured oxygen saturation, and an x-axis 325 corresponding to perfusion index, PI. FIGS. 3A and 3B represent multiple data points with a best fit line 315 , 330 indicating the trend of the data points. Each data point represents a measurement. As illustrated, the best fit line for FIG. 3A trends slightly downward and the best fit line for FIG. 3B trends slightly upwards. However, there is generally only a small change in the y-axis for the best fit line as PI increases, with the change in FIG. 3A around 0.1 and the change in FIG. 3B around 4.
FIGS. 4A and 4B illustrate graphs of oxygen saturation values for another normal microcirculation state data set. FIG. 4A has a y-axis 405 corresponding to the measured ratio, R/IR, and an x-axis 410 corresponding to perfusion index, PI. FIG. 4B has a y-axis 420 corresponding to measured oxygen saturation, and an x-axis 425 corresponding to perfusion index, PI. FIGS. 4A and 4B represent multiple data points with a best fit line 415 , 430 indicating the trend of the data points. Each data point represents a measurement. As illustrated, the best fit line for FIG. 4A trends slightly upwards and the best fit line for FIG. 4B trends slightly downwards. However, there is generally only a small change in the y-axis for the best fit line as PI increases, with the change in FIG. 4A around 0.1 and the change in FIG. 4B around 3.
FIGS. 5A and 5B illustrate graphs of oxygen saturation values for an anomalous microcirculation state data set. FIG. 5A has a y-axis 505 corresponding to the measured ratio, R/IR, and an x-axis 510 corresponding to perfusion index, PI. FIG. 5B has a y-axis 520 corresponding to measured oxygen saturation, and an x-axis 525 corresponding to perfusion index, PI. FIGS. 5A and 5B represent multiple data points with a best fit line 515 , 530 indicating the trend of the data points. Each data point represents a measurement. As illustrated, the best fit line for FIG. 5A trends significantly upwards on the y-axis by around 0.3 and the best fit line for FIG. 5B trends significantly downwards on the y-axis by around 13 as PI increases.
In comparison to FIGS. 3A and 4A , FIG. 5A shows a high R/IR ratio for low values of PI that becomes a high R/IR ratio as PI increases. In comparison to FIGS. 3B and 4B , FIG. 5B shows a high reading for low values of PI that becomes a low reading as PI increases. Differences between the graphs can be explained by the microcirculation state in FIGS. 5A and 5B being different from the microcirculation state in FIGS. 3A-4B . For example, FIGS. 5A and 5B can represent a “blocked” or partially blocked microcirculation state where the blood passing through the sensor includes mostly plasma. As discussed above, this can skew R/IR and the measured oxygen saturation derived from R/IR.
FIG. 6 illustrates a flow diagram for a process 600 for determining the state of microcirculation usable by a pulse oximeter. Microcirculation state can be determined by comparison with microcirculation data stored on a patient monitor, such as the pulse oximeter 100 of FIG. 1 . The process 600 can be implemented by embodiments of the sensor 110 and/or patient monitor 100 of FIG. 1 or other suitable device.
While in conventional pulse oximetry, measurements are generally taken pulse-by-pulse and averaged over pulses, microcirculation measurements can be measured using only a single pulse or a portion of a single pulse. This can be done, for example, at the minimum and/or maximum blood flow of a pulse. Microcirculation measurements can also be determined over multiple pulses. In some embodiments, microcirculation measurements are taken during a portion of the normal measurement time used by a physiological sensor to take a measurement of a parameter, thereby allowing detection of aberrant parameter measurements using the microcirculation measurements. For example, while a pulse oximeter is measuring SpO2 over several pulses, microcirculation measurements can be taken per pulse and a warning given if an irregular microcirculation state is detected, thereby notifying a user of a possible aberration in the current SpO2 reading.
At block 610 , oxygen saturation is measured at a tissue monitoring site. In one embodiment, oxygen saturation is determined using a pulse oximeter sensor.
At block 620 , perfusion index or pulse strength is measured. In one embodiment, the perfusion index is determined using the same sensor used to measure oxygen saturation so that readings are taken at the same monitoring site.
At block 630 , a ratio of oxygen saturation to perfusion index is determined. Oxygen saturation can be a SpO2 value based on the measured R/IR ratio looked-up against a calibration curve. Alternatively, the ratio can be perfusion index to oxygen saturation. In other embodiments, the measured R/IR ratio can be used directly instead of SpO2.
In some embodiments, multiple readings of perfusion index and oxygen saturation can be taken and averaged together before determining the ratio in order to account for outliers. The multiple readings can be filtered before averaging. For example, readings can first be filtered based on closeness of PI values before the readings are averaged together.
At block 640 , the determined ratio in block 630 is compared to stored microcirculation data. The stored data can be data sets for microcirculation states. In some embodiments, a ratio, a curve, a line, table, data points, or formula can be stored that corresponds to a data set. The measured perfusion index and oxygen saturation can then be compared to the stored data. In some embodiments, multiple readings are taken and a best fit line or curve is generated and compared to a stored best fit line or curve. In some embodiments, readings are collected at various PI values in order to generate a trend line.
At block 650 , the microcirculation state is determined from comparison of the stored microcirculation data. For example, if the determined ratio is similar to a stored ratio corresponding to a data set for unblocked microcirculation, the microcirculation state is determined to be unblocked. Other data sets for other microcirculation states, such as blocked and/or partially blocked can also be stored. Where multiple data sets are stored, the state can be determined by selecting the state corresponding to the stored ratio closest to the measured ratio.
At block 660 , the monitor can optionally generate an alarm and/or display the microcirculation state. For example, an alarm signal can be generated by the monitor to indicate that the readings may be anomalous, such as when a blocked or partially blocked microcirculation state is detected. The alarm can be a visual indicator (e.g., icon, message or image) and/or an audio indicator. In an embodiment, the alarm can indicate the detection of cyanosis, sepsis, SIRS or other medical condition based at least partly on the determined microcirculation state. In some situations, no action is taken, such as when readings are determined to be normal or non-threatening.
At block 670 , the monitor can optionally compensate for the microcirculation state in order to improve accuracy of the readings. After the microcirculation state returns to normal, the compensation process can be ended.
In one embodiment, an offset can be added to the measured parameter value, such as SpO2. The offset can be calculated based on data sets for microcirculation state. Different microcirculation states can have different offsets. For example, if a “blocked” microcirculation state produces high readings for low PI values, a negative offset can be used. However, if a “blocked” state produces a low value for high PI values, then a positive offset can be used. In one embodiment, a varying offset can be used depending on the value of PI.
In one embodiment, a different wavelength emitter can be used to compensate for a microcirculation state. For example, rather than using a regular infrared emitter, typically 905 nm, an emitter with a different infrared wavelength, such as 970 nm can be used. In one embodiment, the different wavelength is selected such that the wavelength is at a “flat” section of the light absorption curve for plasma, that is, where the light absorption is not much affected by changes in oxygen saturation. In one embodiment, the selected wavelength with regards to plasma mimics the properties of the regular wavelength with regards to normal flowing blood. In some embodiments, a different wavelength red emitter can be used instead of the regular red wavelength emitter.
In some embodiments, the pulse oximeter sensor used to measure oxygen saturation and PI can be provided with an additional emitter at a different wavelength than the existing emitters. When a certain microcirculation state is detected, such as a “blocked” state, the additional emitter can be used. For example, a pulse oximetry sensor can be equipped with LED's capable of emitting at 660 nm, 905 nm, and at 970 nm wavelengths. Under normal operation, the 660 nm and 905 nm emitters are active. However, upon detecting a blocked microcirculation state, the 905 nm emitter can be deactivated and the 970 nm emitter activated in its place. In some embodiments, a variable wavelength emitter can be used rather than separate emitters. In some embodiments, the additional emitter can be a red wavelength emitter.
FIG. 7 illustrates a flow diagram for a process 700 for determining the state of microcirculation wherein multiple data points are collected. The process 700 can be implemented by embodiments of the sensor 110 and/or patient monitor 100 of FIG. 1 or other suitable device.
At block 710 and block 720 , oxygen saturation and perfusion index are measured. At block 725 , measured values are stored in memory. Each paired measurement forms a data point.
At block 730 , the number of stored data points is checked to determine if sufficient data has been collected to determine the microcirculation state. Data can be sufficient if a set number of data points have been collected, a set amount of time has passed, and/or a spectrum of data points have been collected, such as for differing values of PI.
At block 740 , the stored measured data is compared with stored microcirculation data. Typically, the microcirculation data is pre-stored on the pulse oximeter before use, as opposed to collected during use. A comparison can involve generating a curve or line from the measured data, calculating a rate of change for the stored data, generating a trend line for the measured data or the like and comparing with the stored microcirculation data.
At block 750 , the microcirculation state is determined from comparison of the stored microcirculation data. For example, if the measured data is similar to microcirculation data corresponding to a data set for unblocked microcirculation, the microcirculation state is determined to be unblocked. Other data sets for other microcirculation states, such as for blocked and/or partially blocked can also be stored. Where multiple data sets are stored, the state can be determined by selecting the state corresponding to the stored ratio closest to the measured ratio.
Blocks 760 and 770 are similar to steps 660 and 670 described in FIG. 6 .
As will be apparent from the above description, the R/IR ratio corresponds to oxygen saturation or SpO2 and can be used in place of oxygen saturation or SpO2 for the above comparisons, and vice versa.
While the above systems and methods have been described in terms of oxygen saturation and PI, other physiological parameters can be measured in place of or in addition to oxygen saturation and/or perfusion index and used to determine microcirculation state. For example, perfusion index is an indication of amplitude and/or signal strength and other parameters or measurements indicating amplitude and/or signal strength can be used. In some embodiments, one or more different sensors can be used in place of or in addition to a pulse oximeter sensor.
Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list.
Various systems and processes for determining microcirculation state have been disclosed in detail in connection with various embodiments. These embodiments are disclosed by way of examples only and are not to limit the scope of the claims that follow. Indeed, the novel methods and systems described herein can be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein can be made without departing from the spirit of the inventions disclosed herein. The claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of certain of the inventions disclosed herein. One of ordinary skill in the art will appreciate the many variations, modifications and combinations. For example, the various embodiments of the microcirculation determination process can be used with other oxygen saturation sensors and with both disposable and reusable sensors. In some embodiments, the determination process can be applied to other blood vessels to detect a blockage, even in vessels not involved in microcirculation.
Furthermore, in certain embodiments, the systems and methods described herein can advantageously be implemented using computer software, hardware, firmware, or any combination of software, hardware, and firmware. In one embodiment, the system includes a number of software modules that comprise computer executable code for performing the functions described herein. In certain embodiments, the computer-executable code is executed on one or more general purpose computers or processors. However, a skilled artisan will appreciate, in light of this disclosure, that any module that can be implemented using software can also be implemented using a different combination of hardware, software or firmware. For example, such a module can be implemented completely in hardware using a combination of integrated circuits. Alternatively or additionally, such a module can be implemented completely or partially using specialized computers or processors designed to perform the particular functions described herein rather than by general purpose computers or processors.
Moreover, certain embodiments of the invention are described with reference to methods, apparatus (systems) and computer program products that can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the acts specified herein to transform data from a first state to a second state.
Each of the processes, methods, and algorithms described in the preceding sections may be embodied in, and fully or partially automated by, code modules executed by one or more computers or computer processors. The code modules may be stored on any type of non-transitory computer-readable medium or computer storage device, such as hard drives, solid state memory, optical disc, and/or the like. The processes and algorithms may be implemented partially or wholly in application-specific circuitry. The results of the disclosed processes and process steps may be stored, persistently or otherwise, in any type of non-transitory computer storage such as, e.g., volatile or non-volatile storage.
The various features and processes described above may be used independently of one another, or may be combined in various ways. All possible combinations and subcombinations are intended to fall within the scope of this disclosure. In addition, certain method or process blocks may be omitted in some implementations. The methods and processes described herein are also not limited to any particular sequence, and the blocks or states relating thereto can be performed in other sequences that are appropriate. For example, described blocks or states may be performed in an order other than that specifically disclosed, or multiple blocks or states may be combined in a single block or state. The example blocks or states may be performed in serial, in parallel, or in some other manner. Blocks or states may be added to or removed from the disclosed example embodiments. The example systems and components described herein may be configured differently than described. For example, elements may be added to, removed from, or rearranged compared to the disclosed example embodiments.
While certain example embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions disclosed herein. Thus, nothing in the foregoing description is intended to imply that any particular feature, characteristic, step, module, or block is necessary or indispensable. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions disclosed herein. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of certain of the inventions disclosed herein.
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As placement of a physiological monitoring sensor is typically at a sensor site located at an extremity of the body, the state of microcirculation, such as whether vessels are blocked or open, can have a significant effect on the readings at the sensor site. It is therefore desirable to provide a patient monitor and/or physiological monitoring sensor capable of distinguishing the microcirculation state of blood vessels. In some embodiments, the patient monitor and/or sensor provide a warning and/or compensates a measurement based on the microcirculation state. In some embodiments, a microcirculation determination process implementable by the patient monitor and/or sensor is used to determine the state of microcirculation of the patient.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International application no. PCT/EP2004/008545, filed 29 Jul. 2004, which claims priority of German application no. 103 35 198.1, filed 30 Jul. 2003, and each of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a device, especially sporting equipment for use in surfing or similar activities, and a method for producing fiber composites.
BACKGROUND OF THE INVENTION
[0003] Known equipment used in surfing, such as surfboards, skateboards, skimboards, wakeboards, kneeboards or kiteboards can comprise a base made of foamed plastic, which in a first processing step is formed into a desired board-like shape having an upper and a lower side, and in a second processing step is provided with laminate coatings. In this, the laminate coatings are applied in two successive processing steps, since the upper and lower sides of the board-shaped base must be laminated separately from one another in order to produce a complete laminate covering over the entire surface of the base. However, the laminate coating may also be applied in a single strengthening pass.
[0004] During use, a surfboard, for example, is subjected to substantial levels of stress, which can lead to a deformation of the surfboard of up to 30 cm. This is combined with the problem that the laminate covering will separate from the foamed plastic base in areas where axial compression occurs as a result of the mechanical stress on the surfboard. This process of separation of the laminate covering progresses with the continued use of the surfboard, until the surfboard can no longer be used properly and eventually breaks.
OBJECTS AND SUMMARY OF THE INVENTION
[0005] An object of the invention is overcome the drawbacks of the prior art.
[0006] Another object of the invention is to provide a device, especially sporting equipment for use in surfing and similar activities, and to disclose a method for producing fiber composites, with which, despite high mechanical stress levels, the laminate covering will not become separated from the foamed plastic base, and the breaking strength is increased.
[0007] The object of the invention is achieved with a device including a base made of foamed plastic, which includes at least one laminate coating comprised of a fabric laminate and an underlay compound.
[0008] The invention solution further includes that an intermediate layer is provided between the base and the at least one laminate coating. With an intermediate layer of this type, the attachment between the base and a laminate covering comprised of two laminate coatings can be substantially improved even under extreme levels of mechanical stress. Furthermore, in this manner an optimal combination of lightness, flexibility and stability can be achieved.
[0009] It is preferably provided that the intermediate layer comprises material of the base and of the underlay compound. Combining these two materials in the intermediate layer gives the intermediate layer mechanical properties that reduce mechanical tensions that occur on a boundary layer between two different materials under mechanical stress.
[0010] In a further embodiment it is provided that the intermediate layer comprises material from the fabric laminate. In this, fabric laminate sections can be pressed into the base, or the base is coated with the fabric laminate, after which the fabric laminate is pressed at points into the base (stitched). To accomplish this, devices such as a reciprocating saw with a blunt tip, or a blunt needle roller can be used. A device of this type can also withstand extreme stresses.
[0011] In one preferred embodiment it is provided that the intermediate layer comprises a foamed plastic layer that is equipped with indentations. In the indentations in the foamed plastic layer, which has been applied to the base, the underlay compound is allowed to penetrate, thereby effecting an improved attachment between the surface of the foamed plastic base and the laminate covering as a result of the enlarged surface and the improved contact of the roughened surface.
[0012] It is preferably provided that the indentations are designed as grooves, so that along the linear grooves a particularly strong connection between the foamed plastic base and the laminate covering is created.
[0013] In one preferred embodiment it is provided that fabric laminate is arranged, at least in sections, in the grooves, at least in sections. In this manner a significant increase in strength can be achieved in that, for example, multiple, preferably 1 to 20, grooves extending longitudinally are cut into the base, after which the fabric laminate is pressed into the grooves, for example using a suitable tool. The grooves may be filled with underlay compound prior to this pressing step. The fabric laminate can be applied in the form of fabric laminate strips, for example having a width of 15 to 35 cm. However, fabric laminate strips of narrower or greater width, or a full-surface fabric laminate layer may also be used. The laminate coating is then completed with the application of an underlay compound. In this manner the fiber ratio can be increased to up to 80%, which further increases stability and strength.
[0014] In this case, the grooves have a depth of up to 4 cm, in order to produce a connection between the foamed plastic base and the laminate covering that can withstand even extreme mechanical stresses.
[0015] In this case, the grooves extend parallel and/or criss-crossing over the surface of the base, in order to achieve a non-directional improvement of the connection.
[0016] In a further embodiment it is provided that the indentations are configured as sinkholes. The sinkhole-like indentations can be conical or cylindrical in shape, with depths of up to 8 cm and a diameter of up to 5 mm. However the indentations may also connect the upper and underneath sides of the board-shaped base via the formation of passageways, so that the two laminate coatings are connected directly to one another via underlay compound in the passageways. Preferably, however, the indentations have a depth of 1 to 2 cm and a diameter of 1 to 3 mm, wherein the indentations are preferably arranged in a regular pattern. Thus the base has a regular pattern with indentations in which the underlay compound can penetrate thereby improving the attachment between the foamed plastic base and the laminate covering. However, the base may also be provided with an irregular pattern.
[0017] Preferably, the fabric laminate is comprised of glass fibers, aramid, polyethylene fibers, carbon fibers, glass filament fabric, carbon fabric, fiberglass fabric, hemp fiber fabric, Dyneema, bamboo fabric, Texalium, Parabeam, fiberglass layers/fabric, woven glass roving fabric or a combination of the above-listed materials.
[0018] In this, in one preferred embodiment, the fabric surface weight in the case of glass fibers is 80 g/m 2 to 480 g/m 2 and in the case of aramid is 60 g/m 2 to 400 g/m 2 . If particularly high levels of stress are anticipated, the fabric surface weight for glass fibers or aramid can be up to 1,000 g/m 2 .
[0019] Preferably, the fabric laminate comprises at least one type of weave from the group of linen, twill 1/3, twill 2/2, unidirectional, glass staple fiber fabric, woven glass roving fabric, carbon layers, biaxial layers, PE fibers, combined fibers or Parabeam. In this, Parabeam is a spacer fabric.
[0020] Known foamed plastics can be used, but preferably foamed plastics made of polyurethane or polystyrene, which are easy and cost-effective to process. Further, PVC, core-cell SAN (styrene-acrylic-nitride), polymer foam SP 110, and phenolic foam may also be used. In this, the foamed plastic preferably has a closed cell structure. However a foamed plastic having an open cell structure may also be used.
[0021] Preferably, unsaturated polyester resin (UP), epoxy resin (EP), vinyl ester resin (VE) or polyurethane resin (PU) is used as the underlay compound. With these materials, together with the above-listed fabric laminates, foamed plastics such as polyurethane or polystyrene can be coated or encased without problems.
[0022] In one particular embodiment, reinforcement material is added to the underlay compound. This material may comprise hollow glass bead, talcum, wood flour, glass fiber chips, cotton flock, aluminum powder, ground carbon fibers, chalk, ground quartz, ground hemp fibers, silicic acids or dyes, or a combination of these. With these reinforcement materials, the adhesion and workability of the underlay compound can be positively influenced, and its mechanical properties can be adjusted to those of the foamed plastic base, thus preventing a separation of the laminate coating or covering from the base.
[0023] The process of the invention for producing a fiber composite, especially for sporting equipment for use in surfing or similar activities, is based upon a process comprising the steps:
1. forming a base from foamed plastic to a desired shape, 2. at least partially coating the base in a lamination process.
Attainment of the object of the invention includes that prior to the second step, at least one portion of the surface of the base to be coated is provided with indentations or elevated areas. In this, the process of the invention is based upon the surprising discovery that an improvement in the connection between the base and a laminate coating can be achieved by providing the surface of the base with indentations or elevated areas before it is coated with laminate, wherein the underlay compound is allowed to penetrate into the spaces between indentations or elevated areas, and is then used in the lamination process.
[0026] In one preferred embodiment it is provided that prior to the second step fabric particles are applied at least in a portion of the indentations. These fabric particles can be sections of fabric laminate that are of the correct size, or sections of the fabric laminate that are applied flat to the base and are pressed (stitched) into the base at selected points. In this manner an increase in the fiber volume in the intermediate layer can be achieved, which leads to an increase in the mechanical stressability.
[0027] In a further embodiment it is provided that the indentations are filled at least partially with an underlay compound before the fabric particles are applied. In this manner a particularly strong fiber composite, especially for sporting equipment for use in surfing, can be obtained.
[0028] Preferably, the indentations are comprised of grooves and/or sinkholes, so that the underlay compound can penetrate along the linear grooves and in the sinkholes arranged over the surface, effecting an improvement of the connection between the base and the laminate coating.
[0029] The indentations can be produced via milling, for example using a CNC machine, boring, stamping, cutting, compressing, or other processes. For example, multiple, for example 1 to 20, grooves extending longitudinally along the base can be created in the base via milling. In this, the dimensions of the applied grooves are such that the fabric laminate can be pressed into the grooves at least in sections, for example using a suitable tool, before the laminate coating is completed via the application of an underlay compound. Prior to the pressing-in process, the grooves can be filled with underlay compound. Alternatively, the grooves may also be filled in later. With the pressing-in of fabric particles, a fiber ratio of up to 80% can be achieved, which serves to increase strength and stability. It is further provided that the grooves and/or sinkholes are produced by pressing in the surface of the base. In this manner, no manufacturing processes involving the removal of material are necessary, which present a health hazard due to the dust they create.
[0030] It is preferably provided that in a first step the grooves are produced, and in a second step sinkholes are created in the surface of the base. In this, the grooves are preferably generated using a milling cutter, while the sinkholes are generated using a needle roller. In this manner the sinkholes, which are designed to be deeper and larger, do not prevent the creation of grooves on the surface of the base using a cutting comb.
[0031] In one preferred embodiment it is provided that, following the application of indentations in the surface of the base, the base is coated with the underlay compound. With this coating process, the underlay compound is allowed to penetrate into the grooves and/or sinkholes that have been created beforehand in the surface of the base, while at the same time improving the attachment to the fabric laminate to be applied.
[0032] Different underlay compounds may be used for coating and for laminating. However it is preferably provided that the same underlay compound is used, so that the connection between the underlay compound applied in the grooves and/or sinkholes and the underlay compound used for lamination is optimized.
[0033] In one preferred embodiment, the lamination is performed by hand, using a vacuum press, the autoclave process, or the injection process.
[0034] In the case of lamination by hand, the fabric laminate is placed over the filled base. Underlay compound is then poured over the fabric laminate and impregnates the fabric laminate lying on the base. The tools used for this are primarily brushes and grooved rollers/flocking rollers. A tear-off fabric is then applied. The tear-off fabric, which is comprised, for example, of nylon fibers, can be shaved off or torn off once the underlay compound has hardened, thus creating a definitively rough, clean, and non-adhesive surface, which can be further processed. The hardening of the laminates takes place without pressure at room temperature. Hot and cold hardening underlay compounds exist, which harden at temperatures of 10 to 230° C. Afterward, further processing can take place.
[0035] In the case of vacuum pressing, the previously hand-laminated base is placed in a foil sack that can be evacuated. Once the air has been drawn out, the foil becomes pressed onto the laminate and pressed onto the form. The maximum pressure is determined by the surrounding atmospheric pressure, and amounts to ca. max. 1 bar. With the vacuum pressing process, the fiber ratio for the laminate can be increased, or excess underlay compound can be forced out. In addition, lightweight core materials such as foamed plastics or netting with high-strength coating layers of resin or fabrics can be glued to one another, thus forming an extremely lightweight and strong component. An even level of contact pressure is required for this. To accomplish this, the laminate is first covered with a tear-off fabric and a non-adhering punched foil. An air-permeable vacuum web is placed over this, the task of which is to distribute the vacuum pressure evenly and suction excess underlay compound out of the laminate. The subsequent hardening can take place at room temperature, however a tempering is also possible.
[0036] In the case of the autoclave process, a tear-off fabric, a punched foil, a vacuum web and a vacuum foil are also used. A vacuum is then created. The hardening of the underlay compound can take place under a pressure of 6 bar and at temperatures of 170° C., or at room temperature.
[0037] A further process is the injection process, in which dry fabric laminate is placed on the base. This is followed by a tear-off fabric, a punched foil, a vacuum web and a vacuum foil. The impregnation of the fabric laminate with the underlay compound takes place first, after a vacuum has been created.
[0038] Another device for use in surfing and similar activities, especially surfboards, skateboards, skimboards, wakeboards, kneeboards and kiteboards, is based upon a device including a base made of foamed plastic, which has at least one laminate coating including a fabric laminate and a underlay compound.
[0039] This device according to the invention is characterized in that it has a surface that comprises roughness elements at least in sections. With this type of structuring of the surface, the water resistance can be substantially reduced, so that much higher speeds can be achieved.
[0040] A further advantage is that, due to the rough surface, it is no longer necessary to coat at least the upper side of a board of this type with wax, which serves to ensure a more secure stance on the board (and increases the skid-resistance of the board). With this, the labor-intensive process of coating the board with wax is eliminated; this process also involves the removal of the wax after use of the board, which is also highly labor-intensive. It is also problematic that the wax softens under solar radiation and adheres to objects that come into contact with it, thus creating dirty areas, for example inside an automobile.
[0041] It is preferably provided that the indentations are designed to be point symmetric, and are arranged non-directionally. The surface structure thereby serves to achieve not only a speed increase in one direction, but also a reduction in water resistance in all directions, in other words even with backward or lateral movements. Thus the structure of the invention is particularly well suited for surfboards, wakeboards or kiteboards.
[0042] In one preferred embodiment, the maximum surface roughness of the indentations is up to 1,000 μm, preferably between 60 and 150 μm. In this, the maximum surface roughness is defined as the vertical distance between the highest and lowest points in a (filtered) roughness profile within a measuring length according to DIN 4762.
[0043] Preferably, the mean roughness value lies between 5 and 100 μm, preferably between 10 and 15 μm. In this, the mean roughness value is defined as the arithmetic mean of the profile deviations of the (filtered) roughness profile of the center line within the measuring length, according to DIN 4786, DIN 4762 and ISO 4287/1.
[0044] The process for producing a fiber composite, especially for sporting equipment for use in surfing or similar activities, is based upon a process comprising the steps
1. shaping a base from foamed plastic, 2. coating at least one surface of the base by means of lamination.
The process of the invention is characterized in that the surface of the laminated base is equipped at least in sections with roughness elements. In this, the roughness elements have a maximum surface roughness of up to 200 μm, preferably between 60 and 150 μm, wherein the mean roughness value lies between 5 and 50 μm, preferably between 10 and 15 μm, as experimental tests have shown that at these values a significant reduction in water resistance is achieved while at the same time adequate skid resistance on the surface is provided, which makes it possible to eliminate the use of a wax coating.
[0047] These roughness elements can be created through a process of pushing or pressing, or in a cutting process. However it is preferably provided that during the lamination, a tear-off fabric is applied to the base, which upon completion of the lamination is again removed. The use of a tear-off fabric in the case of lamination by hand, using a vacuum press in an autoclave process, and in the vacuum injection process is known. In these processes, the tear-off fabric is placed on the laminate before the underlay compound hardens.
[0048] In one preferred embodiment it is provided that the surface that is equipped with roughness elements is coated with a compound. This compound having a suitably low viscosity penetrates into the indentations and collects at the base of the indentations, so that the indentations become partially filled, and in this manner, by filling in the deepest indentations, the roughness profile is homogenized.
[0049] In this it is provided that the low-viscosity compound contains polyester resin, Teflon, epoxy resin, acrylic lacquer or lotus lacquer.
[0050] The tear-off fabric is preferably comprised of nylon fibers and can be shaved or torn off after hardening of the underlay compound. The tear-off fabric can also be comprised of other materials that do not absorb the underlay compound and thus do not form an attachment to the hardened underlay compound. Once the tear-off fabric has been torn off, a rough, clean and non-adhesive surface remains, which can be further processed. In this, it has been surprisingly found that the surface structure that is created following the removal of the tear-off fabric is equipped with non-directional roughness elements, which lead to a significant reduction in water resistance.
[0051] The tear-off fabric preferably has a linen or twill weave type, which possess a regular structure.
[0052] In one particular embodiment the tear-off fabric has a surface weight of between 50 and 120 μm 2 , preferably between 90 and 110 g/m 2 .
[0053] Relative terms such as left, right, up, and down are for convenience only and are not intended to be limiting.
[0054] Below, the invention will be described in greater detail with reference to a drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] FIG. 1 shows a schematic cross-section through a device according to the invention;
[0056] FIG. 2 shows a plan view of a first embodiment of a device according to the invention;
[0057] FIG. 3 shows a plan view of a further embodiment of a device according to the invention;
[0058] FIG. 4 shows a cross-section through a device according to the invention; and
[0059] FIG. 5-8 show surface profiles of a surfboard according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0060] Below, reference is made to FIG. 1 .
[0061] The device includes a base 2 made of polyurethane or polystyrene or some other foamed plastic, the upper side of which is provided with a laminate coating 4 made of a fabric laminate and a underlay compound. Between the base 2 and the laminate coating 4 is an intermediate layer 6 , which is comprised of a surface section of the base 2 that has been equipped with multiple variously shaped indentations, into which underlay compound has penetrated, with which the fabric laminate has also been impregnated.
[0062] On the upper side of the laminate coating, a number of roughness elements 8 are arranged, the purpose of which is to reduce water resistance.
[0063] Below, the process for producing the device will be described.
[0064] The base 2 is formed in the desired shape, for example a surfboard, using cutting machines, planes, saws and sandpaper or using a CNC machine.
[0065] In a further step, grooves are pressed into the surface of the base using a milling cutter. The entire surface of the base 2 is then equipped with sinkholes using a coarse needle roller. This process step involving the needle roller is then repeated using smaller needles. In this process, the needle roller is rolled in different directions, and these process steps are repeated until an even structure is produced on the surface. With the combination of creating sinkholes with the needle roller and creating grooves using a milling cutter, a particularly strong adhesion of the laminate coating 4 on the base 2 can be achieved.
[0066] In areas of high mechanical stress, the surface can be covered with a particularly high number of indentations, in order to achieve an especially resistant connection between the base 2 and the laminate coating 4 in these areas.
[0067] The cleaned base 2 is then coated or puttied with the underlay compound, so that the underlay compound runs into the generated sinkholes and grooves 10 thus ensuring an optimal connection between the base 2 and the laminate covering 4 .
[0068] This coating of the base 2 with the underlay compound serves to ensure that the underlay compound runs into the indentations rather than the fabric laminate absorbing the underlay compound.
[0069] The following resins are suitable for use as the underlay compound: unsaturated polyester resins, epoxy resins, vinyl ester resins and polyurethane resins. These resins can be equipped with reinforcement materials such as hollow glass bead, talcum, wood flour, glass fiber chips, cotton flock, aluminum powder, ground carbon fibers, chalk, ground quartz, ground hemp fibers, silicic acids and dyes.
[0070] At the start of the actual lamination process, a glass filament fabric, aramid fabric, carbon fabric, fiberglass fabric, hemp fiber fabric, Dyneema, bamboo fabric or veneer, or a composite fabric comprised of the above-listed materials is treated with the underlay compound on a separate table.
[0071] The fabric laminate is then placed on the base 2 . The ratio of fabric laminate layer thicknesses from the upper to the underneath side can range from 5:5 to 6:4. In this, the laminate coatings on the upper and underneath sides overlap, so that in the area of the connecting edges there is a double laminate coating, in order to ensure a sufficiently stable connection under stress, even at the connecting edges.
[0072] Any air bubbles that might become trapped following positioning of the fabric laminate can be forced out using a putty knife.
[0073] In a further process step a tear-off fabric is applied, which is not absorbent and thus does not absorb the underlay compound. The tear-off fabric made of nylon having linen or twill weave type has a surface weight of 50 to 120 g/m 2 . The tearing off of the tear-off fabric roughens the surface of the base 2 , so that a subsequent surface coating will adhere better.
[0074] Any air bubbles that might become trapped during positioning of the tear-off fabric can also be forced out using a putty knife.
[0075] Next a vacuum punched foil is applied, which is used to press laminates.
[0076] This is followed by an absorbent web, which is placed over the punched foil and serves to absorb the excess underlay compound that is forced out during the vacuum process. Everything is then placed in a vacuum bag and sealed air-tight, so that a pressure of ca. 0.75 bar can act, for example, for eight hours on the laminate. Upon completion of this process, the laminated base 2 is separated from the absorbent web and the punched foil. Then the tear-off fabric is removed. Once the tear-off fabric has been removed, a number of roughness elements 8 remain on the surface, which are designed to be point symmetric and are arranged non-directionally.
[0077] The coating is then laminated to the second side of the board-shaped base, in the same art and manner.
[0078] To complete production of a surfboard, fin and leash plugs must then be attached.
[0079] With this the process for producing a surfboard is completed and the surfboard is finished. The repeated application of an underlay compound and the labor-intensive subsequent sanding are no longer necessary, and as a result of the absence of the last coating the surfboard is ca. 15 to 20% lighter.
[0080] With this manufacturing method the production of a negative mold is not necessary; instead, individual forms can be provided with a laminate covering. Thus the method is suitable not only for the production of fiber composites for sporting equipment, such as surfboards, but can also be used advantageously in other fields, such as the production of prostheses, in aeronautics, and in the vehicles industry.
[0081] In addition to the described vacuum process, an injection process may also be used, in which the fabric laminate is positioned dry on the base 2 that has been coated with underlay compound. The underlay compound is then suctioned into the fabric laminate via the vacuum, wherein the underlay compound is equipped with transport channels that will ensure an optimized distribution of the underlay compound. With this, the orientation of the fibers of the fabric laminate is maintained due to the low flow rate of the underlay compound, which results in good mechanical properties that can be reproduced.
[0082] The following refers by way of example to FIGS. 2 through 4 . The surfboard-shaped bases 2 are equipped with three grooves 10 that extend in a longitudinal direction, and have been filled prior to lamination with an underlay compound, for example a resin or a resinous compound. However, other underlay compounds may also be used. On the grooves 10 filled with underlay compound, fabric laminate strips 12 having a width of 15 to 20 cm (see FIG. 2 ) are laid. However, fabric laminate strips 12 having a greater width (up to 35 cm) may be applied to the base 2 (see FIG. 3 ), or a fabric laminate layer 14 may be applied over the entire surface. Prior to a subsequent laminate coating, the fabric laminate strips 12 or the fabric laminate layer 14 are pressed into the grooves 10 , wherein the sections of the pressed-in fabric laminate strips 12 or the fabric laminate layer 14 become impregnated with the underlay compound, with which the grooves 10 are filled.
[0083] As an alternative to this, the fabric laminate strips 12 or the fabric laminate layer 14 can be pressed into the grooves 10 first, followed by a step in which the underlay compound is applied to the base 2 that has been prepared in this manner, and permeates into the grooves 10 with the fabric laminate strips 12 or fabric laminate layer 14 that have been pressed-in in sections. In addition, the fabric laminate strips 12 or the fabric laminate layer 14 can be pressed in using a tool.
[0084] With the pressing-in of fabric laminate strips 12 or of a fabric laminate layer 14 in sections, the fiber ratio can be increased to up to 80%, which results in a further increase in strength and stability.
[0085] Below, reference is made to FIGS. 5 through 8 .
[0086] FIGS. 5 through 8 show surface profiles of surfboards as specified in the invention. The maximum roughness depth is shown as a vertical distance between the highest and lowest point on the filtered roughness profile within the sampling length. In this, the surface profile shown in FIG. 5 has a maximum roughness depth of 118.5 μm, while the surface profile shown in FIG. 6 has a maximum roughness depth of 96.64 μm, the surface profile shown in FIG. 7 has a maximum roughness depth of 71.20 μm, and the surface profile shown in FIG. 8 has a maximum roughness depth of 140.8 μm.
[0087] The mean roughness value, which is defined as the arithmetic mean of the profile deviation of the (filtered) roughness profile of the center line within the measuring length according to DIN 4786, DIN 4762 and ISO 4287/1, amounts in the surface profile shown in FIG. 5 to 12.62 μm, in the surface profile shown in FIG. 6 to 12.09 μm, in the surface profile shown in FIG. 7 to 11.6 μm and in the surface profile shown in FIG. 8 to 12.88 μm. With these surface profiles a definite improvement in surfing properties could be achieved.
[0088] While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, and uses and/or adaptations of the invention and following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention or limits of the claims appended hereto.
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Device, especially a piece of sporting equipment for use in surfing or similar activities, includes a base made of foamed plastic, which has at least one laminate coating made of a fabric laminate and an underlay compound. The device includes an intermediate layer between the base and the laminate coating. Likewise provided are a number of processes for producing fiber composites in connection with foamed plastics.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of U.S. patent application Ser. No. 13/312,547, filed 6 Dec. 2011 (issued as U.S. Pat. No. 8,875,894 on Nov. 4, 2014), which claims benefit of U.S. Provisional Patent Application Ser. No. 61/420,155, filed 6 Dec. 2010, which is hereby incorporated herein by reference, priority of each of which is hereby claimed.
Priority of U.S. Provisional Patent Application Ser. No. 61/420,155, filed 6 Dec. 2010, incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cargo racks for transferring goods between marine vessels and offshore platforms such as oil and gas well drilling and production platforms. More particularly, the present invention relates to an improved cargo rack that enables a user to load the rack with multiple load modules (e.g. fluid containing vessels or tanks), palletized loads, bulk bags (or other loads) and to then transport the entire rack using a lifting device such as a crane or a forklift from one locale (e.g. marine vessel) to another locale (e.g. marine platform). Additionally, the entire rack can be moved on land or on the platform with a crane or forklift. When supporting fluid holding vessels or tanks, a specially configured manifold can be used to empty a particular or selected tank or vessel. Lifting fittings are placed at the top of intermediate columns and inner reinforcement members (e.g. inner braces or walls) transfer load from one intermediate column to another intermediate column.
2. General Background
In the exploration of oil and gas in a marine environment, fixed, semi submersible, jack up, and other offshore marine platforms are used during drilling operations. Fixed platforms are typically used for production of oil and gas from wells after they have been drilled. Drilling and production require that an enormous amount of supplies be transported from land based storage facilities. Supplies are typically transferred to offshore platforms using very large marine vessels called work boats. These work boats can be in excess of one hundred feet (30.48 meters) in length and have expansive deck areas for carrying cargo that is destined for an offshore platform. Supplies are typically transferred from a land based dock area to the marine vessel using a lifting device such as a crane or a mobile lifting and transport device such as a forklift.
Once a work boat arrives at a selected offshore platform, supplies or products are typically transferred from the deck of the work boat to the platform using a lifting device such as a crane.
Once on the deck of a drilling platform or production platform, space is at a premium. The storage of supplies on an offshore oil well drilling or production platform is a huge problem.
Many cargo transport and lifting devices have been patented. The table below lists some patents that relate generally to pallets, palletized racks, and other cargo racks.
TABLE 1
ISSUE DATE
PAT. NO.
TITLE
(MM/DD/YYYY)
2,579,655
Collapsible Container
Dec. 25, 1951
2,683,010
Pallet and Spacer
Jul. 06, 1954
3,776,435
Pallet
Dec. 04, 1973
3,916,803
Loading Platform
Nov. 04, 1975
4,165,806
Palletizing System for Produce Cartons
Aug. 28, 1979
and the Like
4,403,556
Drum Retainer
Sep. 13, 1983
4,828,311
Metal Form Pallet
May 09, 1989
5,078,415
Mobile Carrier for Gas Cylinders
Jan. 07, 1992
5,156,233
Safety Anchor for Use with Slotted Beams
Oct. 20, 1992
5,292,012
Tank Handling and Protection Structure
Mar. 08, 1994
5,507,237
Lifting Apparatus for Use with Bulk Bags
Apr. 16, 1996
5,906,165
Stackable Tray for Plants
May 25, 1999
6,058,852
Equipment Skid
May 09, 2000
6,357,365
Intermediate Bulk Container Lifting Rack
May 19, 2002
6,371,299
Crate Assembly and Improved Method
Apr. 16, 2002
6,422,405
Adjustable Dunnage Rack
Jul. 23, 2002
6,668,735
Pallet with a Plastic Platform
Dec. 30, 2003
6,725,783
Pallet for Stacking Planographic Printing
Apr. 27, 2004
Plates Thereon
BRIEF SUMMARY OF THE INVENTION
The present invention provides a cargo rack having a frame with front, rear, and upper and lower end portions;
The lower end portion of the frame provides a base with a floor providing multiple load holding positions, each configured to hold a separate load module.
A plurality of load modules are supported with the frame during use.
The frame includes a plurality of side walls that attach to and extend upwardly from the perimeter beam base and including at least left and right side walls, the frame having four corners with a corner column at each corner.
At least one intermediate column is positioned in between two corner columns.
A plurality of gates are movably mounted to the frame, including a pair of gates at the front and a pair of gates at the rear of the frame, each gate being movably mounted to the frame between open and closed positions, each gate spanning in a horizontal direction from a corner column to an intermediate column.
A plurality of lifting eyes are attached to the upper end port of the frame, each lifting eye attached to the frame next to an intermediate column.
Inner walls or braces separate the base into the load holding positions, the inner walls spanning between intermediate columns to define a transverse support that is generally aligned with a pair of lifting eyes.
In one embodiment, there are four load holding positions.
In one embodiment, there are a pair of gates at the front of the frame.
In one embodiment, there are a pair of gates at the rear of the frame.
In one embodiment, at least a part of the floor is inclined.
In one embodiment, the floor attaches to an upper end portion of the perimeter beam.
In one embodiment, there is a drain opening in the floor.
In one embodiment, the floor attaches to an upper end portion of the perimeter beam.
In one embodiment, clamps are movably attached to the upper end of the frame between clamping and release positions for restraining vertical movement of a load that is placed on the floor.
In one embodiment, raised portions or pedestals extend above the raised floor for providing a level surface to engage a load placed on a load holding position of the frame.
In one embodiment, the cargo rack provides a frame having a perimeter, a front, a rear, and upper and lower end portions.
The frame includes a plurality of side walls extending upwardly from the frame perimeter and including at least left and right side walls, four corners that each provide a corner column and an intermediate column at the front and rear of the frame in between the corner columns.
A plurality of gates are movably mounted to the frame, including a pair of gates at the front of the frame and a pair of gates at the rear of the frame, each gate being movable between open and closed positions, each gate extending between a corner column and an intermediate column.
The frame has a raised floor that provides a plurality of load holding positions.
Another embodiment provides a cargo rack having a frame with a floor, a front, a rear and upper and lower end portions.
A plurality of load modules are supported within the frame and upon the floor during use.
The frame includes a plurality of side walls extending upwardly from the perimeter beam and including at least left and right side walls, the frame having four corners and a corner column at each corner.
A plurality of gates are movably mounted on the frame, including a pair of gates at the front of the frame and a pair of gates at the rear of the frame, each gate being movable between open and closed positions, the gates enabling the load modules to be loaded laterally to the floor by accessing either the front or the rear of the frame.
The frame has positioning beams that segment the floor into a plurality of load holding positions, each having positioning beams that laterally hold one of the load modules in position once a load module is placed on the floor and in a load holding position.
The gates expose a majority of the width of the floor for loading a tank to a selected load holding position on the floor, either at the front or at the rear of the frame when the gates are opened.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIG. 1 is an elevation view of a preferred embodiment of the apparatus of the present invention;
FIG. 2 is a top, plan view of a preferred embodiment of the apparatus of the present invention taken along lines 2 - 2 of FIG. 1 ;
FIG. 3 is an end view of a preferred embodiment of the apparatus of the present invention taken along lines 3 - 3 of FIG. 2 ;
FIG. 4 is an end view of a preferred embodiment of the apparatus of the present invention, taken along lines 4 - 4 of FIG. 2 ;
FIG. 5 is a sectional view taken along lines 5 - 5 of FIG. 1 ;
FIG. 6 is a sectional view of a preferred embodiment of the apparatus of the present invention, taken along lines 6 - 6 of FIG. 1 ;
FIG. 7 is a sectional view of a preferred embodiment of the apparatus of the present invention, taken along lines 7 - 7 of FIG. 2 ;
FIG. 8 is a fragmentary view of a preferred embodiment of the apparatus of the present invention;
FIG. 9 is an end view of a preferred embodiment of the apparatus of the present invention;
FIG. 10 is a fragmentary view of a preferred embodiment of the apparatus of the present invention;
FIG. 11 is a perspective view of a preferred embodiment of the apparatus of the present invention;
FIG. 12 is a fragmentary perspective view of a preferred embodiment of the apparatus of the present invention;
FIG. 13 is a fragmentary perspective view;
FIG. 14 is a sectional view showing an alternate manifold arrangement;
FIG. 15 is a sectional view taken along lines 15 - 15 of FIG. 14 ;
FIG. 16 is an elevation view illustrating a stacking of two cargo racks;
FIG. 17 is a fragmentary elevation view of a preferred embodiment of the apparatus of the present invention; and
FIGS. 18-23 are fragmentary views illustrating details of the gates and gate closures.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-23 show a preferred embodiment of the apparatus of the present invention designated generally by the numeral 10 . The preferred embodiment 10 provides a transportable cargo rack that is configured to hold multiple cargo modules or tanks 105 .
Cargo rack 10 provides a frame 11 having an upper end portion 12 and a lower end portion 13 . The lower end portion 13 includes a base 14 . Base 14 can provide a bottom 15 configured to rest upon an underlying support surface such as a floor 16 .
Base 14 floor 16 is divided into a number of floor segments or quadrants 17 , 18 , 19 , 20 . Each floor segment or quadrant 17 - 20 can contain a load module or tank 105 . This arrangement can be seen in FIG. 11 wherein four floor segments or quadrants 17 - 20 are provided, each being occupied by a tank or load module 105 .
Frame 11 has sidewalls or gates or doors. In a preferred embodiment, there are four doors 21 , 22 , 23 , 24 . The doors 21 - 24 are arranged in pairs. As shown in FIG. 2 , there are a pair of doors 21 , 22 at one end portion of frame 11 . There are another pair of doors 23 , 24 at the opposing end portion of the frame 11 , positioned generally opposite doors 21 , 22 as shown in FIG. 2 .
Each door 21 - 24 is movably (e.g. hingedly) attached to frame 11 . Hinges 25 , 26 , 27 , 28 are provided. The door 21 attaches to frame 11 at hinges 25 . The door 22 attaches to frame 11 at hinges 26 . Similarly, door 23 attaches to frame 11 at hinges 27 . Door 24 attaches to frame 11 at hinges 28 .
Each of the hinges 25 - 28 is attached to a corner column. There are four corner columns 29 , 30 , 31 , 32 . Frame 11 also provides a plurality of intermediate columns. There is an intermediate column in between each pair of corner columns 29 - 32 . Upper interior horizontal supports 37 - 40 form a connection between each intermediate column 33 - 36 and a central column 41 . Diagonal supports 42 - 45 are also provided, each diagonal support 42 - 45 extending between the central column 41 and an intermediate 33 - 36 (see FIGS. 7 and 9 ). Lower horizontal supports 46 , 47 , 48 , 49 are provide, each extending between the central column 41 and an intermediate column 33 - 36 . Each lower horizontal support 46 - 49 can be positioned below the diagonal supports 42 - 45 as shown in FIGS. 7 and 9 . Thus, interior walls are provided that extend between each intermediate column 33 - 36 and the central column 41 . Each wall or divider can be comprised of an upper interior horizontal support 37 - 40 , a diagonal support 42 - 45 , a lower interior horizontal support 46 - 49 and a plate section 50 - 53 .
Plate sections 50 , 51 , 52 , 53 extend between floor 16 and a lower horizontal support 46 , 47 , 48 or 49 . Each plate section 50 - 53 can have openings 120 for enabling easy cleanup or wash down. In FIG. 7 , the plate section 50 extends between floor 16 and lower horizontal support 46 . Plate section 52 extends between floor 16 and lower horizontal support 48 . Each of the plate sections 50 - 53 can be provided with openings or slots 120 that enable fluid to travel from one floor segment or quadrant 17 , 18 , 19 , 20 to another floor segment or quadrant 17 , 18 , 19 , 20 such as might occur during washing of the apparatus 10 .
Four lifting assemblies 54 , 55 , 56 , 57 are provided. Each lifting assembly (see FIGS. 12, 13 ) is attached to an upper end portion of an intermediate column 33 , 34 , 35 , 36 . Peripheral horizontal members 58 span between each intermediate column 34 , 36 and a corner column 29 , 30 , 31 , 32 . Upper central fitting 59 can be in the form of a block that is receptive of and forms a connection (for example, welded) with central column 41 and each of the upper interior horizontal supports 37 , 38 , 39 , 40 as shown in FIGS. 2 and 7 .
In FIGS. 12 and 13 , each lifting assembly 54 , 55 , 56 , 57 provides a lifting block or body 60 . While one of the lifting assemblies 54 as shown in FIGS. 12 and 13 , it should be understood that each of the lifting assemblies 55 , 56 , 57 can be of the same configuration as shown in FIGS. 12 and 13 for the lifting assembly 54 . Lifting block or body 60 has side surfaces 61 , 62 , front surface 63 , and rear surface 64 . The lifting block or body 60 has an upper end portion 65 and a lower end portion 66 . Upper end portion 65 provides a recess or slot 67 that enables attachment of a lifting sling 80 to the block or body 60 using pin 69 as shown. Openings 68 are provided in block or body 60 extending between each side surface 61 , 62 and the recess or slot 67 . Pin 69 spans between the openings 68 when the apparatus is to be lifted using slings or lift lines 80 . Pin 69 has annular grooves 70 that each interlock with a plate 71 or 72 . Each plate 71 , 72 has an opening 73 or 74 . Similarly sized and shaped openings are provided on body or block 60 so that a bolted connection can be formed using bolt 75 and a nut 79 as shown in FIGS. 12 and 13 .
The annular grooves 70 of pin 69 register in slots 77 end plates 71 , 72 as shown in FIG. 12 . Each of the slots 77 communicates with a circular opening 76 that is slightly larger than the diameter of the pin 69 . In this fashion, the pin 69 can pass through the openings 76 of the plates 71 , 72 . The pin 69 is too large to occupy the recess or slot 77 . However, each annular groove 70 at an end portion of the pin 69 is sized and shaped to enable the pin 69 to interlock with the plates 71 , 72 . The annual grooves 70 enable this fit of pin 69 to the plate 71 or 72 at the slot 77 as shown in FIG. 13 .
A cover plate 78 can be placed over the block or body 60 , the plate 78 being receptive of the bottom 15 of another rack 10 when they are stacked upon one another as shown in FIG. 16 . A lifting line or sling 80 has an eyelet 81 which can be rigged to the pin 69 as shown in FIG. 13 . When a crane or other implement lifts upwardly on the slings 80 , each sling 80 eyelet 81 transfers load to the pin 69 and thus to the lifting assembly 54 , 55 , 56 , 57 and thus to the frame 11 . FIG. 11 illustrates a lifting implement or hook or crown block 82 that is commonly employed in combination with a lifting device such as a crane. Other lifting fitting such as a ring or shackle 83 can be employed as an interface between the slings 80 and the lifting implement 82 .
FIG. 6 illustrates a manifold or header 84 that can be used to transfer fluid from any one of the load modules or tanks 105 and a discharge or outlet fitting or coupling 91 . Header or manifold 84 is contained within base 11 interior 85 . The base 11 has a bottom panel 86 . A pair of beams or channels 87 , 88 extend through base 11 , each providing an opening or bore 89 , 90 that is receptive of a forklift tine. In this fashion, the frame 11 can be lifted using a forklift by engaging the forklift tines in the bores 89 , 90 of the beams or channels 87 , 88 .
Valve 92 having valve handle 93 can be placed immediately upstream of discharge of outlet fitting or coupling 91 . Header 84 communicates with valve 92 . A plurality of four flow lines 94 , 95 , 96 , 97 empty their contents into header 84 as shown in FIG. 6 . Each of the flow lines 94 , 95 , 96 , 97 attaches to a different one of the tanks or modules 105 . A detail of the fluid connection between a tank or module 105 and header 85 can be seen in FIG. 10 . FIG. 10 illustrates the connection of a single flow line 94 to a tank 105 . It should be understood that each of the flow lines 94 , 95 , 96 , 97 can be similarly connected to a tank or module.
Flow line 94 connects to swivel 98 . The swivel 98 connects to a riser 99 at elbow fitting 100 . Another elbow fitting 101 connects to hose section 102 . Hose section 102 is provided with a quick connect fitting 103 that forms a quick connect with a flow line 106 that exits the tank or module 105 . This connected position can be seen in FIG. 11 . In FIG. 11 , a tank discharge flow line 106 is shown which can be provided with a tank discharge valve 107 . Tank discharge flow line 106 can be provided with a quick connect that forms a connection with the quick connect fitting 103 of FIG. 10 . The swivel 98 enables movement of the quick connect fitting 103 as shown by arrows 104 in FIG. 10 .
Each corner column 29 - 32 can be provided with a stacking fitting 110 which enables one cargo rack 10 to be stacked upon another cargo tank 10 as seen in FIG. 16 . Each stacking fitting 110 can be connected to (e.g. welded) to a gusset or stiffener plate 111 . Each stacking fitting 110 provides a horizontal and preferably rectangular plate 112 and two vertical plates 113 , 114 which intersect at right angles and which extend upwardly from the periphery of plate 112 .
Module receptacles 115 are provided for supporting each corner of a tank or module 105 . Each receptacle 115 has a lower plate 116 and side, vertical plates 117 , 118 as seen in FIGS. 1-5, 11, and 16 . Each tank or module 105 has four feet 119 , each foot 119 registering upon a module receptacle 115 as seen in FIG. 11 .
A drain is provided for draining fluids from floor 16 such as might occur during a wash down or if there is leakage from one of the modules 105 . Drain channel 121 is mounted just under floor 16 as seen in FIGS. 7-8 . Drain channel 121 has flow bore 122 . A plurality of floor openings 123 are provided, such as one of the openings 123 under each opening 120 as shown in FIG. 8 . Drain channel inlet openings 124 are ports or openings in the channel 121 and are aligned with the floor openings 123 . Arrows 125 in FIG. 8 illustrate the flow path of fluid that drains from floor 116 to channel 121 bore 122 . Fluid received in channel 121 flows via gravity to drain pipe 126 . Pipe 126 is closed at one end portion with cap 127 . The other end portion of pipe 126 is fitted with valve 129 . In FIG. 8 , arrow 128 illustrates flow direction of fluid in pipe 126 .
FIGS. 17-23 illustrate the doors 21 - 24 and the mechanism for opening or closing a door. While doors 21 - 22 are shown in FIGS. 17-23 , the same configuration could be used for doors 23 - 24 . Each door 21 , 22 has a pair of vertical members. The door 21 has vertical members 130 , 131 . The door 22 has vertical members 132 , 133 . Horizontal members span between the vertical members of each door 21 , 22 as shown. The door 21 has horizontal members 134 that span between vertical members 130 , 131 . Similarly, horizontal members 135 span between the vertical members 132 , 133 of the door 22 . The innermost vertical members 131 , 133 are an assembly that includes vertical flanged members 140 , 141 , rods 138 , 139 , sleeves 142 , 143 and other plates and guides that will be described more fully hereinafter.
Each door 21 , 22 can be opened or closed using levers 153 , 154 which are attached to the rods 138 , 139 . Each rod 138 , 139 is mounted in a sleeve and in rod guides. The rod 138 is able to move up and down while being supported by sleeve 142 , upper rod guide 144 , lower rod guide 146 while being moved up or down with a lever 153 . In FIG. 17 there are two rods 138 associated with the door 21 . It should be understood, that the door 21 as constructed can be used when inverted such as if for replacing one of the other doors.
Similarly, the door 22 has two rods 139 , each rod having an attached lever 154 . The rod 139 is supported by upper rod guides 145 , lower rod guides 147 and sleeve 143 . Each of the rod guides 144 , 145 , 146 , 147 provides a rod opening 148 through which a rod 138 or 139 can pass. An upper plate 136 and a lower plate 149 are provided for locking a gate 21 , 22 in a closed position when a rod 138 , 139 is moved upwardly using a lever 153 or 154 . In FIG. 17 , all of the rods 138 , 139 are in an open position. FIGS. 23 and 23 illustrate a movement of lever 153 from the open position of FIG. 17 to the closed position. In FIG. 23 , the lever 153 is shown being moved to the closed position as indicated by arrows 161 , 162 .
Each of the upper and lower rod guides 144 , 147 can be in the form of a horizontal flange 150 or 151 .
The upper plate 136 has plate openings 137 . Similarly, the lower plate 149 has lower plate openings 152 .
Each lever 153 , 154 has a lever opening for enabling the lever 153 , 154 to be attached to a Tee shaped fitting 157 . The lever 153 has lever opening 155 . The lever 154 has lever opening 156 . Each of the Tee fittings 157 is mounted to a vertical plate. For the door 21 , the plate 158 carries two such Tee fittings 157 as shown in FIGS. 17-23 . Similarly, for the door 22 , the plate 159 carries two of the Tee fittings 157 . For each door 21 , 22 there are a pair of the plates 158 or 159 as shown in FIG. 17 .
In order to lock the gate 21 or 22 , the levers 153 or 154 move toward the upper plate 136 for the upper rods or toward the lower plate 149 for the lower rods. When the levers 153 or 154 are moved to the locking Tee fitting 163 as shown in FIGS. 23 and 23 , the rods automatically interlock with the openings 137 of the upper plate or the openings 152 of the lower plate. The rods also pass through the rod openings 148 of the upper and lower rod guides 144 - 147 .
The following is a list of suitable parts and materials for the various elements of a preferred embodiment of the present invention.
PARTS LIST
PART NO.
DESCRIPTION
10
cargo rack
11
frame
12
upper end portion
13
lower end portion
14
base
15
bottom
16
floor
17
floor segment/quadrant
18
floor segment/quadrant
19
floor segment/quadrant
20
floor segment/quadrant
21
gate/door
22
gate/door
23
gate/door
24
gate/door
25
hinge
26
hinge
27
hinge
28
hinge
29
corner column
30
corner column
31
corner column
32
corner column
33
intermediate column
34
intermediate column
35
intermediate column
36
intermediate column
37
upper interior horizontal support
38
upper interior horizontal support
39
upper interior horizontal support
40
upper interior horizontal support
41
central column
42
diagonal support
43
diagonal support
44
diagonal support
45
diagonal support
46
lower interior horizontal support
47
lower interior horizontal support
48
lower interior horizontal support
49
lower interior horizontal support
50
plate section
51
plate section
52
plate section
53
plate section
54
lifting assembly
55
lifting assembly
56
lifting assembly
57
lifting assembly
58
peripheral horizontal member
59
upper central fitting
60
lifting flock/body
61
side surface
62
side surface
63
front surface
64
rear surface
65
upper end portion
66
lower end portion
67
recess/slot
68
opening
69
pin
70
annular groove
71
plate
72
plate
73
opening
74
opening
75
bolt
76
opening
77
slot
78
cover plate
79
nut
80
sling/lift line
81
eyelet
82
lifting implement/hook/crown block
83
ring/shackle/lifting fitting
84
header/manifold
85
base interior
86
bottom panel
87
beam
88
beam
89
opening/bore
90
opening/bore
91
discharge/outlet fitting/coupling
92
valve
93
valve handle
94
flow line
95
flow line
96
flow line
97
flow line
98
swivel
99
riser
100
elbow fitting
101
elbow fitting
102
hose section
103
quick connect fitting
104
arrow
105
tank/module
106
tank discharge flow line
107
tank discharge valve
108
arrow
109
Tee fitting - lock
110
stacking fitting
111
gusset/stiffener plate
112
horizontal plate
113
vertical plate
114
vertical plate
115
module receptacle
116
lower plate
117
vertical plate
118
vertical plate
119
tank/module foot
120
opening/slot
121
drain channel
122
flow bore
123
floor opening
124
drain channel inlet opening
125
arrow
126
drain flow pipe
127
cap
128
arrow
129
outlet valve
130
vertical member
131
vertical member
132
vertical member
133
vertical member
134
horizontal member
135
horizontal member
136
upper plate
137
upper plate opening
138
rod
139
rod
140
vertical flanged member
141
vertical flanged member
142
sleeve
143
sleeve
144
upper rod guide
145
upper rod guide
146
lower rod guide
147
lower rod guide
148
rod opening
149
lower plate
150
horizontal flange
151
horizontal flange
152
lower plate opening
153
lever
154
lever
155
lever opening
156
lever opening
157
Tee fitting - unlock
158
vertical plate
159
vertical plate
160
arrow
161
arrow
162
arrow
163
Tee fitting - lock
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A cargo rack for transferring loads between a marine vessel and an offshore marine platform (for example, oil and gas well drilling or production platform) provides a frame having a front, a rear, and upper and lower end portions. The lower end of the frame has a perimeter beam base, a raised floor and a pair of open-ended parallel fork tine tubes or sockets that communicate with the perimeter beam at the front and rear of the frame, preferably being structurally connected (e.g., welded) thereto. Openings in the perimeter beam base align with the forklift tine tubes or sockets. The frame includes a plurality of fixed side walls extending upwardly from the perimeter beam that include at least left and right side walls. A plurality of gates are movably mounted on the frame including a gate at least at the front and at least at the rear of the frame, each gate being movable between open and closed positions, the gates enabling a forklift to place loads on the floor by accessing either the front of the frame or the rear of the frame. Each gate can be pivotally attached to a fixed side wall. The frame has vertically extending positioning beams or lugs that segment the raised floor into a plurality of load-holding positions. Each load holding position has a plurality of positioning beams or lugs that laterally hold a load module (e.g., palletized load) in position once a load is placed on the raised floor.
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FIELD OF THE INVENTION
[0001] The invention relates to structural panel of a synthetic type, particularly those which may be used to replace or supplement standard plasterboard, plywood, or other similar primary construction components. Reference is made to Disclosure Document No. 382,221, filed by the Inventor on Sep. 18, 1995, as well as to Provisional Patent Application No. 60/059,224, filed by the Inventor on Sep. 18, 1997.
[0002] Further reference is made to U.S. patent application Ser. No. 09/156,257 filed by the present inventor as a provisional application on Sep. 18, 1997, and made formal on Sep. 18, 1998. Such application was made subject to a restriction requirement and Applicant elected one of three species. Such application, as restricted, has been allowed and the issue fee has been paid but such application has not yet been issued and is still pending. The present application incorporates the amendments to the specification and the drawings for the purpose of correction and clarity and does nor add new matter to the original application. The present application includes only the apparatus species of claims from the original application, The inventor claims priority from the earlier filing described above.
BACKGROUND OF THE INVENTION
[0003] The interior portions of building construction are initially concerned with providing walls between building compartments and, in some cases, walls which may be required to withstand certain extraordinary pressures and conditions. For many years plywood and plasterboard were the primary materials involved in the production of panels which were standardized and used to provide these internal walls or barriers. Typically, such would come in sizes of 4×8 and would be disposed vertically. Additionally, interior building construction concerns flooring and ceilings.
[0004] Of particular interest in these structural panels are their qualities of strength; resistance to the passage of sound through the panel (its acoustic properties); resistance to fire and smoke; weight; resistance to being damaged by exposure to water or moisture; the ability to provide a flat surface; and the ability to be manipulated or positioned and fastened by nails, screws, or other building fasteners. Additionally, such structural panel should offer resistance to and protection from the elements of weather, insects, and provide good thermal insulation properties.
[0005] The Inventor previously obtained U.S. Pat. No. 4,868,039 in which vermiculite was used in a structural panel to provide strong and reliable wallboard with good acoustic, fire-retardant, and strength properties. Earlier efforts in providing synthetic wallboard were U.S. Pat. No. 1,439,954, issued to Emerson; U.S. Pat. No. 3,284,980, issued to Dinkel; U.S. Pat. No. 4,488,909, issued to Galer; and U.S. Pat. No. 4,102,700, issued to Kiveech, et al. There is also some discussion of this topic in the text of Concrete Technology, Neville and Broke, Lemgmen Group, Ltd.; UK, 1987.
[0006] Since such structural panels are intended to be standardized and since a. great number of structural panels are necessary to build even a simple structure (such as a residential dwelling), a primary consideration in the development of any such wallboard will be the ease and cost of its manufacture. Accordingly, inherent in the considerations of devising and creating such a wallboard would be a full consideration of the means and method of its manufacture.
[0007] One significant cost is that of transportation. Structural panel is used in mass quantities for many applications and the cost of shipping is great. There is also waste inherent in breakage and over stacking or over ordering. Raw materials are cheaper and easier to transport. it would be helpful to have the ability to manufacture the structural panel at the work site. In this way breakage during shipping and over ordering would be avoided. Additionally, it would be easier to customize the structural panel composition in order to fit unique circumstances and situations.
[0008] In the Inventor's earlier invention, U.S. Pat. No. 4,868,039, a means for manufacturing the original vermiculite board was disclosed. Such used a fibrous scrim as its surface and used Portland Cement and other traditional building cement ingredients mixed in with a vermiculite which were homogenously mixed between the two layers of scrim. This provided a unique wallboard which had good weight, strength, fire-retardant- and moisture-resistant properties. One quality of such wallboard which was not always desirable was its surface tension. The original material, while very desirable in many respects, was brittle and required some improved capabilities to resist bending and to withstand lateral forces placed upon it. This made it difficult to adapt for use as a floor material.
[0009] Accordingly, what is needed but not otherwise provided in the prior art of synthetic structural panel is a reliable, strong, synthetic structural panel with good construction properties which also has a high level of surface cohesion and tension and may be manufactured efficiently and quickly. It would also be helpful to have a means and apparatus for accomplishing such quick and efficient manufacture.
[0010] What is not provided in the prior art is a synthetic structural panel which has superior qualities to resistance to lateral forces. Also not provided in the prior art is an efficient method and apparatus for manufacturing such a board. Also not provided in the prior art is such a manufacturing method and apparatus which can be moved to a construction site.
SUMMARY OF THE INVENTION
[0011] The Inventor has overcome the shortcomings of the prior art by improving his basic vermiculite wallboard method and apparatus with a new structure which incorporates the use of certain adhesives aid fibers in order to improve surface tension and cohesion and boost the structural panels ability to withstand lateral pressures. The Inventor has also developed a method and apparatus of manufacturing such a board which is efficient and reliable. Both the structure of the board and its method of construction are the subject of this disclosure.
[0012] The apparatus and structural panel can be described as follows. Traditional building cement materials are housed in vats and are primarily mixed as desired to achieve certain weight and strength goals. As these materials are primarily mixed together they are then passed to an area where they encounter further mixing teeth both the synthetic ingredients and the binding liquid, such as water. These ingredients are thoroughly mixed and may be passed along by means of a mixing conveyor assembly. In the mixing conveyor assembly further mixing occurs as these ingredients are passed along and begin to experience some preliminary hardening.
[0013] At this stage, these ingredients may then be passed into a final mixing area wherein fibers may be added to the mixture and in which the surfaces of the mixture may be sprayed and cured with surface hardening materials such as acrylics and epoxies.
[0014] The fibers within the mixture serve to give the structural panel more lateral strength and the addition of the exterior adhesives and/or epoxies assist in providing a stronger surface cohesion and tension. The board may then be exposed to outer levels of foil. The foil may be used to provide thermal transfer properties, resistance to water or fire.
[0015] Following the provision of these finishing touches in a final mixing area, the wallboard may be then placed in storage trays for final hardening and curing. Normally a period of time of twelve to twenty-four hours is required for full curing. During this time, the material could be exposed to heat to speed or otherwise enhance the process.
[0016] Additionally, the Inventor has developed apparatus and methods for transporting the manufacturing apparatus so that structural panel may be built at the site. This would permit the use of as many acceptable local materials as possible and permit custom mixing of the structural panel blend.
[0017] It is, then, an object of the present invention to provide an improved structural panel with improved lateral and surface strength qualities.
[0018] It is a further object of the present invention to provide a means and apparatus for manufacturing wallboard with improved lateral and surface strength qualities.
[0019] It is a further object of the present invention to provide such a wallboard which may be further augmented with a smoother surface or foil surface for improved esoteric or strength, water or fire resistance, or other qualities.
[0020] It is a further object of the present invention to provide, a means and apparatus for providing such a improved structural panel with a foil or other smooth surface for desired thermal, fire or water resistant other properties.
[0021] It is a further object of the present invention to describe means and methods of manufacturing such boards which further depict the specific apparatus assembly.
[0022] It is a further object of the present invention to describe a means and method of providing such a structural panel with attention given to the steps involved in the process, including mixing, assembly, and curing.
[0023] It is a further object of the present invention to describe means and apparatus for onsite manufacture of such fibrous structural panel.
[0024] Other features and advantages of the present invention will be apparent from the following description in which the preferred embodiments have been set forth in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] In describing the preferred embodiments of the invention reference will be made to the series of figures and drawings briefly described below.
[0026] [0026]FIG. 1 depicts the overall apparatus comprising the storage chambers for the various components, the primary mixing areas, the mixing conveyor and tray conveyor, and the collection point.
[0027] [0027]FIG. 2 depicts the overall apparatus as viewed from above.
[0028] [0028]FIG. 3 depicts the storage chambers for the primary ingredients.
[0029] [0029]FIG. 4 depicts the portion of the apparatus in which the mixing of the ingredients initially occurs.
[0030] [0030]FIG. 5 depicts the conveyor apparatus at which the primary mixed ingredients are sent for hardening and may be further augmented with fiber and sent to a drying rack.
[0031] [0031]FIG. 6 depicts the mixing area.
[0032] [0032]FIG. 7 depicts the conveyor and, in particular, a mold compartment.
[0033] [0033]FIG. 8 depicts the mixing portion from above.
[0034] [0034]FIG. 9 depicts the conveyor assembly from above, further depicting where various ingredients may be added.
[0035] [0035]FIG. 10 depicts an alternative embodiment in which storage vats for the various ingredients may be mounted on a trailer.
[0036] [0036]FIG. 11 depicts one a top view of trailer-mounted storage vats.
[0037] [0037]FIG. 12 depicts a trailer-mounted mixing portion.
[0038] [0038]FIGS. 13, 14, and 15 depict alternative embodiments of wallboard according to the present invention.
[0039] [0039]FIGS. 16 and 17 depict a schematic diagram of the various stages of the process or making wallboard according to the present invention.
[0040] While certain drawings have been provided in order to teach the principles and operation of the present invention, it should be understood that, In the detailed description which follows reverence may be made to components or apparatus which are not included in the drawings. Such components and apparatus should be considered as part of the description, even if not included in such a drawing. Likewise, the drawings may include an element, structure, or mechanism which is not described in the textual description of the invention which follows. The invention and description should also be understood to include such a mechanism, component, or element which is depicted in the, drawing but not specifically described.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] Reference will now be made in detail to the present preferred embodiment of the invention. an example of which is illustrated in the accompanying drawings. While the invention will be described in connection with a preferred embodiment, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention defined in the appended claims. Each part will be explained by its function and number relating to the figures which have submitted herewith.
[0042] It is helpful to first examine the overall apparatus used to manufacture the improved synthetic structural panel according to the present invention. It is also helpful to discuss the manufacture of the board in phases.
[0043] In the first phase of the operation certain well-known building cement ingredients are blended together. These include clay particles, volcanic aggregate, and Portland cement. Of course, there may be others, but these are three of the more common ones. These ingredients may initially be stored in a clay particle vat ( 51 ), a volcanic aggregate vat ( 52 ), and a portland cement vat ( 53 ). Additionally, each of these storage vats ( 51 , 52 , and 53 ) are mounted so that they are in a mounting frame ( 41 ), and adapted with respective means ( 34 , 35 , and 36 ), and valve control means ( 47 , 48 , and 49 ). Each of the valves ( 34 , 35 , and 36 ) feed respective conduits ( 39 , 38 , 37 ) which will ultimately deliver the ingredients to a mixing chamber ( 51 ). It should be noted that the Portland cement line ( 37 ) feeds into a separate chamber ( 52 ) so that its rate of flow into the overall chamber may be more closely controlled and adjusted. Accordingly, in the first phase of the operation the, typical dry ingredients are carefully blended into a homogeneous mixture.
[0044] From this point the process is now ready to enter the second stage in which certain synthetic ingredients are blended in to the mixture with water. Additionally, lime can be applied at this point from a lime vat and spreader ( 64 ).
[0045] In a typical apparatus may be used to contain sources of high-intensity plasticisers ( 61 ), vermiculite ( 62 ), and fiber ( 63 ), respectively. Additionally, lime could be stored in a separate vat ( 64 ). The high-intensity plasticizer vat ( 61 ), the vermiculite vat ( 62 ), and the fiber vat ( 63 ) are each adapted with respective control valves ( 65 , 66 , and 67 , respectively). These are each deposited through respective conduits ( 71 , 72 and 73 , respectively) into a mixing conveyor ( 74 ). In this mixing conveyor ( 74 ) all of the ingredients ( 61 , 62 , and 63 ), including the original dry ingredients and the new synthetic ingredients may be mixed with a rolling action and further blended with a source of water ( 75 ).
[0046] The water may, but ,need not be, applied through an injection ring ( 76 ). The injection ring ( 76 ) would be connected to a water source (not depicted) by means of a pressure valve ( 77 ). The interior portion of the injection ring ( 76 ) would be adapted with a series of ports ( 78 ). Water, under pressure, could be injected into a flow of the solid elements before it is deposited into the screw mixing conveyor ( 74 ) which will be described in more detail later in this application.
[0047] At this point, all of the primary ingredients have been added. By the time they are prepared to leave the exit port ( 81 ) of the mixing conveyor ( 74 ) they should be homogeneously blended with the appropriate amount of water. They are now fed into a feeding assembly ( 82 ) through an intake port ( 83 ) so that they may be then deposited into a cement hopper ( 84 ). The cement hopper ( 84 ) spreads the blend out so that it may be placed upon a conveyor belt ( 91 ) which is turned by a pair of rollers ( 92 and 93 ). The conveyor belt ( 91 ) is, however, first fed with an aluminum backing foil ( 208 ) which is supplied by a roller ( 102 ) on a mounting assembly ( 103 ) which is adapted to spread it along the width ( 694 ) of the conveyor belt ( 91 )
[0048] It should be described that this conveyor belt ( 91 ) may be adapted with sections ( 95 ) within which a mold ( 94 ) in the dimensions of structural panel (typically 4′×8′) is made. As will be described in more detail later, such mold ( 96 ) receives the foil ( 208 ) which will form one surface of the structural panel. The foil ( 208 ) is pressed into the mold ( 96 ) by means of an upper roller ( 97 ). The foil ( 208 ), after being pressed into the mold ( 96 ), is sprayed with a rapid hardening adhesive ( 97 ) from a sprayer ( 98 ). In this manner the foil ( 208 ) gains rigidity to help form the structural panel. Calcium chloride ( 622 ) may be used to accelerate the adhesion and rigidity of the foil.
[0049] Now the blend may, but need not, be augmented with additional fibers which are fed into two separate fiber vats ( 111 and 112 , respectively) which may each in turn be controlled by their own valves ( 113 , 114 , respectively) and fed upon the structural panel blend by their own respective conduits ( 105 , 106 ) and hoppers ( 117 , 118 ). In addition, apparatus may be supplied for applying a final finishing coat of adhesive to the blend. Such finishing coat means is depicted at ( 121 ). Such finishing coat means could include separate chambers for a variety of adhesives such as epoxy ( 122 ), acrylic ( 123 ), and could further be adapted with a spraying or atomizing chamber ( 124 ) and fed through a conduit ( 125 ) so that it could be sprayed through spray jets ( 128 ). Now, all ingredients of the board have been supplied and the board is fully blended.
[0050] The blended structural panel ( 104 ), now within a hardened tray and just beginning to cure, is subject (through the conveyor belt ( 91 )) to vibrator ( 104 ). The vibrator ( 104 ) enhances the settling of the blend and promotes a more effective disposition of the fibers ( 202 ). This enhances the bonding of the ingredients as well by settling them in closer together and promoting the passage of fluid from one constituent ingredient to another.
[0051] At this point, it should be mentioned that vermiculite has superior properties to perlite in this regard. This is because vermiculite is better able to absorb and release fluid during the curing process and consequently, makes better bonds with the other ingredients.
[0052] Having been blended, the board ( 104 ) may now be applied to a separate conveyor assembly ( 131 ) which comprises two additional conveyor rollers ( 132 , 133 ) and a conveyor belt ( 134 ).
[0053] A tray ( 141 ) housing a blended mixture ( 104 ) can then be passed along this conveyor ( 134 ) and inserted into a drying, rack assembly ( 142 ). The drying rack assembly ( 142 ) could be comprised of a series of rack-drying compartments ( 143 ), which may be vertically moved up and down to receive a given structural panel tray by means of a vertical rack ( 151 ).
[0054] Accordingly, the overall structure of the device has been described. Now, more detail can be used to discuss various functions of each part and the options available with their use.
[0055] Making reference to FIGS. 13 through 15, the various forms of the utilization of fibers in the boards can be seen.
[0056] For instance, in FIG. 13 is depicted a structural panel which is cut out at various levels. It can be seen that at an upper level ( 201 ), a layer of fibers ( 202 ) are diagonally disposed in various dimensions. Then, in the next level ( 203 ), the structural panel blend ( 204 ) is applied. The structural panel blend ( 204 ) comprising the primary synthetic ingredients ( 205 ) are applied. Then in the next level ( 206 ) another layer of fibers can be applied which are again diagonally disposed to include both directions. Then, in the lower level ( 207 ), the foil cover ( 208 ) is seen.
[0057] This blend would require first an application of epoxy over a lower level of foil ( 208 ), then the fibers ( 202 ), then the structural panel blend ( 204 ) including vermiculite ( 205 ), for instance then another layer of the fibers ( 202 ) which would then prepared for another level of adhesive to be sprayed onto the panel (not depicted in FIG. 13).
[0058] [0058]FIG. 14 depicts another embodiment in which fibers would first be positioned at a lower level ( 210 ) in a vertical disposition. Then, in another level ( 211 ), the structural panel blend ( 204 ) including the vermiculite ( 205 ) could be blended with additional fibers which are randomly disposed ( 202 ). Then in the next layer up, the fibers ( 202 ) can be disposed in a horizontal manner and then in the final layer ( 213 ) the foil ( 208 ) may be applied. This would again require an epoxy ( 121 ).
[0059] [0059]FIG. 15 shows yet another possible disposition of the material. In FIG. 15 is shown a homogeneous blend of fibers ( 202 ), structural panel blend ( 204 ), and vermiculite ( 205 ) which is sandwiched between a level of foil ( 208 ) and some other surface, such as a slurry formed by the vibration of said structural blend, and which is further augmented with fibers ( 202 ) along the lateral surfaces of the board.
[0060] It should be noted that while the basic components of the wallboard will be standard building cement materials (such as clay grog and portland cement) augmented with known synthetics (such as vermiculite and perlite), the feature of the present invention which achieves the desired result is the addition of synthetic fibers into the mixture. The synthetic fibers provide the desired tensile strength. It should be noted that there are two principal ways of achieving the addition of the fibers which, while both keep within the spirit and scope of the present invention, are somewhat different. In one method of combining the ingredients the fibers maybe laid out between successive layers of the aggregate and other synthetic materials within a single panel. In another method of combining the ingredients the fibers may be simply mixed in a homogenous manner along with the other synthetic and standard cement ingredients. Either of these two basic forms of mixing the ingredients may be used with any one of the various methods of surfacing the product which will be developed later in this description.
[0061] Generally speaking, the overall process comprises the following steps. First, certain materials are dry-blended together. These materials primarily comprise traditional cement materials, such as clay grog, clay dust, and portland cement. This is normally accomplished in a series of bins and hoppers which may run along conveyor belts. Lime may also be mixed into the blend.
[0062] Once the dry ingredients are blended, they may be further combined with vermiculite or perlite in a wet screw mixing conveyor. The wet screw mixing conveyor will ensure a thorough blending of all of these ingredients. The wet mix will include water, but may also include high-intensity plasticizers, such as latex, acrylic, or epoxy-acrylic parts in a ten-to-one mixture.
[0063] All of these mixed ingredients may then be placed in a single hopper over a mono-flow pump. A mono-flow pump which would be suitable for this application might be the MOYNO (R) pump. Such a pump must be capable of pumping solid or abrasive materials which are suspended in liquids. It should also be considered that such suspended solids may also comprise a high percentage of the fluid or semi-fluid material to be pumped. Now that the blend is thoroughly mixed (including the water or high-intensity plasticizer), they are then placed in a hopper over the mono-flow pump where they may be transferred to a conveyor or belt hopper and further pressed into pre-molded foil fibrous trays.
[0064] It is at this point that the fibers may be added to the structural panel. One means of adding the fibers to the structural panel will include the provision of the blended material in layers. A layer may be perhaps a quarter inch, but the layers could be thicker or thinner as desired. These fibers could also be entered into the wet mix at the very beginning of the process and could be anywhere from ¼ to 8 feet in length The epoxy acrylic could be sprayed onto the fibers as they are being moved onto the conveyor belt. Clay grog or any fixed clay particles or volcanic aggregate (or a combination in any desired blend) may also be used with the board along with the fibers.
[0065] Additionally, layers of fibers could be put into the pre-made tray after each quarter inch of wet mix slurry so as to increase the overall strength by creating a thin webbed layer of overlapping fibers and then spraying a coat of epoxy acrylic Part A and B in order to bond to the wet cementitious slurry.
[0066] The overall effect of this will be a series of plied layers. This increases the overall strength of the material and also affords better resistance to nail through-put.
[0067] As described, maximum strength is reached after seven days of composition curing. When fully cured, the panel may be applied to standard construction applications in the same fashion as plywood. The only difference would be that the cutting of this material should be accomplished with a diamond-studded blade and standard electrical saws. Accordingly, while this material may be somewhat more difficult for the garage carpenter to use than plywood, its utility in commercial and construction applications is very high and its durability and resistance to wear very high, as well.
[0068] During wet mixing, the vermiculite, perlite, or desired vermiculite/perlite combination may be mixed in to the blend, which is now transported through the mixing conveyor ( 74 ) (such as the MOYNO (R)) to the structural panel molds. The blend may be dispensed from a flanged nozzle ( 82 ) into a cement hopper ( 84 ) and then evenly spread along the mold ( 94 ). These molds ( 94 ) may then be passed by a conveyor ( 91 ) and then passed along under a fiber feeder ( 18 ) and a sprayer ( 128 ) for the epoxy acrylic. (Please see FIG. 5.)
[0069] As mentioned before, the fibers ( 202 ) could be applied either as part of the blend through the pump ( 81 ), or in layers. It can be seen that the layers could be applied through the cement hopper ( 84 ) in any desired thickness. Then the molds ( 94 ) could be passed under the fiber rotary feeder ( 118 ) and epoxy acrylic sprayer ( 128 ) as many times as desired before curing. If the fibers ( 202 ) are to be part of the blend, however, then the layering stages are omitted and the epoxy acrylic will be applied to the fibers as the fibers are fed into the wet mix.
[0070] The operation of the foil ( 208 ) and the mold ( 94 ) should be discussed. Making reference to FIG. 7, it can be seen that each mold ( 94 ) is within a section of conveyor belt ( 91 ), and is adapted with front and rear sides ( 97 , 98 , respectively) and lateral sides ( 95 , 96 ). As foil ( 208 ) is fed from the foil roll onto the conveyor ( 91 ), a roller ( 104 ) presses the foil ( 208 ) down into the mold ( 94 ). The sides ( 107 , 108 ) of the roller fit down into the mold ( 94 ) in close proximity to the mold sides ( 95 , 96 ). In this manner the foil ( 208 ) is pressed into position to receive the structural panel blend ( 104 ). Calcium chloride, or some other suitable material, may then be applied to the mold ( 94 ) in order to promote initial rigidity of the structural panel blend ( 104 ) and to promote bonding between the structural panel blend ( 104 ) and the foil ( 208 ).
[0071] While the invention has been described with respect to a specific method, apparatus, and composition, it is important to note that the ultimate panel could be made with varying proportions of the described materials or with a variety of obvious substitutions or substitute materials which may later be discovered. Each of these should be considered as keeping within the spirit and scope of the present invention. Additionally, the specific apparatus could be modified so as to use different styles of bins, valves, flanges, feeders, mixers, and spreaders than those depicted, or with a different order, as long as the basic tenets of the formula and method of blending the materials is preserved. Such variations should also be considered as keeping within the spirit and scope of the present invention.
[0072] The foil tray (usually aluminum, but any other foil substance could be used) is coated with the epoxy acrylic mixture with the fibers already dispensed in the foil mold.
[0073] Such foil typically comes off of a roll with is 49 to 49-½ inches wide and can be pressed flat to produce a square tray that can become part of the board itself.
[0074] As described, maximum strength is reached after seven days of composition curing. When fully cured, the panel may be applied to standard construction applications in the same fashion as plywood. The only difference would be that the cutting of this material should be accomplished with a diamond-studded blade and standard electrical saws. Accordingly, while this material may be somewhat more difficult for the garage carpenter to use than plywood, its utility in commercial and construction applications is very high and its durability and resistance to wear very high, as well.
[0075] Additionally, the synthetic fibers may be made from a variety of fiber materials. Many of these are plastic synthetic materials, but there may be other acceptable forms of fibers which could be used. The importance of the fibers is that they give the structural panel lateral strength and integrity which was lacking in prior blends of the material.
[0076] There are a variety of epoxies which can be stored in separate chambers and, when sprayed together and allowed to blend together, will form a very tight bond. Such an adhesive could be sprayed on either or both sides of the surface of the structural panel.
[0077] The known fillers include such things as vermiculite particles and perlite particles. The synthetic fillers may be made of a variety of sizes or sized randomly, as long as they can fit within the width of a structural panel.
[0078] Additionally, this surfacing could take place either before or after curing of the remaining ingredients of the structural panel or at a desired point in time during the curing process.
[0079] It should also be noted that the curing process itself blends itself to several alternatives. For instance, the curing process could be allowed to occur in ambient air in a natural manner or it could be enhanced by the application of heat.
[0080] It is envisioned that a rack could be used to hold a variety of structural panels, but this need not be the case.
[0081] It should further be noted that in addition to substituting or changing certain of the ingredients the relative amounts of the various ingredients can be modified in order to achieve certain desired results. For instance, if strength is not a critical an issue as having a very lightweight material, more of the synthetic filler could be used so as to make the structural panel lighter, but the use of more of the synthetic fillers would naturally cause the structural panel to be less strong than one which was made more with traditional building cement materials.
[0082] It is in this way that the fibers offer an advantage over the previous editions which did not have fibers.
[0083] From examination of FIG. 1, it can be seen that the manufacturing process of structural panel according to the present invention basically occurs in three phases. The first phase involves the dispensation and mixture of cement materials from large cement vats. In the second phase, the filler material (either vermiculite or perlite) is mixed in with the cement mixture and water and the material is shaped into a panel by use of a foil mold. A conveyor belt is used to facilitate this process, During this phase, storage vats are immediately present for the vermiculite, perlite, and certain fibers and adhesives, and the first of two conveyors is present. Additionally, an outlet for the water and a vibrating mechanism for the purpose of refining and homogenizing the structural panel is provided.
[0084] In the third and final phase, additional fiber vats are present and another conveyor is used to transport the structural panel (which has, in the second phase, been molded and shaped into a panel and adapted with surfaces) into drying racks. Additionally, additional adhesives could be added at this time and some work could be done on the surfacing of the structural panel.
[0085] What is unique about considering this manufacture in these three phases is that, when viewed as a whole, the manufacturing process could not be transported. If, however, the equipment necessary to accomplish each of these three phases is separated, as they can be, the equipment of any one of these three phases of operation could be placed on a trailer suitable for being towed by a truck and delivered over a highway.
[0086] In this manner, a portable structural panel manufacturing operation could be established near a large work site and a contractor or a construction team would have the capability of assembling exactly the type and specification of structural panel desired, be sure of its quality and integrity, and save substantial transportation costs and losses due to waste.
[0087] To further show the feasibility of this, FIGS. 10, 11, and 12 show the portions of the apparatus as they could be separated. FIG. 10 depicts the storage vats for the solid ingredients cement vats in isolation. FIG. 11 depicts them as arranged from above. FIG. 12 depicts the manufacturing stages, as mounted on a truck.
[0088] Each of these corresponding mechanical components works exactly the same as its counterpart in FIGS. 1 through 10. The portable apparatus could be mounted on a surface such as the bed of a large trailer ( 400 ).
[0089] What is significant about the differences between the components as depicted in the trailer mount manufacturing assembly of FIG. 12 is that inlet ports ( 437 , 438 , 439 , 464 , 471 , 472 , 473 , 505 , and 506 ) depict the receiving inlet ports to receive the respective solid components transmitted from the storage vats (FIGS. 10 and 11) through transporting conduit (not depicted in either figure). In all other respects, however, but for the fact that the apparatus is indeed loaded on a trailer ( 500 ), the apparatus works the same. For instance, inlet ports ( 437 , 438 , and 439 ) receive the primary traditional cement ingredients. Inlet ports ( 464 , 471 , 472 , and 473 ) receive the filler and fibers. A water ejector ( 475 ) works the same as its permanently installed counterpart. In each other case, it is a simple matter to consider the last two digits of each feature as labeled on FIG. 12 to be the same as its counterpart with the same last two digits in FIGS. 1 through 10.
[0090] Finally, FIG. 16 is useful to demonstrate a flow diagram of the present apparatus. This flow diagram would be accurate for either the permanently installed or portable manufacturing apparatus as the structural panel is manufactured in the same way in each case.
[0091] Accordingly, it can be seen that a portable plant would not be difficult to establish and operate. Each phase of the apparatus could easily be stored and towed on one trailer and then positioned in any reasonable arrangement so as to provide the necessary material communication with the next phase of operation.
[0092] It needs to be discussed at this point that the materials which may be used to manufacture these structural panels may substantially vary, not only in the specific identities of the materials themselves, but in the relative proportions. For instance, it is well accepted that there are three grades of Portland type cement, grades 1, 2 and 3, and that these grades may vary in the amount or exclude “HIGH EARLY (R)” grades. The variances here would enable selection of cement which hardens faster or has stronger binding. characteristics. In addition, a variety of clay slurries could be used. This is particularly important when the portable manufacturing apparatus as described above is considered. It is the ability to use a variety of cements and clays (and other ingredients, for that matter) which makes the portable aspects of this invention attractive. It now becomes possible to ship a portable structural panel factory in three parts to a work site and use readily available raw materials to manufacture structural panel on site. This could result in the significant advantages of flexibility in materials, reduced shipping costs, and reduction of waste.
[0093] The use of fibers is introduced in this patent to provide the surface integrity and lateral strength which was previously lacking in synthetic or manufactured structural panel. These fibers may also be selected from any one of a variety of fiber problems. For instance, the fibers could be general bi-component fibers, TREVIRA(R) fibers, polyester fibers, fiberglass fibers, CELBOND(R) fibers, or polypropylene fibers. Surely, there are a variety of other fibers which would be satisfactory for use in this manner, and there may in the very near future be new materials developed which would serve these purposes. Additionally, the fibers may be of variable width, as long as they will pass readily through the equipment used to manufacture the panel, and their length may vary anywhere from a quarter of an inch to the entire eight-foot length of a given piece of structural panel. All such alternative fibers should be seen as keeping within the spirit and scope of the present invention.
[0094] Likewise, the present invention teaches the use of certain adhesives, both to assist in the formation of a surface and to bind the foil to at least one side of the panel. These adhesives could also be selected from a variety of materials, such as high-intensity plasticisers, latexes, acrylics and acrylic polymer emulsions, epoxy acrylics, and surfactants, (mixed with or without calcium chloride). Each of these could be used with or without chemical compositions, such as Ligno Sylfonates, or Gluconolactone. All such alternative adhesives should be seen as keeping within the spirit and scope of the present invention.
[0095] Further modification and variation can be made to the disclosed embodiments without departing from the subject and spirit of the invention as defined in the following claims. Such modifications and variations, as included within the scope of these claims, are meant to be considered part of the invention as described.
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The present invention comprises apparatus for the manufacture improved structural panel with synthetic ingredients, such as vermiculite and fibers. The improved structural panel achieves enhanced lateral and surface integrity by the use of fibers within the core of the structural panel and adhesives and smooth materials (such as foil) as a surface coating. The apparatus is particularly suited for manufacture of the structural panel at low cost and high efficiency.
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BACKGROUND OF INVENTION
A. Related Applications
There are no applications related hereto now filed in this or any foreign country.
B. Field of Invention
My invention relates generally to aerodynamically stable kites and more particularly a statically indeterminate kite structure stabilized by plural rotatable tail elements.
C. DESCRIPTION OF PRIOR ART
Kite art may be divided for convenient analysis into a first class of kites requiring no tail and a second class which utilizes a tail either as a primary stabilization device or secondarily to stabilize in conjunction with kite shape. This second class is distinguished into sub-groups: the first including those kites having flat aerodynamic surfaces such as box kites; the second including kites having airfoils of curvilinear cross-section which are pre-formed to shape -- generally as a single airfoil such as the common stressed "T" stick paper kite; and the third sub-group, and that in which this invention falls, including kites which provide a free form or statically indeterminate aerodynamic configuration.
The distinction between members of the different classes is obvious. Within its sub-class my kite provides a shape somewhat similar to prior art kites but somewhat longer and narrower as allowed by the inter-action of the tail members which provides stability not found in the prior art.
My kite differs from the prior art of its class primarily in tail design and in construction features of the kite itself. Rigid supporting framework normally used in kite construction provides taping or other similar joinder techniques at points of intersection of framework elements and for joinder of surface material to framework. My kite construction does not join supporting framework elements together per se and so eliminates these typically complex and weak intersections. I interweave the supporting framework into the surface material itself through appropriately spaced cuts therein to eliminate surface framework joinder problems. To accomplish this weaving the face material between alternate pairs of slits is positioned on the first side of a spar and the interweaving material on the opposite side of the spar as it is inserted into the slit group. I provide a nose-piece formed by folding a flat pattern into a rigid box-like structure having slotted openings to releasably receive the various framework elements positionally to support these elements while they at the same time support and maintain the nose-piece structure.
Kite tails of the prior art normally have provided an elongate, flexible depending element such as knotted cloth which stabilizes the kite it serves only by its mass. Some few prior art tails have provided a rotational element generally as an aesthetic or novelty feature, still however, stabilizing only because of their appropriately positioned mass and bulk. My tail, in counter-distinction, on the other hand, provides plural spaced rotatable propeller-like elements journaled on a flexible line depending from the kite to provide not only traditional mass stabilization but also additional aerodynamic drag which normally increases during period of kite instability caused by turbulance. My invention provides a flexible planar surface member of diamond shape having a plurality of lineally aligned spaced parallel cuts along the vertical center axis and inwardly adjacent each of the top edges. The rigid elongate support elements are joined to the top edges. The rigid elongate support elements are joined to the surface member by weaving through the relieved portion formed by the cuts. A rigid nose-piece is fabricated from flat material to provide a triangular box-like structure with slots to releasably receive and positionally maintain the support elements at their proximate ends so that the support elements are maintained as cantilevered beams positioned to maintain the kite surface nearly flat, but still allowing the face to deflect somewhat between adjacent sticks.
My tail provides a flexible elongate cord depending from the bottom of the center stick somewhat more than the height of the kite. Plural propeller elements are rotatably carried by this cord at spaced intervals along its length for rotation normal thereto.
In providing such a device, it is:
A principal object of my invention to create a kite having great inherent aerodynamic stability caused by the combination of a flexible statically indeterminate kite surface with a particular tail configuration.
A further object of my invention to provide such a kite with an elongate tail providing plural spaced rotatable propeller-like elements to provide a stabilizing force greater than its mass alone would provide and one that increases with turbulance.
A further object of my invention to provide such a kite that is easily assembled by releasable joinder of elements, from components that can be stored in a minimal area.
A still further object of my invention is to provide such a kite that is of new and novel design, of rugged and durable nature, of simple and economic manufacture and one otherwise well adapted to the uses and purposes for which it is intended.
Other and further objects of my invention will appear from the following specification and accompanying drawings which form a part hereof. In carrying out the object of my invention, however, it is to be understood that its essential features are susceptible to change in design and structural arrangement with only one preferred and practical embodiment being set forth in the accompanying drawings as required.
BRIEF DESCRIPTION OF DRAWINGS
In the accompanying drawings which form a part hereof and wherein like numbers of reference refer to similar parts throughout:
FIG. 1 is an orthographic plan view of the kite body of my invention showing its elements, their configuration and relationship.
FIG. 2 is an isometric view of the tail of my kite.
FIG. 3 is an orthographic plan view of the flat pattern of the nose-piece of my kite.
FIG. 4 is an isometric view of the nose-piece of FIG. 3 folded into its erected configuration.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in more detail it will be seen that my invention comprises generally a kite body having surface member 10 carried by support elements 11 which are positionally maintained in the nose-piece 12 and carry depending tail member 13.
Surface member 10 provides a planar, generally quadrilateral element 14 fabricated from a light weight flexible material having sufficient tear resistance to withstand unstable aerodynamic buffeting. Thin kraft-type paper or one of the poly-vinyl sheet plastic materials will serve well as surface material. In the embodiment illustrated the surface geometry is lozenge-like similar to standard kites commonly known in commerce.
The peripheral edge portion 14a of the surface member may be folded inwardly and fastened to provide a more finished edge of greater strength, especially where the upper edges are slit. Plural spaced parallel slits 15 in surface 14 are formed linearly along the longitudinal axis between upper apex 16 and lower apex 17 and inwardly adjacent the upper sides 18 of the surface element between upper apex 17 and lateral extremities 19. Slits of the center slit group 20 are aligned perpendicular to the kite's longitudinal axis and the slits of the side slit group 21 are aligned perpendicular the sides they are adjacent to. The size and location of these slits must be such to allow support spars to be woven therethrough but otherwise depends on the particular face geometry; strength of materials and support size. Those shown in the drawing are suggestive and not meant to be exclusive. The upper and lower apex of the kite surface are preferably truncated to facilitate joinder of the other elements as shown in FIG. 1.
Support elements 11 comprise elongate linear spars 22 of a size appropriate to be woven through slits 15. These members may be formed of any rigid material of sufficient strength to withstand dynamic pressure incurred in kite flight; wood or modern plastics serve my purposes well. In the embodiment shown, center spar 22ais of a length slightly longer than the longitudinal dimension of the kite and is joined thereto by weaving into the center slit. To accomplish this weaving the face material between alternate pairs of slits is positioned on the first side of a spar and the interweaving material on the opposite side of the spar as it in inserted into the slit group. The resultant joinder of spar and surface is maintained by friction engagement between the members and yet is easy to assemble or disassemble and requires no secondary fastening as by tying or stapling. Side spars 22b are slightly longer than upper edges 18 of the surface 14 and are installed and maintained in side slits 21 in a manner similar to that employed for the center spar. The particular support elements described in the specific embodiment are not meant to be limiting and other types or arrangements of support elements could be substituted therefore without altering the essence of this invention. For instance the spars well could be curvilinear and still allow a bellowing type of support for the kite surface or the kite surface could be differently shaped within limits of the construction described.
Nose-piece 12 is a triangular box-like structure which supports the spars 22 in a radiating fashion as illustrated to provide the kite with its ultimate air foil shape and complete the upper portion of that shape. The nose-piece is constructed from the flat pattern element 26 shown in FIG. 3, which in this instance is fabricated from medium weight laminated cardboard. Paired opposed spar orifices 27 are formed in the center portion and elongate slots 28 are formed inwardly adjacent the edge of each lateral portion 31, 34 as illustrated in FIG. 3. Orifices 29, of a configuration to frictionally receive spar elements 22 are positioned on the end flaps as shown. To form the erected nosepiece as shown in FIG. 4, flap 31 is folded downwardly (with reference to the positioning shown in the drawings) 90° on a line A-B and end 32 is folded downward 90° on line A-C to bring corner 30 directly beneath corner 33. Similarly flap 34 is folded downward 90° on line A-D and end 35 is folded downwardly 90° on line A-E to bring corner 36 directly beneath corner 37 on flap 31 and corner 38 on front 39. Bottom 40 is then folded downward 90° and tab 41 is inserted into now aligned slots 28 to secure the nose-piece in its folded position. Lip 42 is then folded upward along line F-G to a position adjacent bottom 40 to complete the nose-piece erection.
Tail member 13 provides elongate flexible line 43, in this instance constructed from round rope approximately the length of the longer kite dimension. Plural propeller-like elements 44, comprising substantially planar opposed symmetrical end portions 45 joined by narrower center portion 46 with hole 47 therein, are rotatably carried by plural spaced bearings 48 fixedly attached to line 43 to allow propeller rotation but provide longitudinal restraint. The bearings 48 are of the known simple bushing type with end restraints to maintain a propellor in rotatable position thereon. The propeller blades may be turned at an angle to the center part to give them an agle of attack to further aid their rotation. The uppermost portion of line 43 is attached to the lower end of spar 22a by known means such as tying to allow the remainder to depend therefrom.
Having thusly described my invention, its operation may now be understood.
Firstly a kite and tail assembly are formed according to the foregoing specification. It is to be noted that the particular shape of the kite is not essential though the configuration of the other elements do relate somewhat to the kite shape chosen.
To assemble the kite center spar 22a is inserted into holes 29 and side spars 22b are inserted into slits 27 of nose-piece 12 with a sufficient portion of the sticks extending into the nose to provide rigid support. Holes 29 and slits 27 are sized such that the spars must be inserted with some force so that they will thereafter be frictionally maintained. The nose-piece is constructed so that the spars extend therefrom in co-planar fashion with the side spars at similar acute angles to the center spar. This angle will be such that when the spars are inserted into the surface of the kite, the surface will not be taut but sufficiently loose to deflect somewhat between adjacent spars. In flight this deflected portion acts as an air foil to catch the wind and aid lift to a greater degree than with a planar face.
Each tail propeller 44 provides an increment of drag which tends to increase during periods of turbulence to give greater stability at such times. A substantial number of propellers may be provided on the tail line which is somewhat longer than normal to give an appropriate drag for stability to a kite of similar size. These rotational tail elements also provide a unique aesthetic appearance unavailable with known tails.
Flight is attained by joinder of the center spar, in its upper part, to an appropriate length of string and launching the kite into the wind as is normally done with present day kites of commerce. In flight the complex surface portion of my kite catches the wind to form air foils that provide more lift than a simple planar surface. The propeller elements provide drag to maintain the kite's angle of attack and provide additional sidewise stability against yawing that normally occur in flying prior art kites.
The foregoing description of my invention is necessarily of a detailed nature so that a specific embodiment of it might be set forth as required but it is to be understood that various modifications of detail, arrangement and multiplication of parts may be resorted to without departing from its spirit, essence or scope.
Having thus described my invention, what I desire to protect by Letters Patent, and
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A highly aerodynamically stable kite having a flexible statically indeterminate face which during flight forms a curvilinear airfoil that is maintained in the center and top edges by rigid linear stiffeners removably retained in a novel nosepiece. The nosepiece is a rigid three dimensional structure formed by folding a thin flat pattern. A novel tail member aids kite stability by providing plural aerodynamically rotatable elements spacedly depending beneath the kite upon a common flexible line.
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BACKGROUND OF THE INVENTION
Dispersion paints based on polyvinyl acetate, polyvinyl propionate, styrene-butadiene or acrylate-styrene or even solvent-containing paints based on acrylate copolymers are used for painting the surfaces of mineral building materials, particularly when they are used for facades.
The disadvantage of dispersion coatings is that they become soiled relatively quickly and, in many cases, also chalk rapidly, thus resulting in degradation of the paint film.
Paints based on the above-mentioned dispersions and the solvent-containing copolymers have the disadvantage of being poorly resistant to chemicals, particularly solvents. This is an obstacle inter alia in the removal of dirt from walls using aggressive cleaning agents and organic solvents. For these reasons, polyurethane systems have for several years been used to a limited extent for painting facades. The main advantages of polyurethane systems are their high weather resistance, their good surface smoothness, their minimal tendency towards soiling, their high resistance to chemicals and the fact that they are easy to clean.
Light-stable, aliphatic polyurethane paints, however, have the disadvantage of being relatively highly resistant to the diffusion of water vapor (μ-factor according to DIN 52 615), with the result that they cannot be used for every type of wall construction (Klopfer: Wassertransport durch Diffusion in Feststoffen, pages 115-122, Bauverlag GmbH, Wiesbaden and Berlin (1975)).
Accordingly, the object of the present invention is to provide polyurethane formulations which show a considerable improvement over conventional polyurethane paints in their permeability to water vapor, so that the paint systems may also be used for coating substrates and wall constructions of the type required to show extremely low resistance to diffusion without the known advantageous properties of polyurethane-based coating compositions or of the coatings produced from them being adversely affected as a result.
Surprisingly, this object may be achieved by using the additives described in more detail hereinafter in dissolved form.
SUMMARY OF THE INVENTION
The present invention relates to the use of hydroxyl alkyl amines optionally containing ether groups and having a molecular weight in the range of from about 61 to 2,000 or their salts with inorganic or organic acids as additives which reduce resistance to the diffusion of water vapor in one- or two-component polyurethane-based coating compositions.
Preferred additives according to the present invention include:
1. hydroxyl alkyl amines having a molecular weight in the range of from about 61 to 300 and corresponding to the following general formula: ##STR1## wherein R 1 represents hydrogen, a C 1 -C 4 alkyl radical or a C 2 -C 4 hydroxy alkyl radical, in which case at least 2 carbon atoms are situated between the hydroxyl group and the nitrogen atom,
R 2 represents hydrogen or a C 2 -C 4 hydroxy alkyl group, in which case at least 2 carbon atoms are situated between the hydroxyl group and the nitrogen atom, and
R 3 represents a C 2 -C 4 hydroxy alkyl group having at least 2 carbon atoms situated between the oxygen atom and the nitrogen atom,
or their salts with inorganic or organic acids of the type mentioned by way of example hereinafter; and in particular
2. salts of hydroxy alkyl amines containing ether groups and having a molecular weight in the range of from about 163 to 2,000, preferably from about 1,000 to 1,500, of the type obtainable using a known method by alkoxylating starter molecules containing at least one ═N--H group and preferably at least 2 hydrogen atoms bound to nitrogen, with inorganic or organic acids of the type mentioned by way of example hereinafter.
DETAILED DESCRIPTION OF THE INVENTION
Suitable hydroxy alkyl amines corresponding to the above formula are, for example, ethanolamine, diethanolamine, triethanolamine, 2-hydroxypropyl amine, bis-(2-hydroxypropyl)-amine, N-methyl diethanolamine or N-ethyl-di-(2-hydroxypropyl)-amine.
Suitable hydroxy alkyl amines containing ether groups are, in particular, the addition products known per se of ethylene oxide and/or propylene oxide with amines containing at least 1 ═N--H--group and preferably at least 2 hydrogen atoms bound to nitrogen, alkoxylation leading beyond the above-mentioned hydroxy alkyl amines to hydroxy alkyl amines containing ether groups. Suitable starter molecules are, for example, ammonia, methyl amine, ethylene diamine, hexamethyl diamine or even the above-mentioned amino alcohols which do not contain any ether groups and which in turn are formed as an intermediate stage in the alkoxylation of the monoamines just mentioned.
The amino alcohols mentioned in 1 are used either as such or in the form of salts while the amino polyethers mentioned in 2 are preferably used in the form of salts with inorganic or organic acids. Acids suitable for salt formation are any inorganic or organic acids preferably having a pK value of more than about 2 and, in particular, more than about 4, such as phosphoric acid, acetic acid, benzoic acid, butyric acid, hexanecarboxylic acid or 2-ethyl hexanoic acid. In general it can be said that those acids which correspond to above pK values and whose salts with the hydroxy alkyl amines are soluble in the coating compositions are particularly preferred. Such acids are i.e. benzoic acid or 2-ethyl hexanoic acid. Inorganic acids such as sulphuric acid or hydrochloric acid or Lewis acids such as aluminum chloride are suitable but less preferred.
The additives according to the present invention are added to the one- or two-component polyurethane systems in quantities of from about 1 to 20% by weight, preferably in quantities of from about 5 to 10% by weight, based on the binder content of the final polyurethane composition.
The additives according to the present invention may be used in any polyurethane-based coating compositions. They are suitable both for solvent-free and for solvent-containing polyurethane coating systems which contain as binders NCO prepolymers crosslinkable with atmospheric moisture (one-component systems) or mixtures of organic polyisocyanates and compounds containing isocyanate-reactive hydrogen atoms (two-component systems). Polyurethane lacquers or coating compositions of this type are known and are described in detail in the literature (cf. for example, Kunststoff-Handbuch, Volume VII, "Polyurethane", Carl Hanser Verlag, Munich (1966), pages 21 et seq; British Pat. No. 1,411,434, German Auslegeschrift No. 1,494,465, German Offenlegungsschrift No. 1,225,274, German Auslegeschrift No. 2,304,893, German Offenlegungsschrift No. 2,313,004, U.S. Pat. No. 3,267,078, incorporated herein by reference, U.S. Pat. No. 3,351,573, incorporated herein by reference, or German Auslegeschrift No. 1,931,053). The coating compositions to be modified in accordance with the present invention are preferably coating compositions based on polyisocyanates containing aliphatically, cycloaliphatically or araliphatically bound isocyanate groups. It is also possible, however, to use coating compositions based on polyisocyanates containing aromatically bound isocyanate groups. Reactants for the polyisocyanates either in the production of the NCO prepolymers or in the above-mentioned two-component systems are preferably the polyester polyols, polyether polyols or polyhydroxy polyacrylates commonly encountered in polyurethane lacquer technology. Epoxide resins may also be used, particularly in two-component systems.
When the additives according to the present invention are used in accordance with the invention, it is necessary, in calculating the quantitative ratios between the binder components, to take into account the fact that the additives used in accordance with the invention also contain isocyanate-reactive hydrogen atoms. This means that, in one-component systems, an excess of NCO groups must always be present in relation to the isocyanate-reactive groups of the additives while in two-component systems the quantity in which the polyisocyanate component is present has to be increased accordingly where high concentrations of isocyanate-reactive groups emanating from the additives are present.
In addition to the additives according to the present invention, the coating compositions may contain the conventional auxiliaries and additives of the type described, for example, in the above-mentioned literature references.
The coating compositions modified in accordance with the present invention are particularly suitable for the production of coatings required to show high permeability to water vapor on the surfaces of mineral building materials. The coating compositions are especially suitable for coating mineral substrates as i.e. concrete, plaster, asbestos cement, sand stone or glass fibre reinforced concrete or similar materials which are used in the building industry. If exterior building surfaces of such materials particularly masonry surfaces are coated with the coating compositions of the invention they are preferably used in such quantities which correspond to a quantity of about 150 to about 250 g/m 2 based on solid components of the coating composition. It is, of course, also possible to apply the compositions of the invention on other surfaces such as i.e. wood, leather or plastics.
The present invention is illustrated by the following Examples in which all the percentages quoted represent % by weight.
The following additives according to the present invention were used in the following Examples:
Additive A
Benzoic acid salt of an ethoxylation product of ammonia; molecular weight of the product: approximately 1,300.
Additive B
Propoxylation product of methyl amine; molecular weight: approximately 1,200.
Additive C
Triethanolamine.
The following starting materials were used for the production of the coating compositions:
Polyisocyanate 1
A biuret-polyisocyanate mixture consisting essentially of tris-(isocyanatohexyl)-biuret, obtained by biuretizing hexamethylene diisocyanate. The NCO content of the product in the form of a 75% solution in ethylene glycol monoethyl ether acetate amounts to approximately 16.5%.
Polyisocyanate 2
An aromatic urethane-polyisocyanate containing free NCO groups, obtained by reacting 3 mols of tolylene diisocyanate with 1 mol of trimethylol propane. The NCO content of a 75% solution in ethyl acetate amounts to approximately 13%.
Polyisocyanate 3
An aliphatic urethane polyisocyanate which contains free NCO groups and which hardens under the effect of atmospheric moisture, consisting essentially of the reaction product of a tris-(isocyanatohexyl)-biuret with a saturated phthalic acid/trimethylol propane polyester containing 2% OH. The NCO content of a 60% solution in ethylene glycol monoethyl ether acetate/xylene (1:1) amounts to approximately 9.5%.
Polyalcohol I
A saturated polyester of phthalic acid and trimethylol propane containing approximately 8% of free hydroxyl groups.
Polyalcohol II
A hydroxy-functional polyacrylate resin obtained by copolymerizing butyl acrylate, 2-hydroxy propyl methacrylate and monostyrene. The solid resin has an OH content of approximately 2.7%.
Polyalcohol III
A saturated polyester containing 4% of hydroxyl groups and modified with 25% of saturated fatty acid, but otherwise consisting of approximately 40% of trimethylol propane and approximately 35% of phthalic acid.
Polyalcohol IV
Polypropylene glycol having a hydroxyl content of approximately 3.5%.
Polyalcohol V
A saturated polyester containing approximately 8.8% of free hydroxyl groups obtained from a mixture of phthalic acid and adipic acid esterified with trimethylol propane.
Coating compositions according to Examples 1 to 7 below were applied by spraying to flat polyethylene sheets in such a way that they produced an average dry film thickness of approximately 0.11 mm. After drying for 4 weeks at room temperature, the films were mechanically removed from the substrate and their resistance to the diffusion of water vapor (μ-factor) was determined in accordance with DIN 52 615.
EXAMPLES
EXAMPLE 1
A polyurethane film obtained from the following coating composition:
Polyalcohol I: 100 parts by weight
Pigment (titanium dioxide, rutile): 152 parts by weight
Levelling agent (polyacrylate resin or cellulose acetobutyrate): 1 part by weight
Accelerator (zinc octoate): 0.4 part by weight
Solvent: ethylene glycol monoethyl ether acetate: 102 parts by weight
Polyisocyanate 1: 120 parts by weight
has a resistance to the diffusion of water vapor (μ-factor), as measured in accordance with DIN 52 615, of approximately 55,000. The addition of 9.5 parts by weight of additive A reduces the μ-factor to approximately 25,000. The addition of 19 parts by weight produced the following results:
______________________________________ With 10% of No addition additive A______________________________________μ-factor 55,000 12,000Dust-dry after 8 hours 7 hoursErichsen value 9 mm 9 mm (crack formation) (crack formation)______________________________________
EXAMPLE 2
A polyurethane film obtained from the following coating composition:
Polyalcohol II: 100 parts by weight
Pigment (titanium dioxide, rutile): 65 parts by weight
Levelling agent: cellulose acetobutyrate: 0.65 part by weight
Solvent: ethylene glycol monoethyl ether acetate: 120 parts by weight
Polyisocyanate 1: 40 parts by weight
has a resistance to the diffusion of water vapor (μ-factor of approximately 23,000. The addition of 13 parts by weight of additive A reduces the μ-factor to approximately 11,000. The drying times of the coating and its resistance to solvents remain unaffected. The Erichsen value is also above the crack formation point, i.e. 9.0 mm.
The same behavior was observed in the case of hydroxy-functional polyacrylate resins having OH-contents of 3.5% and 4.1%.
EXAMPLE 3
A polyurethane film obtained from the following coating composition:
Polyalcohol III: 100 parts by weight
Pigment (titanium dioxide, rutile): 80 parts by weight
Levelling agent: cellulose acetobutyrate: 0.8 part by weight
Accelerator: zinc octoate: 0.3 part by weight
Solvent: ethylene glycol monoethyl ether acetate: 135 parts by weight
Polyisocyanate 1: 75 parts by weight
has a resistance to the diffusion of water vapor (μ-factor) of approximately 45,000. The addition of 15.6 parts by weight of additive A reduces the μ-factor to approximately 15,000. The drying time of approximately 8 hours remains unchanged. Similarly, the characteristic solvent resistance of the films is obtained after drying for 14 days both with, and also without, additive A. In both cases, the Erichsen value of the films is above the crack formation point.
EXAMPLE 4
A polyurethane film obtained from the following coating composition:
Polyalcohol V: 100 parts by weight
Pigment (titanium dioxide, rutile): 112.5 parts by weight
Levelling agent: cellulose acetobutyrate: 1.2 parts by weight
Solvent: ethylene glycol monoethyl ether acetate: 181 parts by weight
Polyisocyanate 2: 168 parts by weight
has a μ-factor of approximately 35,000. The addition of 22.5 parts by weight of additive A reduces the μ-factor to approximately 18,000. The films applied are dust-dry after about 4 hours both before and after the addition, although the characteristic solvent resistance is obtained after drying for only 3 days as opposed to 6 days.
EXAMPLE 5
A polyurethane film obtained from the following coating composition:
Polyalcohol IV: 100 parts by weight
Vinyl copolymer: 50 parts by weight
Pigment (titanium dioxide, rutile): 340 parts by weight
Filler: barium sulphate: 422 parts by weight
Solvent: ethylene glycol monoethyl ether acetate: 571 parts by weight
Polyisocyanate 2: 205 parts by weight
has a μ-factor of approximately 25,000. The addition of 25.3 parts by weight of additive A reduces the μ-factor to approximately 5,000. The films are dust-dry after 1 hour as opposed to 2 hours while their characteristic solvent resistance is obtained after drying for only 6 days as opposed to 14 days. The elasticity of this relatively hard film intended as a primer is measurably improved. Thus, the Erichsen values increase from 1.5 mm to approximately 4 mm.
EXAMPLE 6
A polyurethane film obtained from the following coating composition:
Polyalcohol I: 100 parts by weight
Pigment (titanium dioxide, rutile): 152 parts by weight
Levelling agent: cellulose acetobutyrate: 1 part by weight
Accelerator: zinc octoate: 0.4 part by weight
Solvent: ethylene glycol monoethyl ether acetate: 102 parts by weight
Polyisocyanate 1: 120 parts by weight
has a μ-factor of approximately 55,000. The addition of 9.5 parts by weight of additive B or C reduces the μ-factor to approximately 20,000. The drying time (to the dust-dry state) is slightly reduced from 8 to 7 hours, while the characteristic solvent resistance is obtained after drying for 2 days in either case.
EXAMPLE 7
A polyurethane film obtained from the following coating composition:
Polyisocyanate 3: 100 parts by weight
Pigment (titanium dioxide, rutile): 30 parts by weight
Levelling agent: polyacrylate resin: 0.03 part by weight
Accelerator: dibutyl tin dilaurate: 0.06 part by weight
Drying agent for pigment: tolyl sulphonyl monoisocyanate: 3.75 parts by weight
Solvent: ethylene glycol monoethyl ether acetate: 16 parts by weight
and hardened by the action of atmospheric moisture has a μ-factor of approximately 45,000. The addition of 6 parts by weight of additive A reduces the μ-factor to approximately 17,000. The drying time (to the dust-dry state) is reduced from 8 to 5 hours and the films have their characteristic solvent resistance after only 3 days as opposed to 14 days. The Erichsen value of the films remains unchanged above the crack formation point.
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
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A process for improving the water vapor permeability of polyurethane coatings by incorporating a hydroxy alkyl amine, an alkoxylated amine or the salt of either with an inorganic or organic acid into the coating composition is taught. Coating compositions including this water vapor diffusion enhancing additive are also taught as is a process for coating water vapor permeable substrates.
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BRIEF SUMMARY OF THE INVENTION
The present invention relates to aircraft, such as airplanes and helicopters, and more particularly to a VTOL aircraft having a wing including a rotor supported on the tip of each wing laterally rotating and towards the longitudinal axis of said Craft's wings to generate lift for vertical take off or landing (V.T.O.L.) and a thrust-flap to generate thrust between the wing's aerofoil and the rotors.
The main object of this invention is to provide a superior wing for an aircraft. The wing, in conjunction with the rotor and thrust-flap, generates lift and thrust simultaneous or independently.
A further object of this invention is to increase the wind velocity relative to the wing by means of the rotors to increase lift force.
Another object of this invention is to provide the fuselage tail of the aircraft with a divergent-convergent nozzle configuration to create air-pressure at the tail-propeller thereby creating further thrust for propulsion.
A further object of this invention is to replace part of the initial stage blades of an aircraft's compressor with the wing's rotor.
A still further object of this invention is to dispose a rotating tail nozzle in a horizontal position parallel to the longitudinal axis of the aircraft's fuselage to generate thrust for propulsion and being rotatable to any position between longitudinal and vertical positions for V.T.O.L. or rolling.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings schematically illustrate by means of example, and not by way of limitation, several embodiments of the invention in which corresponding numbers designate corresponding parts in the several views, and in which:
FIG. 1 is a perspective view of a first embodiment of the VTOL Craft of the present invention;
FIG. 2 is a perspective view of a second supersonic embodiment of the VTOL Craft;
FIG. 3 is a schematic view partially in cross-section to illustrate the function of the thrust-flap when extended;
FIG. 4 is a schematic view partially in cross-section, to illustrate the function of the thrust-flap when deflected;
FIG. 5 is a schematic view of the wing of FIG. 4, looking forwardly, to illustrate the thrust-flap when deflected;
FIG. 6 is a schematic perspective view of a third, subsonic, embodiment of the VTOL Craft of the present invention;
FIG. 7 is a schematic view to illustrate an arrangement of bevel gears provided for driving the rotors and the tail propeller;
FIG. 8 schematically illustrates the multi-stage turbine used in the "VTOL aircraft" of FIG. 2; and
FIG. 9 is a temperature vs. entropy graph of the turbine of FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
The invention, the scope thereof being defined in the appended claims, is not limited in this application to the details of manufacture, construction and arrangement of parts illustrated and described, since the invention is capable of other embodiments based on the principles of this invention carried out in various other ways. Also, it is understood that terminology or phraseology or symbolism used herein is for the purpose of description.
The VTOL Craft described hereinafter takes the form of three basic embodiments:
(a) a supersonic embodiment;
(b) a subsonic embodiment; and
(c) a light embodiment.
(A) ALL EMBODIMENTS IN GENERAL
The principles underlying the present invention are applicable to all the above-mentioned embodiments, conserve energy by increasing the efficiency of operation of supersonic and subsonic aircrafts, as well as helicopters, by increasing the lift force. With higher lift force and with the same horsepower, the VTOL aircraft can achieve greater speed and range. From the fundamental equation of lift (see equation (a) below), the wind velocity relative to the wing is directly proportional to the lift force. The speed of the rotor located below the wing increases the velocity of the wind relative to the wing as a result of which the force of lift is further increased. As the lift and weight are opposite forces, the greater the lift force relative to the weight, the less power is needed for propulsion for the VTOL craft.
Fundamental equation of lift:
L=C.sub.L P2V.sup.2 S'
where C L =Lift coeff.; V=velocity; S=airfoil area.
As shown in each of FIGS. 1, 2 and 6, each wing 2 of the "VTOL craft" is supported by the fuselage 9. A rotor 1, 4 is attached at each wing tip. The rotor is of a fixed pitch and is designed, when rotating, to make the "VTOL craft" hover. The right rotor 4 is shown to be rotating clock-wise while the left rotor 1 is shown to be rotating counter-clock-wise. Thus the general torque from the rotors is in balance. The rotors are caused to rotate via shafts 24, 24 which extend through the wings. The shafts are driven by Bevel gears 29, 70, 70'. The Bevel gears can be driven by the crankshaft of an internal combustion engine or turbine engine.
A vertical stabilizer 5 and rudder is disposed on each wing tip above the rotor's spinner, thus increasing further the stability and yawing moment of the "VTOL craft".
The fuselage 9 and the tail of the "VTOL craft" are provided with a convergent-divergent nozzle shape. The throat of the convergent nozzle is connected to the fuselage and at the throat of the divergent nozzle the tail propeller 7 is attached. A pair of horizontal stabilizers 6, 6 are provided at the tail of the "VTOL craft".
The tail propeller can be driven by a shaft 72 (see FIG. 7) from the same engine 66 which drives the rotors at the wing tip. The tail propeller can also be driven by an internal combustion engine located at the tail of the "VTOL craft's" fuselage. In this case, the shaft which drives the tail propeller will preferably be connected to a clutch 73 to neutralize the tail propeller during take off or landing.
The wings of the aircraft function to simultaneously create lift and generate thrust, while the rotors function to make the "VTOL craft" hover and compress air on the airfoil of the wing, based on the principles underlying this invention.
For military purposes (see FIG. 2), the tail propeller 7 can be replaced by a nozzle 19 and a turbine 75 can be placed in the fuselage at a middle position after the wings. In the embodiment of FIG. 6, an internal combusion engine drives the rotors while a small turbine creates thrust for propulsion by means of pivotable nozzles 63 and also drives the tail-propeller 50.
(B) THE SUPERSONIC EMBODIMENT
FIG. 2 illustrates a "VTOL aircraft" having vertical take-off or landing capability, a nozzle shaped fuselage, and wings 3 have an aerodynamic composite airfoil. Each of the wings supports a pivotally mounted thrust-flap 2, 32 located at the lower camber curvature or trailing edge. The thrust-flap selectively changes the aerodynamic effects by deflecting chordwise airflow to form a combined convex-concave lower camber curvature or one extending chordwise to conform with the conventional camber's lower curvature design profile. Lifting and propulsion is generated by means of rotors 1, 4 fixedly mounted on the wing's frame at the wing tip 36. Wing tip 36 includes a cowling to accommodate bevel gear 25 and spinner 35. The rotors 1, 4 generate thrust when the thrust-flap 2, 32 is deflected. The rotors 1, 4 generate the lift when the thrust-flap 2, 32 is extended. Angular stabilizers and rudders 5 are located at the wing tip opposite to rotors 1, 4 at a designated angle of 45°-85° between the vertical and lateral axis of the wing 3. The total wing span of the "VTOL aircraft" is the length of the wings 3 plus the length of each wing's rotor blade 1, 4. The wings 3 in conjunction with the rotors 1, 4 and thrust-flap 2, 32 generate lift and thrust simultaneously or independently. The thrust-flap 2, 32 are extended or retracted by means of at least two hydraulic cylinders 23 connected to the wing's frame and a lever arm coupled to the thrust-flap platform 2. Openings 14 are positioned directly in front of the leading edge of the wing. The opening 14 is diagonally in alignment with the lateral axis of the fuselage, and the rotors 1, 4 cause part of the airstream 10 (see FIG. 3) to enter the opening leading to the turbine compressor 75 of the aircraft. On each side of the aircraft, between the nose 12 and fuselage 9, a case 16 is attached to accommodate weapons, missiles or the like. The rotors 1, 4 are provided with fixed pitch and fixed blades, and are designed to create lift. During supersonic flight, the rotors 1, 4 do not create dynamic forces on the wings because they are aligned with the airstream 10. The rotors 1, 4 are driven by means of at least one hollow shaft 24 attached to a bevel gear arrangement 29, 28, 27 by means of at least one turbine. The bevel gear arrangement 29, 28, 27 is powered by means of the turbine's extended shaft 30 attached to the lower bevel gear 27. The tail nozzle 19 discharges combustion gases through holder 18 into the pivotable-nozzle. The holder 18 is a tube with extended lip edges to engage the pivotable-nozzle 17, and is capable of rotating about the holder's axis.
FIG. 8 illustrates the turbine system assembly for propulsion of the aircraft shown in FIG. 2, which includes:
a. a two-stage compressor which consists of a first stage compressor C 1 having blades located at the wing's tip rotors 1, 4 for generating thrust between the thrust-flap 2, 32 and the wing 3, and for forcing part of air-stream 10 to enter opening 14; and a second stage high-pressure-compressor C 2 attached to the shaft 30 driven by a high-pressure-turbine 87;
b. two burners including a first burner 82 located between the high-pressure compressor C 2 and the high-pressure-turbine 86, and a second burner 83 located between the high-pressure-turbine 86 and the low-pressure-turbine 85; and
c. a three-stage turbine which includes a first stage high-pressure-turbine 86 for driving the H-P-compressor 87 and rotors 1, 4 of the first stage compressor C 1 ; a second stage low-pressure-turbine 85 for discharging combustion gases from the H-P-turbine 86 and the burner 83 at high speeds into a divergent-confergent nozzle 33; and a third stage turbine 84 located in the divergent nozzle 33 to further accelerate the exhaust gases into the holder 18 and the pivotable-nozzle 17.
The pivotable nozzle 17 is located and supported on the tail 21 of the fuselage. The pivotable-nozzle 17 is divided into two segments each discharging combustion gases exiting from the divergent-convergent nozzle 33. The pivotable-nozzle's segments are supported and rotated between longitudinal and vertical axes for vertical take-off, landing or rolling by means of at least one adjusting hydraulic cylinder 22 and rod 20 disposed at the top of the nozzle 33 and at the lower base of the nozzle 33. The segments are fixed by means of a holder 18 to the frame of the tail 21. The turbine employed in this aircraft is not disclosed in detail in this description or in the drawings; instead, schematic views are used to illustrate by means of example the propulsion system of the VTOL aircraft of this invention.
FIG. 3 illustrates the wing 3 with the thrust-flap 2, 32 retracted. In this position, the pressure of airstream 10 between the rotor 1 and the wing lower camber is unaffected, and the airstream 10 passes the thrust-flap 2, 32 unaffected as seen at 11. The thrust-flap platform is divided into a first flap portion 2 and a second flap portion 32. The first flap portion 2 is pivotably attached to a lever arm. The second flap portion is pivotably held at the trailing edge 48 of the wing 3 by means of a cylindrical rod 38 formed at the edge of the flap portion 2 and accommodated in a housing 48 at the wing's trailing edge. A small leaf-spring 49 is provided at the wing's trailing edge to force the second flap portion 32 downwardly at the beginning of the deflection movement of thrust flap 2, 32. The flap portions are pivotably attached together. The rotor 1 is of fixed pitch and fixed blades attached on a spinner 35 driven by a shaft 46 and held on the shaft 46 by means of a spinner bolt 45. The shaft 46 is driven by means of bevel gears 25. The wing's frame supports the hydraulic cylinder 23. The lever arm of the first flap portion is attached to slot 42 in a beam by means of a rod 44.
FIG. 4 illustrates the arrangement of the thrust flap and wing assembly when the flap portions are extended or deflected from the undersurface of the wing. When the thrust-flap is deflected, a convergent-divergent nozzle is created on the entire length of the trailing edge of the wing. An aerodynamic composite airfoil section is thus formed by extending or retracting chordwise thrust-flap 2, 32, thereby changing said airfoil's lower camber's profile by means of at least two adjusting hydraulic cylinders 23 connected on the wing's frame 39 and a lever arm coupled to the flap 2 to operable effect adjustments in the attitude assumed by the thrust-flap 2, 32. The lever arm is attached to slot 42 in a beam mounted on the underside of wing 3 by means of a rod 44 to guide its movement longitudinally of the wing's chord. The beam is supported by the wing's frame longitudinally of the chord. The bevel gears 25 are enclosed in a wing-cowling 43. The bevel gears 25 are driven by a means of a shaft 24 or 24' mounted on the wing's frame. The shaft 24 is powered by means of a bevel gears arrangement attached to at least one turbine or at least one internal combustion engine. The rotors 1, 4 are attached at the tip of each wing and both rotate towards the fuselage. When the thrust-flap 2, 32 is deflected, the airstream 10 is restricted forming airstream 11 thereby creating thrust at the end of the trailing edge. The hydraulic cylinder's pump is shown at 40.
FIGS. 3, 4 and 5 are applicable to all three embodiments of the VTOL craft and illustrate the aerodynamic principles underlying this invention.
C. THE SUBSONIC EMBODIMENT
FIG. 6 illustrates a subsonic embodiment of the "VTOL craft" having vertical take-off or landing capability, and employing a nozzle-shaped fuselage. The wings have an aerodynamic composite airfoil, each of which supports a pivotally mounted thrust-flap 2, 32 located at the lower camber curvature or trailing edge as has been disclosed in FIGS. 3, 4 and 5 and described. The horizontal stabilizer 62 is located before the exhaust nozzle 63. The fuselage 52 has an opening 53 within said fuselage and directly underneath said wing's trailing edge. The opening intakes air from the ambient and guides it to the turbine's compressor located in the fuselage tail 61. The opening 53 is diagonally in alignment with the axis of the rotors 1 and 4. The rotors force part of the airstream to enter opening 53. Exhaust nozzle 63 is positioned underneath horizontal stabilizer 62 and elevator 6. The exhaust nozzle is pivotably mounted on the tail and is tiltable in the horizontal and vertical position. When exhaust nozzle 63 is in a vertical position, it is forwardly moving the "VTOL craft's" tail upwards, and when tiltable in horizontal position relative to longitudinal axis of the fuselage, the thrust generated by the turbine moves the "VTOL craft" forwardly in conjunction with the tail-propeller. In the subsonic embodiment of said "VTOL craft," the rotors and tail propeller 50 are driven by means of a combination of at least an internal combustion engine and at least one propfan in a thrust propulsion arrangement located in the fuselage and the tail. Collectively, or singly, the rotors 1, 4, the tail propeller 50 and the exhaust nozzle 63 generate thrust for vertical or horizontal motion. The fuselage tail is shaped in a divergent-convergent nozzle to increase and create high air presure at the tail propeller 50, and to generate more thrust. Angular stabilizers 51 and rudder 5 are located at the wing tip opposite to the rotors at a designated angle of between 45° and 87° inclination between the vertical and lateral axis of the wing. The bevel gear arrangement 27-29 drives the rotors by means of shafts 24, 24'attached to the second bevel gear 29. The first bevel gear 27 is driven from an internal combustion engine's crankshaft. Each rudder is tilted by means of a hinge 64 and a gear driven support 65. 60 denotes the beginning of the turbine in the tail 61.
D. THE LIGHT EMBODIMENT
FIG. 1 illustrates the "VTOL craft" light embodiment having vertical take-off or landing capacility with nozzle-shaped fuselage. The wings have an aerodynamic composite airfoil including a pivotably mounted thrust flap 2, 32 located at the lower camber curvature or trailing edge as has been disclosed in connection with FIGS. 3, 4, and 5. This embodiment of the "VTOL craft" is a propeller-driven, light version. The rotors 1, 4 and the tail propeller 7 both are driven by means of at least one internal combustion engine, the rotors and tail propellers generating thrust for horizontal motion and the rotors 1, 4 generating thrust for vertical or horizontal motion.
FIG. 7 illustrates the bevel gear arrangement for the "VTOL craft" of FIG. 1 as including two bevel gears 27, 29 and a shaft 28. Bevel gear 27 is driven by means of an extended shaft 67 with a bevel gear 69 attached on shaft 67. The shaft 67 is attached to the crankshaft 68 of an internal combustion engine 66. Bevel gear 29 is attached to the bevel gear 27 by means of a shaft 28. Bevel gear 29 drives the shafts 24 and 24' by means of two bevel gears 70 and 70'attached on the shafts 24 and 24' and engaging the bevel gear 29. The tail propeller shaft 72 is connected to a clutch 73 for disengaging the tail propeller shaft from the tail propeller during take off or landing.
FIG. 6 illustrates in the "VTOL craft" the tail propeller being driven by means of a propfan. The shaft of the propfan driving the tail propeller is connected to a clutch to disengage the tail propeller from rotating during take-off or landing. The tail propeller 7 in FIG. 1 is rotating in a reverse direction from that rotation of the crankshaft 68 to balance the generated torque. The tail propeller shaft 72 is attached to a bevel gear 71 to engage the bevel gear 29 and can be connected to clutch 73 and a gear box.
E. IN ALL THREE EMBODIMENTS
The aerodynamic principles of the present invention are embodied in all three embodiments of the "VTOL craft." The rotors 1, 4 function to eliminate vortices at the wing tips. With one thrust flap 2, 32 extended and the other thrust flap 2, 32 retracted, the "VTOL craft" can be made to rotate about the lateral and vertical axis.
F. THE AERODYNAMIC PRINCIPLE OF THE PRESENT INVENTION
The wings of a "VTOL craft" function to create lift and/or generate thrust. When the thrust flap is retracted to conform with the conventional lower curvature camber profile, it has no effect on the flow of the airstream between the rotor and the wing's airfoil lower camber.
The rotation of the rotor causes the "VTOL craft" to function as a helicopter, or as a vertical take-off or landing aircraft. The fixed pitch of the rotors function to make the "VTOL craft" hover and compress the airflow on the wing's thrust flap to generate thrust.
When the thrust flaps are deflected at an angle with respect to the wing's lower surface, the air is compressed and then allowed to expand to generate thrust.
The thrust flap therefore functions as a selectively adjustable convergent-devergent nozzle. The thrust flaps extend laterally on the entire length of the wing.
The tail propeller, located at the tail of the VTOL craft of FIGS. 1 and 6, functions to generate thrust for propulsion to increase the total generated thrust, therefore increasing the speed of the "VTOL craft." For further increase of the total generated thrust of the "VTOL craft," the propeller and internal combustion engine may be replaced with a turbine as embodied in the aircraft shown in FIGS. 2 and 6.
The present invention is by no means limited to the examples described in the foregoing specification and illustrated in the accompanying drawings. The aircraft, the thrust flap, the control device for such a thrust flap, and/or the propulsion systems described, may be constructed in all sorts of combinations, shapes and dimensions without going beyond the scope of the invention.
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An aircraft having vertical take-off and landing capability including a nozzle-shaped fuselage housing a power-generating mechanism, a propulsion-developing mechanism at the rear end, and laterally-extending wings located forwardly of the rear end. Each wing includes an aerodynamically composite airfoil having a lower surface possessing a camber curvature. A propeller is provided at the free end of each wing for rotation in a plane parallel to the plane of the wing. The lower surface of each wing includes a thrust flap which may be moved between a first position in which the flap coincides with the camber curvature of the wing lower surface and the propeller provides primarily lift, and a second position in which the flap projects below the camber curvature of the wing lower surface to cooperate with the propeller to compress the flow of air therebetween thereby generating thrust useful for propelling the aircraft in a forward direction.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/442,152, having a filing date of Apr. 9, 2012, which is a continuation of U.S. patent application Ser. No. 12/590,184, having a filing date of Nov. 4, 2009, now U.S. Pat. No. 8,235,631, the entire contents and disclosure of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a temporary or permanent wall for retaining material, and more particularly to a bag used in erecting such a wall.
BACKGROUND
[0003] There have been a variety of methods and techniques developed in the past for building structures that retain material. Some of these structures have been temporary, while others have been intended to be permanent. For example, during times of flooding or expected flooding, temporary levees are sometimes erected using sand bags that are filled and stacked. This type of structure is very labor intensive and is temporary in nature.
[0004] There have been attempts to develop alternative methods of erecting temporary levees such as those taught in U.S. Pat. No. 6,390,154. However, the shape of the bag and method of using the bag described in that patent restricts the use of the bag to a limited number of environments and filling material.
[0005] Alternatively, it is known to build retaining walls that require preformed bricks or stones to be stacked and supported so that material is retained such as a hillside or other embankment. Erecting these types of retaining structures is expensive in both the materials and transporting them to the work site. Also, skilled installers are required for all but the simplest structures to ensure the retaining structure has the structural integrity to perform as expected.
[0006] There remains the need, therefore, for a bag and a system and method for using that bag to build a retaining structure that is flexible in the structures that can be constructed, that is flexible in the variety of material that can be used to fill the bag, that is simple to use, and can reduce the costs of building retaining structure, whether temporary or semi-permanent.
SUMMARY
[0007] The present invention relates to a bag for retaining structures, includes a plurality of cells aligned side-by-side in a continuous manner and configured to be filled with a filling material. Each cell of the bag includes a bottom wall, a first side wall, a second side wall, a back wall, and a front wall, the front wall being longer than the back wall. Furthermore, the first and second side walls each include a) a first corner located where the back wall connects with the bottom wall, said first corner being substantially 90 degrees; and b) a second corner located where a respective top edge of each side wall connects with the rear wall, said second corner being substantially 90 degrees. Embodiments of the present invention also relate retaining structures erected using such a bag.
[0008] It is understood that other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only various embodiments of the invention by way of illustration. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Various aspects of a bag, system and method for erecting retaining structures are illustrated by way of example, and not by way of limitation, in the accompanying drawings, wherein:
[0010] FIGS. 1A and 1B show, respectively, a side view and a top view of a portion of a bag in accordance with the principles of the present invention;
[0011] FIG. 2A shows a top view of a portion of a bag in accordance with the principles of the present invention;
[0012] FIG. 2B shows a side-wall deformation of the bag of FIG. 2A in accordance with the principles of the present invention;
[0013] FIG. 2C and 2D show alternative side-wall embodiments of the bag of FIG. 2A in accordance with the principles of the present invention;
[0014] FIG. 3 shows a retaining structure erected using the bag of FIG. 2A in accordance with the principles of the present invention;
[0015] FIG. 4A and 4B show alternative retaining structures erected using the bag of FIG. 2A in accordance with the principles of the present invention;
[0016] FIG. 5 shows a free standing retaining structure capable of being erected in accordance with the principles of the present invention; and
[0017] FIG. 6 shows another free standing retaining structure capable of being erected in accordance with the principles of the present invention.
DETAILED DESCRIPTION
[0018] The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the invention and is not intended to represent the only embodiments in which the invention may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without these specific details. In some instances, well known structures and components are shown in block diagram form in order to avoid obscuring the concepts of the invention.
[0019] In the figures, description and in the claims, the terms “front”, “back”, “side”, “bottom” etc. are used to simplify referring to a particular embodiment of a bag. However, one of ordinary skill will recognize that these terms are relative and that the shape of the bag and its relative dimensions remain the same when viewed from different perspectives or used in different orientations. Thus, use of these terms is not intended to limit embodiments of the present invention to bags having only a single orientation in space.
[0020] FIG. 1A and 1B show, respectively, a side view and a top view of a portion of a bag in accordance with the principles of the present invention. In FIG. 1A a cross-sectional view of a bag 100 is depicted. There is a back wail 102 , a bottom wall 104 , and a front wall 106 . The top 108 may include a top wall or be open. If there is a top wall present, then it may be configured in such a way that it connects with either the back wall 102 or front wall 106 to form a flap. Such a flap would be moved out of the way to allow the bag 100 to be filled and then positioned over the bag 100 once it is filled.
[0021] Of particular benefit to the bag 100 are the relative angles formed by the different walls and their respective lengths. The right angle 110 formed by the back wall 102 and bottom wall 104 adds stability and versatility to the use of the bag 100 . The right angle 111 formed along the top edge of the back wall 102 also provides stability and versatility.
[0022] Making the bottom wall 104 longer than the back wall 102 provides a shape that adds stability to a structure erected using the bag 100 . By making the bottom wall 104 longer than the back wall 102 , the angles 112 and 113 are formed at each edge of the front wall 106 and the front wall 106 is longer than the back wall 102 .
[0023] One of ordinary skill will recognize that the bag 100 of FIG. 1A may be have a variety of sizes while keeping the relative lengths and angles as discussed above. Thus, embodiments of the present invention are not limited to a particular size of bag 100 . However, the use of ordinary heavy machinery to fill and move a bag 100 makes certain sizes for the bag 100 more practical than others. For example, the top opening 108 may be between one foot to two feet in length and width to accommodate typical front-end loader buckets (or specialized filling equipment). The back wall 102 may vary from about 4 feet to about 8 feet in length and a corresponding bottom wall would vary from about 7 feet to 11 feet in length. These relative dimensions and sizes are provided as examples and not as a limitation of which sizes are contemplated within the scope of the present invention.
[0024] As for material, the bag 100 can be constructed from polypropylene or similar material that can withstand the elements of a harsh environment. In particular, the material can be a weaved material with the weave spacing and thickness selected based on such things as the type of fill material being used to fill the bag, and the degree to which the bag is intended to retain fluid such as water. In addition, the bag may be coated with a water-proof seal if it is intended to be substantially impervious to water flow. One of ordinary skill will recognize that the specific material of the bag can be selected so as to be suitable for the intended application of use. A material can be selected that is woven or unwoven, impervious to fluid or porous, rugged or biodegradeable without departing from the intended scope of the present invention.
[0025] The fill material contemplated within the bag 100 includes sand, sand mixed with stones, cement or concrete, and crushed rock of various sizes. Alternatively recycled materials from tires and plastics may also be used that can be condensed to form a solid filling material.
[0026] In addition to the back wall 102 and side wall 106 , already discussed, the view of FIG. 1B also shows a first side wall 116 and a second side wall 118 . The fill material will be delivered to inside the bag 100 through the top opening 108 .
[0027] FIG. 2A shows a top view of a portion of a bag in accordance with the principles of the present invention. The bag 200 of FIG. 2A shows that adjacent bags 100 are aligned to extend along a first direction. Thus, the bags 100 discussed above can more properly be referred to as bag cells 100 such that a bag 200 is comprised of a plurality of bag cells 100 adjacent to one another. In this arrangement, there is a side wall 202 that is shared by adjacent cells 100 . Thus referring to FIG. 1B and FIG. 2A , the shared wall 202 would correspond to the second side wall 118 of one bag cell 100 and also correspond to the first side wall 116 of an adjacent bag cell 100 . Each such shared wall 202 will have a cross-section that resembles that depicted in FIG. 1A .
[0028] FIG. 2B shows a side-wall deformation of the bag of FIG. 2A in accordance with the principles of the present invention. Two adjacent shared walls 202 are shown in the view. In particular, each shared wall is constructed of a material (such as those described above) that is flexible enough to bow out in its center but rigid enough to substantially retain its shape along its edges.
[0029] For example, when cells 100 are filled with fill material, the top edge 205 (and the bottom edge, not shown) of the shared wall 202 substantially retain their shape but the material of the shared wall 202 stretches or bulges to create the bump 204 . While selecting a material rigid enough to prevent this bump 204 can be accomplished, the bump 204 has benefits. For example, the bump 204 extends into the adjacent bag cell and tends to tie the whole structure together rather than allowing adjacent cells to slip or slide with respect to one another.
[0030] FIG. 2C and 2D show alternative side-wall embodiments of the bag of FIG. 2A in accordance with the principles of the present invention. In FIG. 2C , one or more holes 206 are present in the shared wall 202 , these holes allow filling material in one bag cell to contact with filling material in an adjacent bag cell. In one particular example, if the filling material is cement or concrete, then the holes will allow adjacent cells to tie into one another.
[0031] In FIG. 2D , there are one or more protrusions 208 in the shared wall 202 . These protrusions can be located on one side or both sides of the shared wall 202 .
[0032] FIG. 3 shows a retaining structure erected using the bag of FIG. 2A in accordance with the principles of the present invention. The bags 200 extending in a direction perpendicular to the plane of the sheet of paper. A firm foundation 306 is provided for a first bag 200 and then additional bags 200 are stacked on top of a bag underneath. The material to be retained 302 is thus retained by the stack of bags 200 . In particular, a structure can be erected such that the slope of the face 304 of the retaining structure 300 slopes at an angle that is the substantially similar to the angle 112 shown in FIG. 1A . Thus, by selecting the appropriate lengths and dimensions for the bag cells 100 , a retaining structure 300 having a desired sloping face can be easily constructed.
[0033] Although not depicted in FIG. 3 , the bottom walls of the cells in the bags 200 can also be allowed to bulge slightly so that they tie into the bag 200 underneath. This feature provides additional strength and stability to the retaining structure 300 . In constructing the structure 300 , the bags 200 can be filled to different lengths. For example, the bags 200 may be collapsible like an accordion so that pulling (in the direction that the bag extends) on a plurality of folded-up cells will expose and open one cell. This cell can be filled and then the pulling continues to expose and open the next, adjacent cell for filling. If an entire bag 200 is not used when a desired wall length is reached, then the unused cells may be cut away. If, however, additional bags 200 are needed to achieve a desired length, then a bag can be attached to the last cell of a first bag and the pulling, opening, and filling steps continue with the second bag.
[0034] FIG. 4A and 4B show an alternative retaining structures erected using the bag of FIG. 2A in accordance with the principles of the present invention. The retaining structures 400 and 420 depicted in these figures illustrate the versatility of the bags 200 . In these structures, the substantially straight back wall is exposed and the slanted front wall is in contact with the retained material 402 , 422 . The exposed façade 404 , 424 can then be treated with ornamental, structural (e.g., shotcrete or gunite) or preservative materials as desired.
[0035] FIGS. 5 and 6 illustrate the versatility and ease of use of bags constructed in accordance with the principles of the present invention. The substantially straight back wall allows construction of free-standing structures such as structure 500 that can act, for example, as a levee. Thus, structure 500 can be constructed without relying on nearby earth or material on one side for its structural strength and integrity. A bag 502 can be filled and then a corresponding back-to-back bag 504 can be filled. These two bags provide a foundation for smaller bags 506 and 508 , which are filled to provide a foundation for even smaller bags 510 and 512 . Although the structure 500 in FIG. 5 is depicted as symmetrical, the bags can vary in size so that the slope on one outward-facing side is different than the slope on the other outward-facing side. Top flaps 514 and 516 are shown that can be lowered once the bags 510 and 512 are filled.
[0036] Another alternative structure 600 is depicted in FIG. 6 . Bags 602 and 604 can be filled and oriented so as to provide a flat outward face (although they could be flipped around as well). Then material 606 can fill in the area between the two bags 602 , 604 . Sand, sand bags, concrete, etc. can all be used for the material 606 . On top of this base structure other bags can be placed such as bags 608 and 610 . Although not shown, additional bags can continue to be stacked to make a retaining structure of a desired height.
[0037] The previous description is provided to enable any person skilled in the art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments. Thus, the claims are not intended to be limited to the embodiments shown herein, but are to be accorded the full scope consistent with each claim's language, wherein reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. §112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”
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A bag for retaining structures, includes a plurality of cells aligned side-by-side in a continuous manner and configured to be filled with a filling material. Each cell of the bag includes a bottom wall, a first side wall, a second side wall, a back wall, and a front wall, the front wall being longer than the back wall. Furthermore, the first and second side walls each include a) a first corner located where the back wall connects with the bottom wall, said first corner being substantially 90 degrees; and b) a second corner located where a respective top edge of each side wall connects with the rear wall, said second corner being substantially 90 degrees.
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CROSS REFERENCE TO RELATED APPLICATIONS
This applications claims priority to United Kingdom patent application No. GB 1113075.4, filed Jul. 29, 2011, the entire contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to earphone arrangements, and it relates in particular to such arrangements as are configured to accommodate an acoustically-resistant couple within critical spatial constraints of the kind dictated by the compact dimensions of ear-bud type earphones.
BACKGROUND OF THE INVENTION
Acoustically-resistant couples play a significant role in determining and adjusting the acoustic characteristics and performance of earphones, especially when a particular frequency response characteristic is required. This is especially the case in the design of earphones which feature electronic ambient noise-cancellation (ANC) technology, and specifically to those utilising “ear-bud” type thin rubber flanges that seal the outlet conduit of the earphone into the entrance of the listener's ear-canal. Such earphones are sometimes referred to as “in-ear” earphones, or “ear-bud type” earphones, and they are now widely used for portable communications and entertainment applications whilst the listener is travelling, including listening to music and, in conjunction with cellular telephone handsets, for hands-free calls and conversations.
Although the thin rubber ear-bud flanges might appear to effectively “seal” the earphone assembly into the listener's ear-canal, an earphone thus positioned and located does not provide an effective acoustic seal between the listener's ear canal and the ambient environment, because low-frequency sound vibrations can still pass through the rubber flanges themselves. In addition, as already mentioned, and as disclosed for example in U.S. Pat. No. 4,852,177, acoustically-resistant couples are often incorporated into acoustic coupling pathways that are provided in earphone structures so as to adjust the acoustic performance for a desired frequency response at the listener's ear, and such pathways allow external sound energy to be transmitted directly through the actual structure of the earphone and into the ear-canal. Acoustic coupling pathways are often implemented as small apertures, with acoustical resistance provided by an acoustically resistive mesh material overlying an aperture. Such pathways are usually situated to provide an acoustic connection either between the outer ambient air and the internal space situated at the front surface of an internal microspeaker (or in the space behind it), or between these two internal spaces themselves, or some combination thereof, and these pathways contribute to the complexity of the acoustic structure of the earphone.
The general structure of a prior-art ear-bud type earphone 10 is shown in FIG. 1 , in which a microspeaker 12 is sealed into a central substrate 14 , which, in turn, is sealed to both a front housing 16 and a rear housing 18 . The front housing 16 includes an elongate outlet port comprising an inner opening 20 coupled to an in-ear extension piece 22 on to which a rubber ear-bud flange 24 is affixed, and the rear housing 18 often is formed with one or more rear vents, such as 26 , linking the rear of the microspeaker 12 to the external ambient. It is convenient to refer to the volume of air in the front housing 16 , lying between the front of the microspeaker 12 and the inner opening 20 of the outlet port, as the “front volume” 28 , and to the volume of enclosed air lying in the rear housing 18 behind the microspeaker 12 as the “rear volume” 30 . The rear housing 18 is also used to carry and locate the electrical flex connections to and from the microspeaker 12 , though these are not shown, for reasons of clarity.
As already mentioned, it is usual to provide the earphone 10 with one or more vents or acoustically-resistant couples, such as that shown at 32 , in order to modify the frequency response to provide, for example, high-quality sound reproduction. Such couples usually include acoustic resistors, formed by sealing a thin, acoustically resistant nylon mesh (or similar) over a small diameter (<1 mm), short length (<1 mm) aperture in the housing. This is often done by means of small, double-sided adhesive tape discs, as illustrated in FIG. 2 , which shows an acoustic resistor 32 , comprising a nylon mesh disc 34 mounted on to an adhesive disc 36 in which there is a central aperture 38 defining the active area of the acoustic resistor 32 .
Typically, the disc 34 / 36 has an outer diameter of 3 mm, and a central aperture of 1 mm. It is beneficial to deploy such a resistance either between the front volume 28 and the ambient, as shown in FIG. 1 , or between the front and rear volumes 28 , 30 . This expedient provides an additional benefit, in preventing a total hermetic seal of the earphone in the ear of the user, which could otherwise cause an unpleasant “blocked ear” feeling in use.
Further, the provision of a pathway between the ear-canal and the ambient (either directly or via the rear volume 30 ) allows air to escape from the ear-canal when the ear-bud 10 is inserted. This prevents damage to the microspeaker 12 as, without such a pathway, the air in the canal and front volume 28 would be momentarily compressed, and this could force the diaphragm of the microspeaker 12 beyond its mechanical limits, potentially buckling the diaphragm and causing permanent damage.
In practise, only one of these acoustic couples is required to avoid the above problems: either a front volume-to-ambient couple, or a front volume to rear volume couple (assuming that the rear volume itself is also vented). The present invention utilises an acoustic couple between the front volume and the rear volume.
When it is required to implement a front volume to rear volume acoustic couple, such as in the acoustic module design disclosed in GB-A-2,475,526, it is convenient to position the elements of the acoustic couple directly adjacent to the microspeaker 12 . This is illustrated in FIGS. 3( a ) and 3 ( b ), in which features corresponding to those already described with reference to FIGS. 1 and 2 are identified by the same reference numbers. FIG. 3 shows only part of an earphone 40 , comprising a front housing 16 and its contents, but it will be appreciated that a rear housing, such as that shown at 18 in FIG. 1 , would be attached to the front housing 16 to form an enclosed unit defining a vented rear volume, such as that shown at 26 , 30 in FIG. 1 .
In FIGS. 3( a ) and 3 ( b ), the front housing 16 of an earphone shown in part at 40 includes an acoustic resistor 42 mounted over an aperture 44 formed in the substrate 14 , beside the aperture provided for the microspeaker 12 , thereby providing an acoustic leakage path, via the resistor 42 , between the front volume 28 and the rear volume (not shown in FIG. 3) of air in the earphone. However, this layout increases the lateral dimensions of the earphone 40 significantly beyond those needed to accommodate the microspeaker 12 , as is clear from the drawing. In addition to the area of the acoustic resistor 42 , which may typically have a diameter of around 3 mm, it is necessary to allow for manufacturing clearances around the edges of the individual components, and consequently the overall lateral dimensions of an earphone such as 40 are considerably larger than those of an earphone such as that shown at 10 in FIG. 1 .
It is one object of the present invention to provide an earphone which incorporates a front volume to rear volume acoustic couple, without requiring significant addition to the lateral dimensions of the earphone.
SUMMARY OF THE INVENTION
According to the invention from one aspect there is provided an earphone arrangement comprising an earphone housing having an elongate sound outlet port dimensioned and configured to locate into a listener's ear canal and bearing an external flange of resilient material thereon for intimate contact with said ear canal; the housing bearing, internally thereof, a support surface formed with an aperture there-through communicating with said outlet port; the arrangement further including a microspeaker supported on said support surface and located to project sound through said aperture and toward said outlet; the housing comprising a front cavity in front of said microspeaker and in communication with said outlet port and a rear cavity behind said microspeaker; said support surface being further formed with a recess therein communicating with said front cavity, said recess accommodating an acoustic resistor; wherein the microspeaker overlies at least a substantial part of said recess, and the arrangement further comprises a channel linking said front and rear cavities acoustically by way of said acoustic resistor.
By having the microspeaker overlay, at least to a substantial extent, the recess containing the acoustic resistor, the invention facilitates the provision of acoustically resistant couple between the first (front) and second (rear) cavities without significantly increasing the lateral dimensions of the earphone housing.
Preferably, the recess and the acoustic resistor therein are completely overlain by the microspeaker.
In some preferred embodiments of the invention, said channel comprises a first portion formed partly in the base of said recess underlying said acoustic resistor, and a second portion, substantially orthogonal to the first, running past an edge of said microspeaker and linking the first portion to the rear cavity.
In some such embodiments, the first portion of said channel is substantially linear, thereby minimising the overall length of the channel. In other preferred embodiments, the first portion of said channel is extended to follow an arcuate path beneath an edge of said microspeaker, thereby to extend the overall length of said channel.
Preferably, the microspeaker has a circular footprint on said support surface.
Preferably, the said aperture is circular in plan, and further preferably said recess and said acoustic resistor are also circular in plan. In other preferred embodiments, however, the recess and/or the acoustic resistor may be non-circular (e.g. square) in plan.
Preferably, the housing is apertured to provide a port venting said rear cavity to the ambient. Such a port may be fitted with an acoustic resistor.
In some preferred embodiments, the said venting port is located at a significant distance from an opening into the rear cavity of said second portion of the acoustic channel.
In preferred embodiments of the invention, the earphone arrangement is further provided with a microphone means for detecting ambient noise, and with electrical connections to and from an ambient noise cancelling device.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be clearly understood and readily carried into effect, embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings of which:
FIGS. 1 to 3 have already been referred to in relation to discussion of prior art, and show respectively:
in FIG. 1 , a cross-sectional view of a prior art earphone with a front-to-ambient acoustic couple;
in FIGS. 2( a ) and 2 ( b ), plan and cross-sectional views respectively of a typical acoustic resistance; and
in FIGS. 3( a ) and 3 ( b ), plan and cross-sectional views respectively of a prior art earphone arrangement with a front-to-rear acoustic couple;
FIGS. 4( a ) and 4 ( b ) show, in partially exploded cross-section and in plan views respectively, part of an earphone arrangement in accordance with one example of the invention;
FIG. 5 is similar to FIG. 4( a ), but shows the exploded components fully assembled;
FIGS. 6( a ), 6 ( b ) and 6 ( c ) show, all in similar perspective view, various stages in the assembly of the front portion of an earphone housing of the kind described with reference to FIGS. 4 and 5 ;
FIG. 7( a ) is a replication of FIG. 4( b ) for comparison with FIG. 7( b ), which shows a plan view of an arrangement in accordance with an aspect of the invention configured to provide an extended acoustic coupling channel; and
FIG. 8 shows, in cross-sectional view, an earphone arrangement in accordance with an example of the invention configured for use with an ambient noise-cancelling device.
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely examples and that the systems and methods described below 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 subject matter in virtually any appropriately detailed structure and function. Further, the terms and phrases used herein are not intended to be limiting, but rather, to provide an understandable description of the concepts.
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 “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.
One embodiment of the invention will now be described, by way of example only, with reference to FIGS. 4( a ) and 4 ( b ), FIG. 5 , and FIGS. 6( a ), 6 ( b ) and 6 ( c ), in all of which similar components are identified by the same reference numbers.
FIG. 4( a ) shows, in somewhat simplified form, an exploded cross-section through the front housing 50 of an earphone 52 in accordance with one example of the invention. FIG. 4( b ) shows the front housing 50 and its contents in plan view.
Referring now to FIG. 4( a ) the front housing 50 is formed with a substantially planar internal support surface 54 which is formed with a through-aperture 56 constituting an inner opening to an outlet port 58 in an elongate ear-canal extension 60 . A microspeaker 62 is located on the surface 54 , so as to project sound through the aperture 56 , and it is sealed onto the support surface 54 by means of a thin annular mounting ring 64 made from double-sided adhesive foam rubber. Typically, for example, the microspeaker 62 is 10 mm in diameter, and the adhesive mounting ring 64 has an outer diameter of 10 mm and an inner diameter of 7 mm.
The support surface 54 is also formed, beside the aperture 56 , with a recess 66 which underlies a portion of the microspeaker 62 and the base of the recess 66 is formed with, and acoustically coupled to, an upwardly-open, U-shaped channel 68 a , running underneath the ring 64 outwards to beyond the outermost edge of the ring 64 . This can best be seen in the plan-view of FIG. 4( b ), where the channel 68 a is shown in dashed outline. An acoustic resistor 70 is placed on a lip 66 a of the recess 66 , such that its central aperture 70 a overlies channel 68 a at its innermost end, and the adhesive ring 64 for mounting the microspeaker 62 partly overlies the outer edge of the resistor 70 and also the channel 68 a , thereby sealing and completing the channel structure. The outermost end of channel 68 a communicates directly with an orthogonal channel 68 b which is several millimeters in length. Channel 68 b is formed in and runs along the inside surface 72 of the rim of the front housing 50 , in an upward direction in relation to the orientation of FIG. 4( a ), and is bounded on its inner side in part by the outer rim of the microspeaker 62 and in part by the sealing/mounting ring 64 . At the upper end of the channel 68 b , i.e. at the top edge of the microspeaker 62 , the channel 68 b is exposed to the rear-volume of the earphone 52 , and this point can be considered to be the coupling port (channel 68 port) between the front and rear volumes.
A preferred method of assembly is as follows.
1. The acoustic resistor 70 is mounted in place on the lip 66 a of the recess 66 formed in the internal support surface 54 of the front housing 50 . 2. The annular, self-adhesive sealing ring 64 for mounting the microspeaker 62 is adhered to the internal support surface 54 of the front housing 50 . 3. The microspeaker 62 is aligned and located face-downwards on to the adhesive sealing ring 64 .
The entire operation takes only a few seconds, and forms reliable acoustic seals. It will be appreciated that a rear housing (not shown) is attached to the front housing 50 , similarly to the manner in which the prior art front and rear housings 16 and 18 , referenced earlier, were attached; and that the rear housing is provided with a vent, similar to the prior art vent 26 described earlier.
FIG. 5 shows, similarly to FIG. 4( a ) and with common numbering of components, the front-housing 50 of the earphone 52 after the assembly process. The uppermost face 74 of the acoustic resistor 70 is exposed to the air in the front volume 76 , forming a resistive acoustic couple between it and channel 68 a , which extends laterally underneath the microspeaker sealing ring 64 , and links directly with the orthogonal channel 68 b which opens into the rear volume (not shown) which lies to the rear of the microspeaker 62 . Hence, the air in the front volume 76 is acoustically coupled, via the acoustic resistor 70 and the channels 68 a and 68 b , to the air in the rear volume which, as mentioned above, is vented to the external ambient.
FIGS. 6( a ), 6 ( b ) and 6 ( c ) show similar perspective views looking into the front housing 50 at different stages of the assembly process described.
FIG. 6( a ) shows the front housing 50 ready for the addition of components as will be described. This view shows the shape and extent of the substantially flat support surface 54 , and it shows the location and relative sizes of the outlet port aperture 56 and the recess 66 for the acoustic resistor. In the base of recess 66 can be seen the channel 68 a . It can also be seen that, in practise, the front housing 50 is slightly non-circular, in that it is formed with a slight bulge as shown at 78 ; this being needed to accommodate the run of channel 68 b.
FIG. 6( b ) shows the front housing 50 as above, but with the acoustic resistor 70 in place and partially overlying the channel 68 a . FIG. 6( c ) shows the circular sealing ring 64 seated and adhering to the support surface 54 and ready to receive, support and seal in place the microspeaker 62 . It can be seen in this Figure that the ring 64 overlies most of the remainder of channel 68 a , in addition to overlying part of the acoustic resistor 70 , and that the channel 68 b runs past the rim of the ring 64 (and thus also past the rim of the microspeaker 62 when that is mounted on the ring 64 ).
In the example of the invention described above, the channel 68 a , 68 b has been shown with a minimal length. This is desirable, and preferred in many circumstances, because it minimises the acoustic inertance of the channel, which reduces any consequent resonant effects on the frequency response of the earphone.
However, a further aspect of the invention, valuable in its own right, is the capability of extending the length of the channel, thereby extending the acoustic path-length of the couple between the rear volume of the earphone and the listener's ear-canal. This facilitates the structured incorporation of a pre-determined time delay into the ambient-to-ear path, which the inventors have discovered can be particularly advantageous for ambient noise-cancelling applications.
FIGS. 7( a ) and 7 ( b ) illustrate this aspect of the invention; with FIG. 7( a ) corresponding directly to FIG. 4( b ) and FIG. 7( b ) showing an alternative embodiment with a channel of extended path-length. With reference to FIG. 7( a ), the acoustic path inwards from the surrounding ambient to the ear-canal begins at a rear vent (corresponding, for example, to that shown at 26 in FIG. 1) and traverses the rear volume of the earphone 52 to the opening into channel 68 b , then via channels 68 b and 68 a to and through the acoustic resistor 70 , and thence to the outlet port 58 and the listener's ear-canal. The effective path-length from the opening to channel 68 b to the outlet port 58 is thus equal to the length of channels 68 b and 68 a plus the resistor-to-outlet-port distance.
FIG. 7( b ) shows an alternative embodiment, in which the coupling channel, identified as channel 80 a and shown in dashed outline, has been lengthened by extending it around anticlockwise, underneath the microspeaker adhesive mounting ring 64 , in a one-quarter circumference arc. As before, the channel 80 a links directly to an orthogonal channel 80 b , running up the inside wall 72 of the housing 50 , but it will be appreciated that the exposed upper termination of channel 80 b is thus located in a different position compared to that of channel 68 b . It will also be appreciated that the bulge shown at 78 in FIGS. 6( a ), 6 ( b ) and 6 ( c ) and needed to accommodate the run of channel 80 b past the rims of the sealing ring 64 and the microspeaker 62 has to be moved through 90 degrees from the position shown in FIG. 6 . The inventors have discovered that it is advantageous to position the opening of channel 80 b as far as practicable from the rear-to-ambient vent 26 in the rear housing, in order to maximise the ambient-to-ear path length, and so it is good practise to locate the openings of channels 68 b and 80 b on the opposite side of the earphone 52 to the rear vent 26 .
In terms of absolute dimensions, those currently employed are based on a miniature, 10 mm diameter microspeaker 62 . The arc of channel 80 a is constructed on an 8 mm diameter circle, and, subtending an angle of 90°, its length is nominally 6.3 mm, which corresponds to a sound-wave propagation time of 18.3 μs. At a frequency of 1 kHz, a propagation delay of 18.3 μs corresponds to a phase delay of 6.6°. This arcuate path-length is incremental to the other propagation paths in the system.
The acoustic resistor 82 associated with the extended channel 80 a is shown in FIG. 7( b ) to be square-shaped in plan, merely to indicate that the shape of the acoustic resistor (and, of course, of the recess in which it is mounted) can, if desired, be varied without departing from the scope of the invention.
FIG. 8 shows a front-elevation section diagram of an ambient noise-cancelling earphone featuring an embodiment of the invention as described with reference to FIGS. 4 , 5 and 6 , and with the additional feature of a rear housing 84 containing an electret microphone 86 and having a rear vent 88 , bearing an acoustic resistor 90 , between the rear volume 92 and the external ambient. An important feature is that the rear-vent 88 is located on the opposite side of the rear housing 84 to the outlet of channel 68 b in order to maximise the ambient-to-ear-canal path length.
It will be appreciated by persons skilled in the art that the present disclosure is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope and spirit of the disclosure.
All references cited herein are expressly incorporated by reference in their entirety. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. There are many different features to the present disclosure and it is contemplated that these features may be used together or separately. Thus, the disclosure should not be limited to any particular combination of features or to a particular application of the disclosure. Further, it should be understood that variations and modifications within the spirit and scope of the disclosure might occur to those skilled in the art to which the disclosure pertains. Accordingly, all expedient modifications readily attainable by one versed in the art from the disclosure set forth herein that are within the scope and spirit of the present disclosure are to be included as further embodiments of the present disclosure.
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The present invention relates to earphone arrangements configured to accommodate an acoustically-resistant couple within the compact dimensions of ear-bud type earphones, and aims to incorporate a front volume to rear volume acoustic couple into an earphone without requiring significant addition to the lateral dimensions of the earphone. The earphone has an elongate sound outlet port that locates into a listener's ear canal and bears an internal support surface which is apertured and communicates with the outlet port. A microspeaker is supported on the support surface and projects sound through the aperture and toward the outlet port. Furthermore, the housing includes a front cavity in front of the microspeaker and in communication with the outlet port, and a rear cavity behind the microspeaker. The support surface bears a recess that communicates with the front cavity, and an acoustic resistor is accommodated in the recess.
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BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to electronic communications systems. More specifically this invention relates to data bandwidth management of electronic communications systems.
[0003] 2. Description of Related Art
[0004] A variety of schemes have been used to provide reliable and efficient transportation of streaming data across a network. Typically, these schemes employ techniques that assume fixed bandwidth such as selectable compression ratios, selectable video resolution, selectable video frame rates, selectable audio quality etc. In addition, generally these schemes are typically designed for controlling bandwidth between two nodes, and not multiple nodes within a network. Moreover, these schemes are not typically designed for dynamically controlling and managing bandwidth for multiple streaming devices across networks such as power line or wireless networks where network conditions are potentially constantly changing.
[0005] Although these references may not constitute prior art, for general background material, the reader is directed to the following United States Patent Documents each of which is hereby incorporated by reference in its entirety for the material contained therein: U.S. Patent and Patent Application No. 2003/0107648, 2003/0043908, 2003/0112335, 2003/0039390, 2002/0158991, 2002/0018450, U.S. Pat. Nos. 6 , 611 , 503 , 6 , 570 , 606 , 6 , 522 , 352 , 6 , 507 , 672 , 6 , 337 , 928 , 6 , 323 , 897 , 6 , 205 , 499 , 6 , 118 , 817 , 6 , 091 , 777 , 6 , 091 , 777 , 6 , 088 , 360 , 5 , 926 , 209 , 5 , 793 , 416 , 5 , 729 , 535 .
SUMMARY OF INVENTION
[0006] It is desirable to provide a system, for reliably sending streaming data across a network, which is efficient yet adaptable to changing network conditions.
[0007] Therefore it is the general object of an embodiment of this invention to provide a bandwidth management system and method for changing compression parameters between a network node and a master node based on network conditions.
[0008] It is an object of an embodiment of this invention to provide a bandwidth management system and method where data from one or more a data sources are compressed and/or the quality of the data source is changed based on network conditions from one or more network nodes and/or a master node.
[0009] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the network conditions cause compression parameters to change can be, but are not limited to obstructions, RF interference, changing network impedance, impedance mismatches, RF harmonics, multipath effects, various channel fading effects, network traffic volume, conducted noise, induced noise, self induced noise, friendly noise, intermodulation products, and the like.
[0010] It is a further object of an embodiment of this invention to provide a bandwidth management system and method for decompressing the data that was compressed by the compression module.
[0011] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the data source is a video source, an audio source, a computer data source, control data, a telephony source, and the like.
[0012] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where an attribute of a data source is controlled from a data interface where the attribute can be brightness, contrast, hue, white balance, saturation, luminance decimation filtering, n tap interpolation horizontal scaling, n tap interpolation vertical scaling, and the like.
[0013] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the protocols that are used can be RTSP, RTP, RTCP, HTTP, ASF, FTP, DDNS, NTP TFTP, TCP/IP, UDP, DHCP, DNS, SMTP, HTML, LDAP, SNMP and SNTP.
[0014] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where a motion detector is used to detect changes in a video source.
[0015] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the motion detector can use any of the following detection types: user determined, automatically learned, defined as geometric shapes, defined as non-geometric shapes, defined by regions, defined by object size, defined by object speed, defined by object micro movements, defined by object macro movements and the like.
[0016] It is a further object of an embodiment of this invention to provide access to a data source connected to a data interface where the data source can be a PAL composite, PAL component video, NTSC composite video, NTSC component video, S-video, serial, I 2 C, SPI, DVI, Digital Camera Interface, CCIR656, CCIR601, UTI656, UTI601, Parallel, and the like.
[0017] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where mass storage is used in a network node and/or master nodes to store off data from a data source based on network conditions.
[0018] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where network nodes and/or master nodes use a type of mass storage such as a hard disk, a flash memory, a random access memory, a floppy disk, and the like to store off data from a data source.
[0019] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the data source is encrypted as it is sent over a local and/or external network.
[0020] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the encryption can be DES, Triple DES, AES, RC4, RC5, 56 Bit, 64 Bit, 128 Bit, RSA, and the like.
[0021] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where network nodes and master nodes can be administered using a web server.
[0022] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where an application program uses data from a data source.
[0023] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where an external network is connected to the system for administering, viewing and/or listening to data sources.
[0024] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the external network can be the Internet, a Local Area Network (LAN), a Wide Area Network (WAN), and the like.
[0025] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the compression parameters are MJPEG, MPEG1, MPEG2, MPEG4, MPEG7, MPEG10, H.263, H.264, H.323, MP3, AC-3, wavelet compression, compression with post smoothing techniques, and the like.
[0026] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the local network is a power line network, a wireless network, an acoustic network, a wired network, an optic network and the like.
[0027] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where a device is connected to a master node which can be a personal computer, a telephone, an e-mail system, a monitor, a Digital Video Recorder, a PDA, and the like.
[0028] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where a device is connected to a master node via a residential gateway, which can be a personal computer, a telephone, an e-mail system, a monitor, a Digital Video Recorder, a PDA, and the like.
[0029] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where a signal is generated based on changes in the data source and where the signal is sent in the form of an e-mail, a text message, a voice message, a lighting control message, a video control message, a home control message, an audio control message, and the like.
[0030] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where a temperature is read from a temperature sensor from a master node.
[0031] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where changing of the compression parameters is based on a constant network load.
[0032] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the changing of the compression parameters is based on a constant media stream rate above a threshold.
[0033] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the changing of the compression parameters is based on a constant media stream rate above a threshold with intermediate streaming.
[0034] It is a further object of an embodiment of this invention to provide a bandwidth management system and method where the compression parameters are controlled in a network without a master node.
[0035] It is a further object of an embodiment of this invention to provide video camera system which changes compression rates based on network conditions.
[0036] It is a object of an embodiment of this invention to provide a data address controller system which allows users to authenticate and access data streams over an external network.
[0037] It is a further object of an embodiment of this invention to provide a data address controller system where the address controller contains a transaction system and/or a subscription system with a database for storing transaction and/or subscription information.
[0038] These and other objects of this invention will be readily apparent to those of ordinary skill in the art upon review of the following drawings, detailed description, and claims. In the preferred embodiment of this invention, the system and method makes use of a novel mechanism for detecting the required bandwidth for each data source on a network and dynamically changing the compression scheme/type and the parameters associated with compression such as such as compression ratios, video resolution, video frame rate, audio quality, applying a motion mask and/or motion detection, mass storage and/or buffering, and the like in relation to changing network characteristics. The result is better bandwidth management/data quality without user intervention as network conditions change.
BRIEF DESCRIPTION OF DRAWINGS
[0039] In order to show the manner that the above recited and other advantages and objects of the invention are obtained, a more particular description of the preferred embodiments of this invention, which is illustrated in the appended drawings, is described as follows. The reader should understand that the drawings depict only present preferred and best mode embodiments of the invention, and are not to be considered as limiting in scope. A brief description of the drawings is as follows:
[0040] FIG. 1 is a block diagram of the present preferred bandwidth allocation network with a network node and master node.
[0041] FIG. 2 is a block diagram of the present preferred bandwidth allocation network with two network nodes and a monitor connected to the master node.
[0042] FIG. 3 is a block diagram of the present preferred bandwidth allocation network with two network nodes and a personal computer with a master node.
[0043] FIG. 4 is a block diagram of the present preferred bandwidth allocation network with two network nodes which have multiple data sources, and a master node within a Digital Video Recorder (DVR) which communicates over an external network to an address controller and a PC.
[0044] FIG. 5 is a block diagram of the present preferred bandwidth allocation network with a Digital Video Recorder with a master node which controls a variety of data sources on a local network.
[0045] FIG. 6 is a block diagram of the present preferred bandwidth allocation network with multiple network nodes connected to multiple master nodes which controls various control systems within a network, and communicates over an external network to various devices and system including an address controller and a PC.
[0046] FIG. 7 is a flow diagram of the present preferred method of a master node allocating bandwidth with a constant network load.
[0047] FIG. 8 is a flow diagram of the present preferred method of a master node allocating bandwidth with a constant media stream rate above threshold.
[0048] FIG. 9 is a flow diagram of the present preferred method of allocating bandwidth with a constant media stream rate with no master node for allocating bandwidth.
[0049] FIG. 10 is a flow diagram of the present preferred method of a master node allocating bandwidth with a constant network load with possibility for intermittent streaming such as introduced by mass storage and/or motion detection.
[0050] FIG. 11 is a flow diagram of the present preferred method of a master node allocating bandwidth with a constant media stream rate above a threshold with the possibility of intermittent streaming such as introduced by mass storage and/or motion detection.
[0051] FIG. 12 is a flow diagram of the present preferred method of allocating bandwidth with a constant media stream rate with no master node for allocating bandwidth with the possibility of intermittent streaming such as introduced by mass storage and/or motion detection.
[0052] FIG. 13 is a flow diagram of the present preferred method of selecting a master node or control node configuration.
[0053] FIG. 14 is a flow diagram of the present preferred method of operating as a network node under control of a master node.
[0054] FIG. 15 is a block diagram of the present preferred bandwidth allocation network with two network nodes and a monitor connected to a Digital Video Recorder with an attached monitor.
[0055] FIG. 16 is a block diagram of the present preferred bandwidth allocation network with two network nodes and a Digital Video Recorder with a variety of locally attached devices with an external network connection.
[0056] FIG. 17 is a block diagram of the present preferred bandwidth allocation network with two network nodes, and a residential gateway which is connected to an address controller and a PC.
[0057] FIG. 18 is a flow diagram of the present preferred method of adding, authenticating and providing access to a bandwidth allocation system using an address controller.
[0058] Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings.
DETAILED DESCRIPTION
[0059] FIG. 1 is a block diagram of the present preferred bandwidth allocation network with a network node 104 and master node 118 . Data of various types such as a video source 108 which can be a video camera, digital camera and the like and/or an audio source 100 such as a microphone, MP3 player, and/or a control data 105 and the like is received by the network node 104 . The data from the audio source 100 and/or the video source 108 and/or the control data is input into the data interface 101 . The data interface 101 can accept data in any of a number of general, standard, and proprietary formats including but not limited to general purpose I/O (GPIO), general purpose parallel, general purpose serial, SPI, I 2 C, PAL composite, PAL component video, NTSC composite video, NTSC component video, S-video, DVI, various digital camera interfaces, CCIR656, CCIR601, UTI656, UTI601, and the like. The data interface 101 also passes data to the processing element 125 using any one of a variety of electrical and/or register, and/or DMA transfer, and/or semaphore transfer, formats. The processing element 125 performs the function of controlling the modules within the network node 104 including the data interface 101 , the compression module 103 , the motion detection module 102 , the encryption/decryption module 115 , the bandwidth adjustment module 133 , the web server module 122 , and the remote address client module 127 , each of which can be hardware or software based functions. The processing element 125 also servers to perform higher level control functions and protocols in communication with devices or elements connected to or networked to the network node 104 . The data interface module 101 is controlled by the processing element 125 and is used to select which data source(s) 100 , 105 , 108 will be processed. Other data sources such as computer data sources can also be fed into the data interface 101 . The processing element 125 , through the data interface 101 , can control the audio source 100 and/or the video source 108 including but not limited to such parameters as brightness, contrast, hue, saturation, luminance decimation filtering, white balance, horizontal interpolative scaling, vertical interpolative scaling, volume control, flow control. In addition, the processing element 125 can insert a time stamp or watermark into the data stream. The processing element 125 controls and formats the data communicated over a local network through the local network interface 107 , using but not limited to any one or more protocols such as RTSP, RTP, RTCP, HTTP, ASF, FTP, DDNS, NTP TFTP, TCP/IP, UDP, DHCP, DNS, SMTP, HTML, SNTP, LDAP, SNMP, and the like. For video data received from the data interface 101 and controlled by the processing element 125 , the compression module 103 can perform various forms of data compression which directly or effectively reduce the data rates such as the application of standard and/or non-standard algorithms and/or techniques similar in function to MJPEG, MPEG1, MPEG2, MPEG4, MPEG7, MPEG10, H.263, H.264, H.323, Windows Media Video 9 (WMv-9), wavelet compression, and compression with post smoothing techniques, or adjust any of a variety of parameters associated with the said algorithms or techniques, or adjust the video resolution of each video stream, or adjust the frame rate of each video stream, based on network bandwidth controlled through the bandwidth adjustment module 133 . In addition, the compression module 103 can be used to perform other effective compression techniques (reduction in data) such as change color content or color space parameters. For audio sources 100 , the compression module 103 can change the quality of the signal from the audio source 100 based on network bandwidth, compression rates, user input and the like. The data received from compression module 103 is processed by the processing element 125 . Video sources 108 , controlled and processed by the processing element 125 , are processed by any of several motion detection algorithms and/or techniques utilized by the motion detection module 102 to determine motion between frames and/or groups of frames. Motion detected by the motion detection module 102 can be compared to a motion mask such that certain predetermined changes can be ignored. The motion mask can be applied wherein the mask parameters can use one or more of the follow methods, user determined, automatically learned, defined as geometric shapes, defined as non-geometric shapes, defined by region, defined by object size, defined by object speed, defined by object micro movements, and defined by object macro, or the like. The motion detector 102 detects changes in the current video image and sends video data to be stored in mass storage 109 or mass storage 126 over the local network, or for viewing over the network, or for viewing over the external network, when motion has been detected. The sent video data can include a certain amount of data prior to or after the detected motion instead of the continuous video stream thereby reducing the amount of data sent from the video source 108 . A compression technique is selected by the compression module 103 . Data from both the video source 108 and/or the audio source 100 are compressed using the selected compression algorithm and/or combined techniques. The compression algorithm and/or combined techniques can be dynamically selected based on system needs. Different audio/video compression algorithms and/or techniques can be selected based on bandwidth requirements, user input, and the like. The data can be encrypted using the encryption/decryption module 115 . The encryption/decryption module 115 can support various types of encryption such as DES, Triple DES, RSA, PK1, RC4, RC5, AES, 128 bit, 64 bit, 56 bit, and the like. Different types of encryption or no encryption can be selected dynamically in the encryption/decryption module 115 if the system requires. The bandwidth adjustment module 133 is used to communicate over the network and allocate bandwidth based on network conditions such as, but not limited to RF interference, changing network impedance, impedance mismatches, RF harmonics, multipath effects, various channel fading effects, network traffic volume, conducted noise, induced noise, self induced noise, friendly noise, intermodulation products, and the like for the data streams from the video source 108 , the audio source 100 , and the control data 105 . If network and/or system conditions are such that it is not required or optimal to send data or based on other conditions including user options, the data can be temporarily stored in mass storage 109 . The types of encryption, compression, resolution, audio quality, data sources, and the like can be administered by input from the web server 122 or from the remote monitoring station 120 . The data streams 100 , 105 , 108 , can be networked to an address controller 131 which communicates with the remote address client 127 . The communication between the remote address client 127 and the address controller 131 constitute a service which administers IP addressing and other administrative information allowing users to securely access their data streams 100 , 105 , 108 remotely. The compressed and/or encrypted data from the video source 108 and/or audio source 100 is sent on a local network interface 107 and an antenna 106 , coupling device, over a wireless or wireless-like local network 110 . The master node 118 can be wholly or partially incorporated into a PC, a set top box, a residential gateway, a digital video recorder (DVR), a person video recorder, a video server, a living room PC, a networking device, or stand alone. The local network interface 107 , in conjunction with the processing element 125 and the bandwidth adjustment module 133 can sense network conditions on the local network 110 . The type of local network 110 can be, but is not limited to a wireless network, a power line network, a wired network, an optic network, an acoustic network, and the like. Generally, a power line network is a network over the AC power lines in a building, facility, home and the like. The data is received on a master node 118 at the antenna 111 or coupling device and the local network interface 112 . The local network interface 112 in conjunction with the processing element 124 and bandwidth adjustment module 132 , within the master node 118 can sense network conditions on the local network 110 . The processing element 124 performs the function of controlling and/or encompassing the modules within the master node 118 including the decompression module 114 , the encryption/decryption module 113 , the bandwidth adjustment module 132 , the web server module 121 , the remote address client module 128 , the application program 116 , the TV/monitor encoder 129 , and the external network interface 117 each of which can be hardware or software based functions. The processing element 124 also servers to perform higher level control functions and protocols in communication with devices or elements connected to or networked to the master node 118 . The processing element 124 controls and formats and receives data communicated over the local network similar and complimentary to the network node processing element 125 . Stream video and/or audio stream data received by the processing element 124 is decompressed using the decompression module 114 and algorithms and/or techniques similar to the compression module 103 . Transmitted/Received data processed through the process element can be encrypted/decrypted using the encryption/decryption module 113 . The bandwidth adjustment module 132 communicates over the local network to determine the needs of each of the data streams 105 , 100 , 108 and the data streams of other network nodes and how much bandwidth is available to each network node 104 to determine the proper compression parameters such as ratios, frame rates, compression types, and the like. The TV/Monitor encoder 129 can accept data from a video stream 108 and/or the mass storage 109 , 126 and display the information on the monitor 130 under control of the processing element 124 and/or under the control of the application program 116 . The application program 116 can perform as a digital video recorder (DVR) receiving or routing video data streams from any network node and/or to/from mass storage in conjunction the processing element 124 and other master node modules such as the decompression module 114 , the TV/monitor encoder 129 , and also receiving flags from the motion detection module 102 . The processing element 124 can send the data to the application program 116 and/or can send the data to mass storage 126 . The application program 116 in conjunction with the web server 121 and remote address client 128 , sends the data to the external network interface 117 , which sends the data over an external network 119 to a remote monitoring station 120 . The external network 119 can be, but is not limited to, the Internet, a Wide Area Network (WAN), a Local Area Network (LAN) and the like. The master node 118 can be administered by the web server 121 and/or the remote monitoring station 120 . Access to the data sources 105 , 100 , 108 , along with mass storage data can be accessed by the remote monitoring station in conjunction with the address controller 131 and the remote access client 128 . The address controller 131 is a service that allows users of the system to access and view the data streams 100 , 105 , 108 , or mass storage 109 , 126 , data over the external network 119 by communicating to the address controller 131 . The processing element 124 can communicate with and/or control and/or exchange data with an external unit 135 such as, but limited to, a set top box, an external DVR, and external processor, an external video processor, and the like. The processing element 124 can communicate with an expansion interface 134 which is connected to an expansion unit 135 . This allows other devices to be connected to the master node 118 .
[0060] FIG. 2 is a block diagram of the present preferred bandwidth allocation network with two network nodes 202 , 205 and a monitor 208 connected to the master node 207 . Data from an audio source 200 and a video source 201 are connected to a network node 202 which is connected to a local network 206 . Data from a second audio source 203 and a second video source 204 are connected to a second network node 205 which is connected to the local network 206 . Both network nodes 202 , 205 communicate over the local network 206 to a master node 207 . The master node 207 can also perform the same function as a network node 202 , 205 . The master node 207 controls how much bandwidth is allocated, the types of compression, the compression parameters, and the data rate reduction parameters, for all the data sources 200 , 201 , 203 , 204 based on the available bandwidth of the local network 206 , system settings, and user settings. The difference between a master node 207 and a network node 202 , 205 is that the master node 207 can control bandwidth for all data sources on the local network 206 , where the network node 202 , 205 can only control bandwidth for the data sources 200 , 201 , 203 , 204 , connected to the network node 202 , 205 . The data from the video and audio sources 200 , 201 , 203 , 204 are displayed/listened to on the monitor 208 . Although shown in this figure, with two network nodes, the concept of this invention is not limited thereto.
[0061] FIG. 3 is a block diagram of the present preferred bandwidth allocation network with two network nodes 302 , 305 and a personal computer with a master node 307 . Data from an audio source 300 and a video source 301 are connected to a network node 302 which is connected to a local network 306 . Data from a second audio source 303 , a second video source 304 , and control data 308 are connected to a second network node 305 which is connected to the local network 306 . Both network nodes 302 , 305 , communicate over the local network 306 to a master node inside of a personal computer 307 . The master node inside the personal computer 307 can also perform the same function as a network node 302 , 305 . The master node in the personal computer 307 controls how much bandwidth is allocated, the types of compression, and the compression parameters, and the data rate reduction parameters, for all the data sources 300 , 301 , 303 , 304 , 308 , based on the available bandwidth of the local network 306 , system settings, and user settings. The data from the video and audio sources 300 , 301 , 303 , 304 , 308 , can be displayed on the personal computer 307 .
[0062] FIG. 4 is a block diagram of the present preferred bandwidth allocation network with two network nodes 402 , 405 which have multiple data sources 400 , 401 , 403 , 404 , 410 , and a master node within a Digital Video Recorder (DVR) 409 which communicates over an external network 408 to an address controller 412 and a PC 407 as well as to a monitor 411 . Data from an audio source 400 and a video source 401 are connected to a network node 402 which is connected to a local network 406 . Data from a second audio source 403 , a second video source 404 and a data source 410 are connected to a second network node 405 which is connected to the local network 406 . Both network nodes 402 , 405 communicate over the local network 406 to a master node within a Digital Video Recorder (DVR) 409 . The master node in the DVR 409 can also perform the same function as a network node 402 , 405 . The master node in the DVR 409 controls how much bandwidth is allocated, the types of compression, the compression rates, compression parameters, and the data rate reduction parameters, for all the data sources 400 , 401 , 403 , 404 , 410 based on the available bandwidth of the local network 406 , system settings, and user settings. The data from the video, audio, and data sources 400 , 401 , 403 , 404 , 410 can be sent from the master node within the DVR 409 over the external network 408 to a personal computer 407 for viewing or storage. The data from the video, audio, and data sources 400 , 401 , 403 , 404 , 410 can also be sent to the monitor 411 in communication with the master node 409 . The digital video recorder 409 is preferably connected to a medium for storage of data from the data source 410 , the audio sources 400 , 403 , and the video sources 404 , 401 . The Address controller 412 is a service or process which allows users access to the data streams 400 , 401 , 403 , 404 , 410 over the external network 408 .
[0063] FIG. 5 is a block diagram of the present preferred bandwidth allocation network with a Digital Video Recorder 505 with a master node which controls a variety of data sources 500 , 501 , 502 , 503 on a local network 506 . Data from a variety of sources 500 , 501 , 502 , 503 is connected to a Digital Video Recorder with a master node 505 , which can be included a set top box located with a master node or a game box located with a master node or a living room personal computer with a master node so long as a DVR capability is present. The possible data sources include a set top box 500 , an audio source 501 , a video source 502 , and a digital camera 503 . The data from the data sources 500 , 501 , 502 , 503 , can be sent over the local network 506 to any master node 505 , 507 , 508 , 510 . The data from the data sources 500 , 501 , 502 , 503 , can be displayed on the monitors 504 , 509 , 511 , 508 .
[0064] FIG. 6 is a block diagram of the present preferred bandwidth allocation network with multiple network 602 , 605 nodes connected to multiple master nodes 621 , 622 , 610 , which controls various control systems within a network, and communicates over an external network 611 to various devices and systems including an address controller and a PC.
[0065] Data from an audio source 600 , a video source 601 , and control data 624 are connected to a network node 602 which is connected to a local network 606 . Data from a second audio source 603 and a second video source 604 are connected to a second network node 605 which is connected to the local network 606 . Both network nodes 602 , 605 communicate over the local network 606 to a residential gateway with a master node 631 . The residential gateway with the master node 631 controls how much bandwidth is allocated, the types of compression, the compression rates, the compression parameters, and the data rate reduction parameters, for all the data sources 600 , 601 , 603 , 604 , 624 , based on the available bandwidth of the local network 606 , system settings, and user settings. Data from a second master node 621 which has an attached monitor 616 can be used to monitor the data from the data streams 600 , 601 , 603 , 604 , 624 . A Digital Video Recorder with a master node 622 also has an attached monitor 617 . The Digital Video Recorder with a master node 622 receives input from a set top box 618 , an audio source 619 , and a video source 620 . The residential gateway with a master node 631 controls the flow of data from the data sources 600 , 601 , 603 , 604 , 624 , 618 , 619 , 620 , connected to each network node 602 , 605 , 622 , 621 , to the personal computer 613 or Personal Digital Assistant 632 which is connected to the residential gateway with a master node 631 over an external network 611 . Administration of network nodes and receipt of the data streams 600 , 601 , 603 , 604 , 624 , 618 , 619 , 620 , can also be received on the locally attached personal computer 610 or on the locally attached Personal Digital Assistant (PDA) 630 . The external network 611 can be, but is not limited to the Internet, a Wide Area Network (WAN), a Local Area Network (LAN) and the like. The residential gateway with a master node 631 is also responsible for controlling other control systems which are attached to the local power line network 606 . Control systems such as lighting systems 607 , temperature sensors 608 , audible devices 609 such as speakers, bells, chimes and the like are connected to the local network 606 . The local network 606 may be a power line network. The residential gateway with a master node 631 can detect changes from a video source 601 , 604 , 620 and/or an audio source 600 , 603 , 619 , and turn on an audio device 609 and/or a lighting system 607 with an audio control signal or a lighting control signal. Input from a temperature sensor 608 can be used to detect and/or change the view of a video source 601 , 604 , in order to observe fire, water damage, or other conditions. When the residential gateway with a master node 631 detects changes in data from a video source 601 , 604 , an e-mail, can be sent over the external network 611 to an e-mail system 612 and/or e-mail recipient. The e-mail can also be sent over the local network 606 to an e-mail system attached to the local network 606 . Voice messages, text messages, can be sent from the residential gateway with a master node 631 over the external network 611 to a telephone/cell phone 614 based on conditions that occur on devices 600 , 601 , 602 , 603 , 604 , 605 , 607 , 608 , 609 , 610 , 630 , 631 , 618 , 619 , 620 , on local network 606 . Alerts or other information can also be sent from the residential gateway with a master node 631 over the external network 611 to the personal computer 613 . An address controller 623 is used to coordinate addressing in so that users can view/listen to the data streams/audio streams from the data sources 600 , 601 , 603 , 604 , 624 , 618 , 619 , 620 , over the external network 611 .
[0066] FIG. 7 is a flow diagram of the present preferred method of a master node allocating bandwidth with a constant network load. The process begins when the identity of the network nodes are determined 700 on the local network. The total available local network throughput capacity is determined 701 typically, though not exclusively by subtracting the overhead required to perform non-media streaming functions within the network from 100%. The network nodes capable of media streaming are identified 702 . Of those network nodes capable of media streaming, the network nodes which currently require local network bandwidth are identified 703 . Throughput capacity is measured 704 for each active media streaming connection. The throughput allocation (percentage of total network bandwidth) is determined 705 for each connection typically, though not exclusively by dividing total available network capacity by the number of active media streaming connections. The stream rate allocation is determined 706 for each active media streaming connection typically, though not exclusively by multiplying throughput allocation available to each connection (percentage) times throughput capacity from each connection times the network load compensation factor. The compensation factor is used to account for changes in available bandwidth within the network. The process checks 707 to see if it is time to look for changes in the connection throughput capacity. If it is time to check 707 for changes in the connection throughput capacity, the process measures 704 the throughput capacity for each active media streaming connection. Otherwise, if test 707 is no, the process checks 708 to see if it is time to look for changes in streaming media demand. If it is time to check 708 for changes in streaming media demand, the process identifies 703 the network nodes capable of media streaming which require local network bandwidth. Otherwise, if test 708 is no, the process checks 709 to see if it is time to look for changes in streaming media device configuration. If it is time to look for changes, the process identifies 702 those networks nodes capable of media streaming. If test 709 is no, the process checks 710 to see if it is time to look for changes in the local network configuration. If changes in the local network configuration need to be made in test 710 , the process identifies 700 all network nodes on the local network. Otherwise, if it is not time to look for changes in the local network configuration in test 710 , the process checks 707 to see if it is time to look for changes in connection throughput capacity. In alternative embodiments the calculations used in the various process determinations may be varied without departing from the concept of this invention. Although these steps are preformed in the designated order in the present embodiments, in alternative envisioned embodiments of this invention, the ordering of the steps can be varied significantly without departing from the concept of this invention.
[0067] FIG. 8 is a flow diagram of the present preferred method of a master node allocating bandwidth with a constant media stream rate above a threshold. The process begins when the identity of the network nodes are determined 800 on the local network. The total available local network throughput capacity is determined 801 typically, but not exclusively by subtracting the overhead required to perform non-media streaming functions within the network from 100%. The network nodes capable of media streaming are identified 802 . Of those network nodes capable of media streaming, the network nodes which currently require local network bandwidth are identified 803 . Throughput capacity is measured 804 for each active media streaming connection. The process allocates 805 a predetermined stream rate to each active streaming connection whose measured throughput capacity is above a predetermined threshold. The process presently allocates 806 the remaining available network throughput capacity evenly among all active streaming connections whose measured throughput capacity is below a predetermined threshold. In alternative embodiments, the allocation network capacity need not be evenly divided among connections. The process checks 807 to see if it is time to look for changes in the connection throughput capacity. If it is time to check 807 for changes in the connection throughput capacity, the process measures 804 the throughput capacity for each active media streaming connection. Otherwise, if test 807 is no, the process checks 808 to see if it is time to look for changes in streaming media demand. If it is time to check 808 for changes in streaming media demand, the process identifies 803 the network nodes capable of media streaming which require local network bandwidth. Otherwise, if test 808 is no, the process checks 809 to see if it is time to look for changes in streaming media device configuration. If it is time to look for changes in the streaming media device configuration, the process identifies 802 those networks nodes capable of media streaming. Otherwise, if test 809 is no, the process checks 810 to see if it is time to look for changes in the local network configuration. If changes in the local network configuration need to be made in test 810 , the process identifies 800 all network nodes on the local network. Otherwise, if it is not time to look for changes in the local network configuration in test 810 , the process checks 807 to see if it is time to look for changes in connection throughput capacity. In alternative embodiments the calculations used in the various process determinations may be varied without departing from the concept of this invention. Although these steps are preformed in the designated order in the present embodiments, in alternative envisioned embodiments of this invention, the ordering of the steps can be varied significantly without departing from the concept of this invention.
[0068] FIG. 9 is a flow diagram of the present preferred method of allocating bandwidth with a constant media stream rate with no master node for allocating bandwidth. The process begins when the network nodes are identified 900 which are capable of media streaming on the local network. The throughput capacity is measured 901 for immediate connections to other network nodes configured to accept streaming media. The process identifies 902 which streaming connections require local network bandwidth. The predetermined stream rate(s) are allocated 903 to each streaming connection whose measured throughput capacity is above a predetermined threshold or thresholds. The predetermined stream rate(s) are allocated 904 to each active streaming connection whose measured throughput capacity is below a predetermined threshold or thresholds. The process checks 907 to see if it is time to look for changes in the demand for streaming media. If it is time to look for changes in the demand for streaming media in test 907 , the process identifies 902 which active streaming media connections require local network bandwidth. Otherwise, if test 907 is no, the process checks 906 to see if it is time to look for changes in connection throughput capacity. If it is time to look for changes in connection throughput capacity in test 906 , the process measures 901 the throughput capacity for immediate connection to other network nodes configured to accept streaming media. Otherwise, if test 906 is no, the process checks 905 to see if it is time to look for changes in the streaming media network node configuration. If it is time to look for changes in the streaming media network node configuration in test 905 , the process identifies 900 those immediate network nodes capable of media steaming on the local network. Otherwise, if test 905 is no, the process checks 907 to see if it is time to look for changes in streaming media demand. In alternative embodiments the calculations used in the various process determinations may be varied without departing from the concept of this invention. Although these steps are preformed in the designated order in the present embodiments, in alternative envisioned embodiments of this invention, the ordering of the steps can be varied significantly without departing from the concept of this invention.
[0069] FIG. 10 is a flow diagram of the present preferred method of a master node allocating bandwidth with a constant network load with possibility for intermittent streaming such as introduced by mass storage and/or motion detection. The process begins by identifying 1000 all network nodes on the local network. The total available local network throughput (the percentage available for media streaming) is determined 1001 presently, but not exclusively by subtracting the overhead required to perform non-media streaming functions within the local network from 100%. The network nodes capable of media streaming are identified 1002 . Of the network nodes capable of media streaming the process identifies 1003 which network nodes currently require local network bandwidth for active media streaming connections. The process measures 1004 throughput capacity for each active media streaming connection. The process checks 1005 to see if motion detection is selected and inactive at one or more video sources. This check 1005 is to see if the video stream has to be a constant stream. The present preferred embodiment checks for video sources, but can also check for audio or data sources and the like to see if the sources can handle non-constant rates. If motion detection is selected and inactive at one or more video sources in test 1005 , the process determines 1009 the throughput allocation for each connection in the current embodiment by dividing total available local network capacity by the number of active media streaming connections. The process determines 1010 the stream rate allocation for each active media streaming connection in the current embodiment by multiplying the throughput allocation available to each connection times the throughput capacity from each connection times one of several alternate network load compensation factors. Otherwise, if test 1005 is no, the process checks 1006 to see if mass storage is available and utilized at one or more video sources. If mass storage is available and utilized at one or more video sources in test 1006 , the process determines 1009 the throughput allocation for each connection in the current embodiment by dividing total available local network capacity by the number of active media streaming connections. The process determines 1010 the stream rate allocation for each active media streaming connection in the current embodiment by multiplying the throughput allocation available to each connection times the throughput capacity from each connection times one of several alternate network load compensation factors. Otherwise, if test 1006 is no, the process determines 1007 the throughput allocation for each connection in the current embodiment by dividing total available local network capacity by the number of active media streaming connections. The process determines 1008 the stream rate allocation for each active media streaming connection in the current embodiment by multiplying the throughput allocation available to each connection times the throughput capacity from each connection times the network load compensation factor. Test 1011 checks to see if it is time to look for changes in connection throughput capacity. If changes in the throughput capacity are required in test 1011 , the process measures 1004 through put capacity for each active media streaming connection. Otherwise, if test 1011 is no, the process checks 1012 to see if it is time to look for changes in the streaming media demand. If there are changes in the streaming media demand in test 1012 , the process determines 1003 which of the network nodes currently require local network bandwidth. Otherwise, if test 1012 is no, the process checks 1013 to see if it is time to look for changes in streaming media network node configuration. If there are changes in the streaming media network node configuration in test 1013 , the process identifies 1002 those network nodes capable of media streaming. Otherwise, if test 1013 is no, the process checks 1014 to see if it is time to look for changes in the local network configuration. If there are changes in the local network configuration in test 1014 , the process identifies 1000 all the network nodes on the local network. Otherwise, if test 1014 is no, the process checks 1011 to see if it is time to look for changes in the connection throughput capacity. In alternative embodiments the calculations used in the various process determinations may be varied without departing from the concept of this invention. Although these steps are preformed in the designated order in the present embodiments, in alternative envisioned embodiments of this invention, the ordering of the steps can be varied significantly without departing from the concept of this invention.
[0070] FIG. 11 is a flow diagram of the present preferred method of a master node allocating bandwidth with a constant media stream rate above a threshold with the possibility of intermittent streaming as introduced by mass storage and/or motion detection. The process begins by identifying 1100 all network nodes on the local network. The total available local network throughput (the percentage available for media streaming) capacity is determined 1101 in the current embodiment by subtracting the overhead required to perform non-media streaming functions within the local network from 100%. The network nodes capable of media streaming are identified 1102 . Of the network nodes capable of media streaming the process identifies 1103 which network nodes currently require local network bandwidth for active media streaming connections. The process measures 1104 throughput capacity for each active media streaming connection. The process checks 1105 to see if motion detection is selected and inactive at one or more video sources. This check 1105 is to see if the video stream has to be a constant stream. The present preferred embodiment checks for video sources, but can also check for audio or data sources and the like to see if the sources can handle non-constant rates. If motion detection is selected and inactive at one or more video sources in test 1105 , the process allocates 1109 one of many alternate predetermined stream rates to each active streaming connection whose measured throughput capacity is above one of many alternate predetermined thresholds. The process allocates 1110 the remaining available local network throughput capacity divided approximately evenly in this embodiment among all active streaming connections whose measured throughput capacity is below one of many alternate predetermined thresholds. Otherwise, if test 1105 is no, the process checks 1106 to see if mass storage is available and utilized at one or more video sources. If mass storage is available and utilized at one or more video sources in test 1106 , the process allocates 1109 one of many alternate predetermined stream rates to each active streaming connection whose measured throughput capacity is above one of many alternate predetermined thresholds. The process allocates 1110 the remaining available network throughput capacity divided among all active streaming connections whose measured throughput capacity is below one of many alternate predetermined thresholds. If test 1106 is no, the process allocates 1107 the predetermined stream rate to each active streaming connection whose measured throughput capacity is above a predetermined threshold. The process allocates 1108 the remaining available local network throughput capacity divided among all active streaming connections whose measured throughput capacity is below a predetermined threshold. Test 1111 checks to see if it is time to look for changes in connection throughput capacity. If changes in the throughput capacity are required in test 1111 , the process measures 1104 throughput capacity for each active media streaming connection. Otherwise, if test 1111 is no, the process checks 1112 to see if it is time to look for changes in the streaming media demand. If there are changes in the streaming media demand in test 1112 , the process determines 1103 which of the network nodes are capable of media streaming and which currently require local network bandwidth. Otherwise, if test 1112 is no, the process checks 1113 to see if it is time to look for changes in streaming media network node configuration. If there are changes in the streaming media network node configuration in test 1113 , the process identifies 1102 those network nodes capable of media streaming. Otherwise, if test 1113 is no, the process checks 1114 to see if it is time to look for changes in the local network configuration. If there are changes in the local network configuration in test 1114 , the process identifies 1100 all the network nodes on the local network. Otherwise, if test 1114 is no, the process checks 1111 to see if it is time to look for changes in the connection throughput capacity. In alternative embodiments the calculations used in the various process determinations may be varied without departing from the concept of this invention. Although these steps are preformed in the designated order in the present embodiments, in alternative envisioned embodiments of this invention, the ordering of the steps can be varied significantly without departing from the concept of this invention.
[0071] FIG. 12 is a flow diagram of the present preferred method of allocating bandwidth with a constant media stream rate with no master node for allocating bandwidth with the possibility of intermittent streaming as introduced by mass storage and/or motion detection. The process begins by identifying 1200 those network nodes capable of media streaming on the local network. Throughput capacity is measured 1201 for immediate connections to other network nodes configured to accept streaming media. The connections which require local network bandwidth are identified 1202 . Test 1203 determines if motion detection is selected and inactive at one or more video sources. If motion detection is selected and inactive at one or more video sources in test 1203 , the process allocates 1207 , one of many predetermined alternate stream rates to each active streaming connection who measured throughput capacity is above one of many predetermined alternate thresholds. The process allocates 1208 one of many alternate predetermined stream rates to each active streaming connection whose measured throughput capacity is below one of many alternate predetermined thresholds. Otherwise, if test 1203 is no, the process checks 1204 to see if mass storage is available and utilized at one or more video sources. If mass storage is available and utilized at one or more video sources in test 1204 , the process allocates 1207 , one of many predetermined alternate stream rates to each active streaming connection who measured throughput capacity is above one of many predetermined alternate thresholds. The process allocates 1208 one of many alternate predetermined stream rates to each active streaming connection whose measured throughput capacity is below one of many alternate predetermined thresholds. Otherwise, if test 1204 is no, the process allocates 1205 predetermined stream rate(s) to each active streaming connection whose measured throughput capacity is above a predetermined threshold(s). The process allocates 1206 predetermined stream rate(s) to each active streaming connection whose measured throughput capacity is below a predetermined threshold(s). The process checks 1209 to see if it is time to look for changes in the streaming media demand. If there is a change in the streaming video demand in test 1209 , the process identifies 1202 which connections require local network bandwidth. If test 1209 is no, the process checks 1210 to see if it is time to look for changes in connection throughput capacity. If there are changes in throughput capacity in test 1210 the process measures 1201 the throughput capacity for immediate connection to other network nodes configured to accept streaming media. Otherwise if test 1210 is no, the process checks 1211 to see if it is time to look for changes in streaming media network node configuration. If there are changes in the streaming media network node configuration in test 1211 , the process identifies 1200 those immediate network nodes capable of media streaming on the local network. Otherwise, if test 1211 is no, the process checks 1209 to see if it is time to look for changes in streaming media demand. In alternative embodiments the calculations used in the various process determinations may be varied without departing from the concept of this invention. Although these steps are preformed in the designated order in the present embodiments, in alternative envisioned embodiments of this invention, the ordering of the steps can be varied significantly without departing from the concept of this invention.
[0072] FIG. 13 is a flow diagram of the present preferred method of selecting a master node or control node configuration. The process begins when a network node which is capable of being a master node looks 1300 for a network message identifying another master node. If there is a message from another master node in test 1300 , the process checks 1301 to see if the other master node is a lower ranking device. If the other master device is a lower ranking device in test 1301 , the master node configures 1302 or stays configured as a master node. The master node operates 1303 as a master node. The master node periodically sends 1304 a message identifying the master node as a master node. The master node checks 1305 to see if it is time to look for a network message identifying another master node. If a network message is not identified in test 1305 , the process operates 1303 as a master node. Otherwise, if test 1305 is yes, the process looks 1300 for a network message identifying another master node. If there is no network message from another master node in test 1300 , the process checks 1306 to see if the local device identifier prohibits the node from being a master node. If no, the network node configures 1302 or stays configured as a master node. If test 1306 is yes, the network node configures 1307 itself to operate as a network node in a system without a master node. The network nodes 1308 operate as a network node in a system without a master node. The network node checks 1309 to see if it is time to look for a network message identifying a master node. If it is not time to look for a network message identifying a master node in test 1309 , the network node operates 1308 as a network node in a system without a master node. Otherwise, if test 1309 is yes, the network node looks 1300 for a network message identifying a master node. If there is not another master node that is lower ranking in test 1301 , the master node configures 1310 itself as a slave master node. The slave master node operates 1311 as a slave master node. The slave master node checks 1312 to see if it is time to look for a network message identifying another master node. If it is not time to look for a network message identifying another master node in test 1312 , the slave master node continues to operate 1311 as a slave master node. Otherwise, if test 1312 is yes, the process looks 1300 for a network message identifying another master node. Although these steps are preformed in the designated order in the present embodiments, in alternative envisioned embodiments of this invention, the ordering of the steps can be varied significantly without departing from the concept of this invention.
[0073] FIG. 14 is a flow diagram of the present preferred method of operating as a network node under control of a master node. The process begins when the network node receives a query message from the master control node or peer node if there is no master node in the network. If so, the network node responds 1400 to the master node or peer and identifies the slave master node's device type and identifier. The network node or slave master node communicates 1401 with the master node or peer to convey the configuration and channel requirement information. This includes, but is not limited to motion detection status, audio/video configuration information, audio/video streaming status, and the like. The network node communicates 1402 with the master node or peer node to participate in measuring connection throughput capacity. The network node 1404 checks to see if there is new bandwidth allocation information from the master node or peer node. If there is new information from the master node or peer node in test 1404 , the local process is controlled 1405 to update data rate requirements to fit such information as some or all of the following: channel allocation, resolution, compression ratio, associated parameters, frame rate, and the like. The network node checks 1400 if a query message was received from a master node or peer note and responds if a message was received with the network node's device type and identifier. Otherwise, if test 1404 is no, the network node checks 1400 if a query message was received from a master node or peer note and responds if a message was received with the network node's device type and identifier. In alternative embodiments the calculations used in the various process determinations may be varied without departing from the concept of this invention. Although these steps are preformed in the designated order in the present embodiments, in alternative envisioned embodiments of this invention, the ordering of the steps can be varied significantly without departing from the concept of this invention.
[0074] FIG. 15 is a block diagram of the present preferred bandwidth allocation network with two network nodes 1502 , 1506 and a monitor 1509 connected to a Digital Video Recorder 1508 . Data from an audio source 1500 and a video source 1501 are connected to a network node 1502 which is connected to a local network 1507 . Data from a second audio source 1503 , a second video source 1504 and a control data source 1505 are connected to a second network node 1506 which is connected to the local network 1507 . Both network nodes 1502 , 1506 communicate over the local network 1507 to a master node with a Digital Video Recorder (DVR) 1508 . The master node with DVR 1508 can also perform the same function as a network node 1502 , 1506 . The master node with the DVR 1508 controls such parameters as how much bandwidth is allocated, the types of compression, and the compression rates, compression parameters, and data rate reduction parameters, associated with all the data sources 1500 , 1501 , 1503 , 1504 , 1505 based on the available bandwidth of the local network 1507 , system settings, and user settings. The data from the video, audio, and data sources 1500 , 1501 , 1503 , 1504 , and 1505 is sent from the master node with the DVR 1508 to the monitor 1509 and/or the DVR 1508 for storage.
[0075] FIG. 16 is a block diagram of the present preferred bandwidth allocation network with two network nodes 1602 , 1606 and a Digital Video Recorder 1613 with a variety of locally attached devices with an external network connection. Data from an audio source 1600 and a video source 1601 are connected to a network node 1602 which is connected to a local network 1607 . Data from a second audio source 1603 , a second video source 1604 and a control data source 1605 are connected to a second network node 1606 which is connected to the local network 1607 . Both network nodes 1602 , 1606 communicate over the local network 1607 to a master node with a Digital Video Recorder (DVR) 1613 . The master node with the DVR 1613 can also perform the same function as a network node 1602 , 1606 . The master node with the DVR 1613 is connected to a third video source 1609 , a third audio source 1610 , and a set top box 1611 . The master node with the DVR 1613 controls such parameters as how much bandwidth is allocated, the types of compression, and the compression rates, compression parameters, and data rate reduction parameters, for all the data sources 1600 , 1601 , 1603 , 1604 , 1605 , 1609 , 1610 , 1611 , based on the available bandwidth of the local network 1607 , system settings, and user settings. A monitor 1612 is connected to the master node with the DVR 1613 . The monitor 1612 is used to view data from the data sources 1600 , 1601 , 1603 , 1604 , 1605 , 1609 , 1610 , 1611 , and/or configure the master node with the DVR 1613 . The data from the video, audio, and data sources 1600 , 1601 , 1603 , 1604 , 1605 , 1609 , 11610 , 1611 , is sent from the master node with the DVR 1613 to the monitor 1509 and/or the DVR 1508 for storage. In addition, the data from the data streams 1600 , 1601 , 1603 , 1604 , 1605 , 1609 , 1610 , 1611 , can be sent to the personal computer 1615 over the external network 1614 and/or the address controller 1515 which is used to coordinate addressing for remote monitoring.
[0076] FIG. 17 is a block diagram of the present preferred bandwidth allocation network with two network nodes 1702 , 1705 , and a residential gateway with a master node 1707 which is connected to an address controller 1715 and a PC 1709 . The residential gateway with a master node 1707 can be stand alone, contained within a PC in part or whole, or contained within a DVR in part or whole. Data from an audio source 1700 and a video source 1701 are connected to a network node 1702 which is connected to a local network 1706 . Data from a second audio source 1703 , a second video source 1704 are connected to a second network node 1705 which is connected to the local network 1706 . Both network nodes 1702 , 1705 communicate over the local network 1706 to a master node with a residential gateway 1707 . The master node with the residential gateway 1707 can also perform the same function as a network node 1702 , 1705 . The master node with the residential gateway 1707 controls such parameters as how much bandwidth is allocated, the types of compression, and the compression rates, compression parameters, and data rate reduction parameters, for all the data sources 1700 , 1701 , 1703 , 1704 , based on the available bandwidth of the local network 1706 , system settings, and user settings. The data from the video and audio sources 1700 , 1701 , 1703 , 1704 , can be sent from the master node with the residential gateway 1707 to the personal computer 1709 over the external network 1708 . In addition, the data from the data streams 1700 , 1701 , 1703 , 1704 , to a remote monitoring station coordinated by the address controller 1715 . The address controller 1715 includes server 1710 that contains an authentication service 1713 which allows users to authenticate and gain access to the data sources 1700 , 1701 , 1703 , and 1704 . The address controller 1715 also includes a transaction service 1712 for tracking access from users who have logged in using the authentication service 1713 . The transaction service 1712 is used to enable and/or bill the users who have logged on a per access and/or time basis. The subscription service 1711 is used to facilitate remote user connections, protect remote users and/or bill users based on a periodic rate such as monthly rate, a weekly rate, a yearly rate, and the like. If a user has subscribed using the subscription service 1711 , users are granted access if their accounts are valid and/or subscriptions are paid. Information for the authentication service 1713 , the transaction service 1712 , and the subscription service 1711 are stored in the database 1714 . A user can authenticate to the address controller 1715 from a personal computer 1709 by providing a password and master node identifier. Once user credentials are validated, a connection to the residential gateway with a master node 1707 is made using the user supplied credentials. The connections to and from the address controller 1715 can be encrypted to ensure security on the external network 1708 . The user which has requested access from the personal computer 1707 can now view and/or listen to the information from the data streams 1700 , 1701 , 1703 , and 1704 . Information obtained from the transaction service 1712 and/or the subscription service 1711 is used to provide statistics and/or billing information and/or protection and/or convenience for the users and/or administrators of the address service.
[0077] FIG. 18 is a flow diagram of the present preferred method of adding, authenticating and providing access to a bandwidth allocation system using an address controller. The process begins when a user accesses 1800 the address controller 1715 web site. The user is asked 1801 if they want to login or sign up for the address service 1715 . If the user is signing up for the address service 1715 in test 1801 , the user enters 1805 the user's information which may include some or all of, general information, password, identifier, and if the service is a paid subscription service credit card information. The password and identifier are supplied to the user who qualifies for the service with an appropriate master node 1707 . The authentication service 1713 checks 1806 to make sure the user's information are filled out and valid. If the information is not valid in test 1806 , the authentication service 1713 displays an error message 1814 and requests 1801 the user to login or sign up. Otherwise, if test 1806 is yes, the authentication service 1713 determines 1807 if the password and Identifier are valid. The password and the gateway identifier and stored in the database 1714 and compared with the password and identifier from the gateway when it becomes active on the external network 1708 . If the password and identifier are not valid in test 1807 , the authentication service 1713 displays 1814 an error message and requests 1801 the user to login or sign up. Otherwise, if test 1807 is yes, the authentication service 1713 stores 1808 the user information, password, and Identifier in the database 1714 . The process determines 1809 if the user is using a subscription service 1711 or a transaction service 1712 . If the user is using a transaction service 1712 , the transaction service 1712 tracks the time, number of accesses, and stores the information in the database 1714 . Otherwise, if the user is using a subscription service 1711 , the subscription service 1711 logs the access and stores the information in the database 1714 . The process enables and/or facilitates a connection to the residential gateway with master node and/or network node or nodes, 1707 1702 , 1705 using the password and identifier for access 1812 . If the address controller 1715 cannot connect to the residential gateway with master node 1707 , the process displays an error message 1814 and requests 1801 the user to login or sign up. Otherwise, if test 1815 is successful, the process notifies 1813 the user of access to the residential gateway with the master node 1707 and can view/listen to the data streams from the data sources 1700 , 1701 , 1703 , and 1704 . If the user has already signed up and is just wants to log in to the address controller 1715 , in test 1801 , the authentication service 1713 requests the user to enter 1802 the password and identifier. The authentication service 1713 checks 1803 for a valid account. If the account is not valid in test 1803 , the authentication service 1703 displays an error message 1820 and requests 1801 the user to login or signup. Otherwise, if test 1803 is yes, the authentication service 1713 checks 1804 for a valid password and identifier. If the password and/or the identifier are invalid in test 1804 , the authentication service 1713 , displays an error message 1820 and requests 1801 the user to login or signup. Otherwise, if test 1804 is yes the process checks 1809 to see if the user selected a subscription service 1711 or a transaction service 1712 .
[0078] In addition, these bandwidth allocation methods can be implemented using a variety of process, but are not limited to computer hardware, microcode, firmware, software, and the like.
[0079] The described embodiments of this invention are to be considered in all respects only as illustrative and not as restrictive. Although specific flow diagrams system diagrams are provided, the invention is not limited thereto. The scope of this invention is, therefore, indicated by the claims rather than the foregoing description. All changes, which come within the meaning and range of equivalency of the claims, are to be embraced within their scope.
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A data networking system and method which allows efficient use of bandwidth for data streams such as video and audio. This invention allows network nodes to dynamically identify changing network conditions which are typical on wireless and power line networks. The system and method dynamically adapt to the changes which affect network bandwidth by changing compression rates, compression types, audio/video quality, motion masks, throughput for specific connections, or mass storage of data streams until the network is capable of sending the data. The result is an improved system that requires little or no user intervention as network conditions change.
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FIELD OF THE INVENTION
[0001] The present invention relates to games and, more particularly, to a puzzle game intended to stimulate and enchant the participants.
BACKGROUND OF THE INVENTION
[0002] Sociologically, families in developed countries are becoming less and less interdependent. Families are geographically distributed and, in many cases, the relationships akin to ‘families’ and ‘relatives’ have diverged from the traditional definitions of relationships by blood or marriage. Moreover, given the degree of affluence in developed countries, it has become more and more expensive to make a favorable impression with a gift. There is a need for mechanisms to (a) foster participation in gift giving by family members who may be geographically dispersed; (b) distribute the cost of the gift giving over a large number of family members, relatives and friends; and (c) regardless of the tangible or intangible nature of the gift, to foster enchantment for the gift recipient through the presentation of a surrogate gift. The present invention addresses all aspects of surrogate gift giving.
[0003] Prior art shows puzzles, gifts, toys, gift and occasion cards, and even customization of such items. However there is no prior art or articles of manufacture that bring all of the recited elements into a single unified article of manufacture.
[0004] One object of the invention is to bring all of the elements of surrogate gift giving into a single article of manufacture.
[0005] Another object of the invention is to facilitate the gifting of a surrogate gift by persons who may be geographically distributed.
[0006] Another object of the invention is to facilitate the customization of the surrogate gift.
[0007] Other objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, various embodiments of the present invention are disclosed.
SUMMARY OF THE INVENTION
[0008] In accordance with a preferred embodiment of the invention, there is disclosed an article of manufacture for surrogate gift giving comprising: a plurality of shapes, each shape capable of bearing affixed colors or printing, a frame capable of receiving at least one of the plurality of shapes in at least one configuration, a receiving receptacle, and printed instructions describing at least one mechanism for how to customize said shapes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] 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:
[0010] FIG. 1 is an exploded view of exemplary elements of an embodiment of the invention in kit form;
[0011] FIG. 2 is a top elevation view of a sample embodiment of a three-dimensional (3D) frame; and
[0012] FIG. 3 is a detail view of a non-volatile memory device for containing a computer program.
[0013] For purposes of clarity and brevity, like elements and components will bear the same designations and numbering throughout the Figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure, or manner.
[0015] While the invention is described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
[0016] FIG. 1 depicts an article of manufacture which is a kit 100 for packaging the shapes, the frame 180 , the receiving receptacle 150 , and the printed instructions 170 . The kit 100 consists of a plurality of shapes 130 , each shape capable of bearing affixed colors or printing, a frame 180 capable of receiving at least one of the plurality of shapes 130 in at least one configuration, instructions describing at least one mechanism on how to customize the plurality of shapes 130 , and a receiving receptacle 150 .
[0017] In one embodiment, the plurality of shapes 130 , frame 180 , and receiving receptacle 150 are manufactured from one of the following materials: paper, cardboard, plastic, wood, metal, a laminate, glass, ceramic. In another embodiment, the plurality of shapes 130 are delivered in a single sheet in pre-assembled form, and the sheet is marked or perforated so as to facilitate easy separation of one shape from another.
[0018] In one embodiment, the plurality of shapes 130 , frame 180 , and receiving receptacle 150 are manufactured from any material that is either inherently rigid (e.g. cardboard, plastic, wood, metal, a laminate, glass, ceramic, etc.) or is capable of being formed into a shape that becomes rigid through any known process (e.g. clay, paper mache, curable plastic, epoxies and resins, etc).
[0019] In another embodiment, the plurality of shapes 130 are selected from non-overlapping portions of one of the following images: a bicycle, a domicile, a hot-tub, a ship, an airplane, a bottle of wine, a landmark, a surfboard, a vehicle, an MP3 player.
[0020] In another embodiment, the plurality of shapes 130 are printed with an image on one side, and text or codes on the other side.
[0021] In one embodiment, the frame 180 is constructed from one of the following rigid materials: paper, cardboard, plastic, wood, metal, a laminate, glass, ceramic.
[0022] In one embodiment, the frame 180 is constructed from a non-rigid material capable of being folded or molded into a rigid form.
[0023] In another embodiment the frame 180 is three-dimensional and is capable of receiving at least one of the plurality of shapes 130 in at least one location.
[0024] In another embodiment, the frame 180 is substantially three-dimensional.
[0025] In the embodiment shown in FIG. 2 , the 3D frame 201 is a three dimensional shape fashioned from a wire. The wire may be made from a semi-rigid segment of wire made from a metal, or the wire may be made from some non-metallic material, so long as the material will hold a shape when bent.
[0026] FIG. 1 shows a set of instructions 170 . The set of instructions 170 may be printed matter. In some embodiments the set offers descriptions of (a) how to play the game, (b) how to modify or customize the front surface 110 of the shapes by affixing an image or text or codes, (c) how to modify or customize the back surface 120 of the shapes by affixing an image text, or code.
[0027] In one embodiment the set of instructions 170 are delivered on a compact disk or on a flash memory device (e.g., Compact Flash, Secure Digital, XD-PictureCard) or on a printed page.
[0028] In another embodiment, the set of instructions 170 includes at least one of the following: a URL to a website, a series of steps to perform, a telephone number to call.
[0029] In another embodiment, the set of instructions 170 includes card stock that may or may not be pre-perforated such that the images and codes discussed herein may be printed on the card stock prior to separation at the perforations. Thus, the plurality of shapes 130 , the frame 180 , and the receptacle 150 may be customized and printed by the user at will.
[0030] In one embodiment the plurality of shapes, the frame 180 , the set of instructions 170 , and the receiving receptacle 150 are printed on card stock.
[0031] In one embodiment the receiving receptacle 150 is delivered in a plurality of parts and construction includes at least one of the following: said parts that snap together, or adhere together, or are mechanically mated by shape to join one to another.
[0032] In one embodiment the receiving receptacle 150 includes at least one of the following features: a cubical shape, a cylindrical shape, an oblong shape, a rectilinear shape, or any other three-dimensional shape.
[0033] In one embodiment the receiving receptacle 150 includes at least one of the following features: the shape of a Christmas gift, a wedding cake, a heart, a likeness of a bride and groom, a vase, a layer, a cross, a mortarboard, a baby pacifier, a lamb, a stork, a computer monitor.
[0034] In one embodiment the receiving receptacle 150 includes an opening 160 of sufficient size and shape as to permit said shapes to be entered into the receptacle 150 .
[0035] In one embodiment the receiving receptacle 150 includes at least one of the following features: an opening 160 which may be a slot, or any arbitrarily shaped aperture.
[0036] FIG. 3 depicts an embodiment of a computer program on media 330 that, when the program is read by the computer program media reader 320 and subsequently executed on the computer and peripherals 310 , the computer and peripherals 310 produce the article of manufacture of FIG. 1 where each element is printed on paper or photo paper or card stock.
[0037] Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
[0038] Having thus described the invention, what is desired to be protected by a Letters Patent is presented in the subsequently appended claims.
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In accordance with a preferred embodiment of the invention, there is disclosed an article of manufacture for surrogate gift giving.
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BACKGROUND OF THE INVENTION
The present invention relates to a safety circuit, especially for transportation systems, such as elevators, comprising at least one switching circuit composed of two digital logical elements, each of which are arranged in a separate information channel and connected at the input side with information transmitters generating anti-valent signals and at the output side with a monitoring circuit in the form of an equivalent (INCLUSIVE-OR)- or anti-valent (EXCLUSIVE-OR) circuit for monitoring the anti-valence of the output signals.
The purpose of such type safety circuits, while taking into account the prevailing regulations, is to check whether there are present the prerequisites for placing into operation without danger the relevant system or installation which is to be protected and upon discovering errors which could lead to a dangerous operating condition preventing placement of the installation into operation.
In the construction of elevators or lifts for instance there exists the requirement that if an error together with a second error can lead to a dangerous operating condition, then at the latest during the next following condition changer during the course of the operation when the faulty functional element should come into play, the system or installation should be brought to standstill and there must be prevented an automatic restarting.
In this connection there is not taken into account that the second error also comes into play in leading to the dangerous operating condition before there is brought about standstill of the installation by the condition change.
In German patent publication No. 1,537,379 there is taught a safety circuit possessing logical components having two separate channels for the equivalent and their anti-valent switching variables. The one channel contains a NAND-element and the other a NOR-element as the logical elements. Further, at the input there are available anti-valent switching variables in the form of squarewave voltages with a predetermined repetition frequency and at the outputs of both logic elements there is connected a monitoring element which can be interrogated by test signals. As the monitoring element there is used an electronic switching amplifier, the supply voltage of which is tapped-off from the outputs of both logic elements. According to a further construction of the safety circuit the monitoring elements associated with the logic components form a series circuit wherein in each case the output of a monitoring element is connected with the input of the following monitoring element, and further, at the first monitoring element of the series circuit there is connected a test signal source and at the last monitoring element a group of components monitoring its output signals and comparing such with the test signals.
The drawback of this safety circuit resides especially in the fact that upon the occurrence of two errors in the logic components, for instance a respective error in both logic elements or a faulty logic element and a signal state of the inputs of the logic elements leading to equivalence of the output signals there can likewise be present anti-valence or anti-equivalence of the output signals. If both of the errors occur in timely succession, then, they can be detected by the test signals which follow one another as a function of time and emanating from the test signal source. However, if the errors occur simultaneously then it is not possible to detect the same by means of the monitoring element.
In German patent publication No. 1,055,782 there is taught a safety device for electrically operated elevators wherein there is used as the feeler or scanning device of a region which is to be protected, for instance within the door opening of an elevator cabin, one or a number of light barriers composed of light sources and photoelectric cells with appropriate relays. This apparatus is particularly characterized by the features that the control current circuit which switches-on the elevator drive is connected via a control device arranged in series with the motor protection switch, the control device comprising a series circuit consisting of the contact of a checking relay and the contacts of the photocell relay. The control device serves to control the feeler or scanning device in such a manner that it briefly shuts-off the light sources and only establishes the electrical connection to the motor protection switch when, upon shutting-off the light sources, the relays associated with the photocells are deenergized.
With this safety device for elevators there is thus checked the correct functioning of the switching element after releasing a travel command, before such is executed, by simulating an error preventing travel.
However, this safety device is associated with the drawback that upon defect of the testing or checking relay or the sticking of one of its contacts the feeler or scanning device no longer can be checked with respect to its functional reliability, so that the drawbacks associated with the light barriers, such as aging of the tubes, disturbances in the amplifiers, sticking of the relays and so forth, have an effect upon the operational reliability of the system. The simultaneous occurrence of two errors therefore leads to a dangerous operating condition which goes unnoticed by the safety circuit.
SUMMARY OF THE INVENTION
Hence, it is a primary object of the present invention to provide a new and improved construction of a safety circuit capable of recognizing two errors which are present or simultaneously occur at the point in time of triggering the testing or checking operation and which errors lead to a dangerous operating condition, and further, prevents their action from coming into play.
Another object of this invention aims at the provision of a new and improved construction of a safety circuit, especially for elevator installations which is extremely reliable in operation, not readily subject to malfunction or breakdown, and capable of positively detecting errors or faults leading to dangerous operating conditions.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the safety circuit of this development is manifested by the features that the logic element of the monitoring circuit which is connected at the output side when there is present equivalence with a control line for shutting-off the installation exclusively consists of diodes and the input side logic elements of the monitoring circuit and the monitored logic elements are connected with a testing circuit which, upon placing into operation the installation or a part of the installation, applies in succession a test signal simulating an error to both monitored logic elements, and that a timing element with a switch-in time-delay is connected in the control line or conductor for the switching-off of the installation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a schematic circuit diagram of a switching circuit of the safety circuit for an elevator system or installation; and
FIG. 2 is a circuit diagram of the safety circuit having a number of switching circuits.
DETAILED DESCRIPTION OF THE INVENTION
Describing now the drawings, in FIG. 1 reference character SK1 designates a switching circuit of a safety circuit which contains two information transmitters G11 and G12 associated for instance with an elevator cabin door of a transportation system such as an elevator. The information transmitter G11 is connected via an information channel IK11 with an input of a digital logic element V11 possessing two inputs, for instance an AND-gate. On the other hand, the information transmitter G12 is connected through the agency of an information channel IK12 at an input of a digital logic element V12, for instance an OR-gate, and which logic element V12 possesses two inputs. At the outputs of the AND-gate V11 and the OR-gate V12 there is connected a monitoring circuit US1 which consists of a NOR-gate V13 and an AND-gate V14, each of which possess two inputs connected with the outputs of the AND and OR-gates V11, V12 respectively. The outputs of the NOR-gate V13 and the AND-gate V14 are connected via a respective diode D11 and D12 with a control line StL and a testing or checking circuit PS1. The testing circuit PS1 consists of an AND-gate V15 having three inputs and an AND-gate V16 having two inputs, a storage SP11 having two inputs and two outputs, a storage SP12 having two inputs and one output and a NAND-gate V17 having two inputs. The inputs of the AND-gate V15 are connected with the output of the NOR-gate V13, the control line or conductor StL and a testing line or conductor PrL and the inputs of the AND-gate V16 are connected with the output of the AND-gate V14 and the control line StL. The outputs of the AND-gates V15, V16 are connected with the inputs e1, e2 of the storage SP11, and its output a1 is connected with the input e1 of the storage SP12 and via a conductor or line LSi2 with an input of the OR-gate V12. The outputs a2 and a1 of the stores SP11 and SP12 respectively, are connected with both inputs of the NAND-gate V17.
In FIG. 2 reference characters SK1, US1, PS1, V11, V12, V13, V14, V15, V16, SP11, SP12, V17, D11, D12, IK11, IK12, LSi1, LSi2, LSi3, LQ1, LQ2, PrL and StL designate the same components as in FIG. 1. Reference characters SK2, SK3 and SK4 constitute switching circuits of the safety circuit which form a series circuit with the switching circuit SK1. Moreover, the monitoring circuits US1, US2, US3 and US4 of the switching circuits SK1, SK2, SK3 and SK4 as well as the testing circuits PS1, PS2 and PS3 of the switching circuits SK1, SK2 and SK3 are identical. The switching circuit SK2 is for instance operatively associated with the chute doors of an elevator installation, whereas the circuit SK3 carries out an optional, not particularly further described, monitoring function of the safety circuit of the elevator installation. In the switching circuit SK4 the data of the switching circuits SK1 to SK3 are assembled together into a resultant data. The switching circuits are connected in series in such a manner that in each instance the output of the corresponding NAND-gate V17, V27, V37 of a preceding switching circuit is connected via the associated conductor LSi3, LSi5, LSi7 respectively, with an input of the digital logic element V21, V31, V41 respectively, of the following switching circuit. The outputs a1 of the stores or storages SP21, SP31, SP41 of the switching circuits SK2, SK3, SK4 respectively, are connected via conductors LQ2, LQ3, LQ4 with the inputs e2 of the stores SP12, SP22, SP32 of the preceding switching circuits SK1, SK2, SK3 respectively.
A storage or store SP0 having two inputs and an output and arranged externally of the switching circuit is connected at the input e1 with a conductor or line LSi0 coupled with the control of the installation and at the input e2 via a conductor or line LQ1 with the output a1 of the storage SP11 (FIG. 1), whereas its output a1 is connected via a conductor or line LSi1 in which there is arranged a NOT-gate V0 with the second input of the digital logical element V11 (FIG. 1).
The input e1 of the storage SP42 of the testing circuit PS4 is connected via a conductor LSi0' with the conductor LSi0 and its output a1 at an input of an OR-gate V47 possessing two inputs. The output of the OR-gate V47 is connected with the testing line PrL and a blocking line SpL which is connected with the control of the installation. The input e2 of the storage SP42 is connected with the output a1 of the storage SP41 and the second input of the OR-gate V47. A timing element ZG arranged externally of the switching circuit and having a switch-in time-delay is connected at the input side with the control line StL and at the output side with the control of the installation.
The information channels IK11/12, IK21/22 and IK31/32 of the switching circuits SK1, SK2 and SK3 are connected with the inputs of the digital logic elements of the switching circuit SK4, the outputs of which are connected on the one hand with the inputs of the monitoring circuit US4 and on the other hand via the information channels IK41/42 with the control of the installation.
The previously described safety circuit functions in the following manner:
During standstill of the elevator cabin and with the cabin doors closed the information transmitter G11 delivers a signal 1 to the AND-gate V11 and the information transmitter G12 delivers a signal 0 to the OR-gate V12. By means of the conductor or line LSi0 (FIG. 2) a signal 0 arrives at the input e1 of the storage SP0, the output a1 therefore likewise has the signal 0. The NOT-gate V0 arranged in the conductor or line LSi1 negates this signal, so that at the corresponding input of the AND-gate V11 there appears a signal 1, and hence its output also has appearing thereat the signal 1. Consequently, the outputs of the NOR-gate V13 and the AND-gate V15 exhibit the signal 0, so that the storage SP11 is not set and via the conductor LSi2 a signal 0 arrives at the corresponding input of the OR-gate V12, the output of which and therefore also the output of the AND-gate V14 exhibits the signal 0. The control line or conductor StL therefore carries a signal 0 defined as "installation not switched-off", whereas the information channels IK11/12 exhibit at the output of the elements V11/12 anti-valent or anti-equivalent signals. If this anti-valence is disturbed, then, the control line StL carries a signal 1 which switches-off the installation. However, if the disturbance is only of short duration, for instance a short coincidence of the information transmitter signals, then the timing element ZG prevents a switching-off of the installation.
The switching circuits SK2, SK3, SK4 function analogous to the switching circuit SK1, wherein in each instance the number of inputs of the digital logic elements V21/22, V31/32, V41/42 corresponds to the number of information to be processed. Further, via the conductors LSi3/4, LSi5/6, LSi7/8, analogous to the conductors LSi1/2 of the circuit SK1 leading to the elements V11/12 the signals 1 or 0 respectively, arrive at the corresponding inputs of the elements V21/22, V31/32, V41/42.
Since the inputs e1 of the storages SP41, SP42 exhibit the signal 0 there is present at their outputs a1 as well as at the output of the NOR-gate V47 likewise the signal 0. The testing line or conductor PrL and the blocking line SpL therefore carry a test signal 0 or a signal 0 defined as "unlocking the travel".
During faultless functioning of all of the switching circuits the information channels IK41/42, which signal the readiness to travel and lead to the control of the installation, likewise exhibit anti-valence or anti-equivalence of the signals.
Upon initiating travel of the elevator and shortly prior to closing of the doors a logic signal 1 is delivered to the conductor LSi0 by the control of the installation for the purpose of checking the safety circuit. This signal sets the storages SP42 and SP0. Thereafter there appears at the output of the OR-gate V47 a signal 1 which, during the duration of the testing operation, blocks the travel via the blocking line SpL and via the test line PrL is supplied into the switching circuits SK1 to SK4. At the output a 1 of the storage SP0 there likewise appears a signal 1 which arrives via the conductor LSi1 and the NOT-gate V0 as a logic signal 0 at the corresponding input of AND-gate V11. Consequently, the output of the AND-gate V11 and the NOR-gate V13 have appearing thereat the signals 0 and 1 respectively, and at all three inputs of the AND-gate V15 there is present the signal 1. The diode D12 thus prevents that there also will be present the signal 1 at both inputs of the AND-gate V16. Consequently, the storage SP11 is set, so that a signal 1 on the one hand resets the storage SP0 via the conductor or line LQ1 and, on the other hand, via the line LSi2 arrives at the corresponding input of the OR-gate V12. Thus, there is present at its output the logic signal 1 and since in the meantime due to resetting of the storage SP0 there is present at the output of the AND-gate V11 the signal 1 also the output of the AND-gate V14 has appearing thereat the signal 1. At both inputs of the AND-gate V16 there is thus likewise present the signal 1. This has the result that the storage SP11 is reset and there appears at its output a2 a signal 1, and the diode D11 prevents that it will again be reset. Since at the output a1 of the storage SP12 there is likewise present the logic singal 1, there thus is brought about a change of the signal 1 which is present at the output of the NAND-gate V17 into the signal 0. This signal 0 is transmitted via the conductor or line LSi3 to the switching circuit SK2 in which there now take place the same operations as in the switching circuit SK1.
After setting the storage SP41 in the switching circuit SK4 there is reset the storage SP42 and by means of the line LQ4 the storage SP32 of the switching circuit SK3. At the same time the signals 1 and 0 present at both of the inputs of the OR-gate V47 are altered into the logic signals 0 and 1 respectively, so that the conductors or lines PrL and SpL again carry the signal 1. First after resetting the storage SP41 does there appear the logic signal 0 at the output of the OR-gate V47, so that the testing operation is terminated and the blocking of the travel of the elevator is released.
Upon occurrence of defects the safety circuit functions in the following manner:
It is assumed that both digital logic elements V11, V12 of the switching circuit SK1 are defective at the moment of starting the travel of the elevator, the defects can arise in succession or at the same time. The inputs of the elements V11, V12 -- which inputs are connected with the information transmitters G11, G12 -- carry for instance the logic signals 0 and 1 respectively. By means of the conductors LSi1 a test signal 0 arrives at the second input of the AND-gate V11, so that its output likewise carries the signal 0. The assumed defect might be of the type that the output however exhibits the signal 1. Since the second input of the OR-gate V12 possesses the signal 0, its output carries the logic signal "1"; due to the here assumed defect however appears as logic signal "0". At the output of the NOR-gate V13 there is thus present a signal 0, and the storage SP11 cannot be set and through the agency of the conductor LSi2 no signal 1 can reach the OR-gate V12. Since the output of the AND-gate V14 and the output a2 of the storage SP11 each possess a signal 0, there does no occur at the output of the NAND-gate V17 any change in the signal state, so that via the conductor LSi3 no test signal can be delivered to the switching circuit SK2. Consequently, also no test signal arrives via the conductor LSi7 at the switching circuit SK4, so that the storages SP41, SP42 are not reset and the conductor SpL further carries the signal 1 bringing about blocking of travel.
Further, it may be assumed that the diode D12 of the switching circuit SK1 is defective, and the defect is of the type that current can neither flow in the forward direction nor in the reverse or blocking direction. Now if the inputs of the elements V13, V14 during the course of the testing operation exhibit the signals 1, then there appears at the output of the NOR-gate V13 the signal 0 and at the output of the AND-gate V14 the signal 1. At both inputs of the AND-gate V16 there are thus present the signals 0 and 1, so that its output carries the signal 0. Consequently, the storage SP11 cannot be reset, and at the output of the NAND-gate V17 there does not occur any signal change. The test signal is therefore not further transmitted, so that the conductor SpL continues to carry the logic signal 1 bringing about blocking of travel.
As a further example it is assumed that both of the digital logic elements V23, V24 of the monitoring circuit US2 of the switching circuit SK2 are defective at the point in time when there is initiated the travel, and the defects may be of the type occurring in succession or at the same time. The inputs of the elements V21, V22 which are connected with the not particularly illustrated information transmitters of the chute doors, with the chute doors closed, carry the signals 1 and 0 respectively. Now after checking the switching circuit SK1 which does not exhibit any defect and is associated with the elevator cabin doors a test signal 0 arrives via the conductor or line LSi3 at the relevant input of the AND-gate V21, with the result that its output carries the signal 0. Since by means of the conductor or line LSi4 no test pulse has yet arrived at the relevant input of the OR-gate V22 its output also carries the logic signal 0. Consequently, there appears at the output of the NOR-gate V23 the logic signal "1" and at the output of the AND-gate V24 the logic signal "0". The assumed defect may be of the type wherein the complementary signals appear at the outputs. Consequently, the storages SP21 and SP22 connected via the AND-gate V25 cannot be set and the input of the NAND-gate V27 which is connected with the output a23 of the storage SP22 again possesses the logic signal 0. At its input there thus does not appear any signal change, so that the test signal is not further transmitted. Consequently, the storages SP41, SP42 of the switching circuit SK4 cannot be reset, so that the conductor or line SpL continues to carry the signal 1 bringing about blocking of elevator travel.
The invention is not limited to the illustrated exemplary embodiment, rather also encompasses possible variant constructions. Thus, for instance, for both of the digital input-logic elements V11, V12 there can be used instead of an AND-gate and an OR-gate a NOR-gate and an AND-gate and for both of the logic elements V13, V14 of the monitoring circuit US1 there can be employed instead of a NOR-gate and an AND-gate an OR-gate and a NAND-gate. Also, for instance, the entire circuitry can be designed in NOR-technique or MOS-logic with self-blocking MOSFETS. Finally, the proposed safety circuit is not only usable in conjunction with elevator system or installations, rather also for other transportation systems or installations which should have a fail safe system built-in, such as for instance in railroads.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims.
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A safety circuit arrangement, especially for transportation systems such as elevators, comprising at least one switching circuit equipped with two digital logical elements, each arranged in a separate information channel and connected at its input side with anti-valent signal generating information transmitters and at its output side with a monitoring circuit monitoring the anti-valence of the output signals. A control line for switching-off the installation in the presence of equivalence. A logical element of the monitoring circuit which is connected at its output side with the control line exclusively comprises diodes and input side logical elements of such monitoring circuit and the monitored digital logical elements are connected with a testing circuit which, upon placing into operation the elevator, applies a test signal simulating a defect in succession to both monitored digital logical elements. There is further provided a timing element having a switching-in time-delay connected in the control line for switching-off the elevator.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates generally to automatic riveting devices, and more particularly to a rivet magazine for an automatic feed blind or pop-rivet setting device.
[0006] 2. Description of Related Art
[0007] Considerable technological effort has been expended in developing blind or pop or mandrel-type rivets, hereinafter collectively referred to as blind rivets, and the associated manually operated devices for setting such rivets. The primary requirement for setting blind rivets is to support the enlarged flange of the rivet body against an anvil or rivet table with the rivet body inserted through a closely mating hole in a work surface. The mandrel extends axially through the rivet table and is gripped by jaws which tension and pull the mandrel rearwardly, expanding the body of the rivet to a point where the mandrel is fractured away. Thus, blind rivets are particularly useful in situations where a conventional riveting tool does not have access to both sides of the working surfaces to be rivet-connected together.
[0008] What appears to be a second stage in the development of blind rivets has been toward the automatic setting of the rivet wherein a source of power such as a motor, a pneumatic actuator or hydraulics are utilized to replace manual effort in expanding and setting the rivet through mandrel pull.
[0009] This riveting technology has also expanded into the development of automatic riveting devices which include an automatic feed means for the rivets themselves. Prior to such development, the user has been required to manually insert each fresh rivet into the rivet table one at a time. Because these devices still require the user to depress an actuator or trigger to set each rivet, these devices are referred to as “semi-automatic” rivet machines having an automatic feed.
[0010] The bulk of these automatic feed rivet devices fall generally into two categories. The first category is one wherein the nosepiece and/or rivet table is pivotally or arcuately connected wherein these components swing apart radially outwardly from one another so that a new rivet may be passed forward longitudinally from behind this arrangement into position, whereupon the nosepiece and/or rivet table components are closed around the rivet body and mandrel with the flange of the rivet against the distal end surface of the rivet table.
[0011] The second general category of automatic rivet feed means is directed to an external arm arrangement which swings or pivots a fresh rivet into coaxial alignment forwardly of the rivet anvil and then either automatically draws or allows the rivet to be manually moved rearwardly wherein the mandrel enters the longitudinal aperture of the rivet anvil.
[0012] Despite this considerable effort and incentive in developing such an automatic feed rivet setting device, only one such machine has successfully been marketed and is disclosed in U.S. Pat. No. 5,136,873. A rivet magazine is also disclosed in U.S. Pat. No. 5,184,497.
[0013] The present invention provides an improved feed magazine for compactly holding a large quantity of blind rivets for such a rivet setting device, which in prototype and pre-production form, has operated successfully and reliably to date. This invention offers fully automatic rivet magazine feed means for an accompanying riveter which will set rivets automatically as quickly as an operator can act to position each new rivet head into another hole in the work surface and activate the riveter.
BRIEF SUMMARY OF THE INVENTION
[0014] This invention is directed to an improved one-piece magazine for compactly holding and feeding therefrom a quantity of blind rivets to a blind rivet setting device which automatically feeds blind rivets into a specially designed rivet table, then sets the rivet by pulling and detaching the mandrel. The magazine holds a thin elongated strip or ribbon of flexible material which holds and grips the mandrel tips pierced through the strip in evenly spaced apart fashion. The strip, spiral wound on the magazine, is drawn from the magazine into a feed slot formed transversely through a rivet table of the rivet setting device generally transverse to the longitudinal axis of the riveter. A spring biased retracting device may be used to continuously pull the strip through the feed slot so that the next rivet in succession facing the rivet table is automatically drawn into axial alignment within the rivet table ready for positioning and setting into a work surface.
[0015] It is therefore an object of this invention to provide an improved magazine for grippingly holding a quantity of rivets for automatic feed into an automatic rivet setting device for setting blind rivets which includes an automatic rivet feed arrangement.
[0016] It is still another object of this invention to provide an improved economically manufactured one-piece magazine for holding a quantity of rivets as part of an automatic blind rivet feed arrangement for riveting devices.
[0017] In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0018] FIG. 1 is a perspective view of a fully assembled prior art magazine utilized with the semi-automatic rivet setting tool as disclosed in U.S. Pat. No. 5,136,873.
[0019] FIG. 2 is an exploded view of the two-part magazine shown in FIG. 1 .
[0020] FIG. 3 is a perspective view of one embodiment of the improved magazine of the present invention holding a quantity of rivets each held by an elongated strip of flexible material.
[0021] FIG. 4A is a top plan view of the improved magazine of FIG. 3 absent the rivets and flexible rivet carrying strip.
[0022] FIG. 4B is a top plan view of FIG. 3 including the rivets and flexible rivet carrying strip.
[0023] FIG. 5 is a perspective view of another embodiment of the magazine invention.
[0024] FIG. 6 is a top or bottom plan view of FIG. 5 .
[0025] FIG. 7 is a front elevation view of FIG. 6 .
[0026] FIG. 8 is a side elevation view of FIG. 6 .
[0027] FIG. 9 is a perspective view of yet another embodiment of the invention.
[0028] FIG. 10 is a top plan view of FIG. 9 .
[0029] FIG. 11 is a perspective view of still another embodiment of the invention.
[0030] FIG. 12 is a front elevation view of the preferred embodiment of the invention showing the support shaft releasably attached thereto.
[0031] FIG. 13 is a perspective view of FIG. 12 .
[0032] FIG. 14 is a longitudinal section view of FIG. 13 .
[0033] FIG. 15 is a top plan broken view of FIG. 13 showing a distal lead portion of the rivet carrying strip and rivet attached thereto in phantom.
[0034] FIG. 16 is a perspective view of the magazine support shaft.
[0035] FIG. 17 is a longitudinal section view of FIG. 16 .
DETAILED DESCRIPTION OF THE INVENTION
[0000] Prior Art
[0036] The complete specification and drawings disclosed in U.S. Pat. No. 5,184,497 have been previously incorporated by reference and are repeated herein.
[0037] Referring firstly to FIGS. 1 and 2 , a prior art magazine is there shown generally at numeral 10 and includes two identical mating magazine halves 12 shown in FIG. 2 which mating engage together to form the magazine 10 . Each of the magazine halves 12 includes radially extending longitudinal panels 16 and 18 which are oriented in spaced apart radially extending coplanar fashion and formed at a proximal end thereof with a rectangular transversely oriented end plate 14 . Each end plate 14 includes a central drive aperture 20 which is operably engageable onto a rotatable support and drive spindle (not shown). The distal ends of each longitudinal panel 16 and 18 , respectively, include locking tabs 26 and 28 and locator pins 30 and 32 , respectively, which align and lockingly engage into cavities 22 and 24 and locator holes 34 and 36 , respectively, formed on the inner surface of each of the end plates 14 .
[0038] When assembled, a length of flexible MYLAR or plastic strip or ribbon carrying spaced apart rivets as disclosed in the '497 patent are windingly engageable around the outer distal longitudinal edges or margins 38 and 40 of each of the longitudinal panels 16 and 18 , respectively, and in the same orientation of rivet heads inward and shanks outward as shown in FIGS. 17 and 18 of the '497 patent. The end plates overhang the distal longitudinal edges 38 and 40 at 46 and 48 , respectively.
[0000] The Invention
[0039] Referring now to FIGS. 3, 4A and 4 B, one embodiment of the present invention is there shown generally at numeral 50 and includes a uniquely configured magazine 52 and a loaded flexible plastic or MYLAR rivet carrying strip 54 carrying a quantity of rivets 58 in evenly spaced relation therealong. The distal end portion 60 a of each of the mandrels 60 of each rivet 58 is pierced through the flexible plastic strip 56 which is of sufficient strength and resiliency to retain the tip portion 60 a of each of the rivets 58 in the position shown until such time as the carrying strip 56 delivers each rivet 58 into the prepared slot formed into the rivet table of the '497 rivet setting tool.
[0040] The magazine 52 is formed as a single unit of molded plastic and includes a central support passageway 72 for the mounting of the rivet magazine 52 onto a mating support or drive shaft either attached to a rivet setting tool (not shown) or a separate support. Each of the four longitudinal panels 70 includes stiffening ribs 76 and stiffened distal longitudinal edges 78 longitudinally extending therealong. An end plate 74 is disposed at one end of the magazine 52 to provide structural strength and stability for each of the longitudinal panels 70 and to provide some supportive assistance in preventing the heads 62 of the rivets 58 from falling outside of the end envelope of the rivet magazine 52 .
[0041] However, because of the relative spacing along the flexible strip 56 of each of the mandrel end portions 60 a , the rivet heads 62 each press against one of the longitudinal panels 70 thus acting together in pairs tipped inwardly as best seen in FIG. 4B to create a flexure of the flexible carrying strip 56 which has been wound taught around the longitudinal distal edges 78 of each of the longitudinal panels 70 starting at 64 and ending at 66 . By this arrangement, a biasing effect is produced by the flexing of the tensioned flexible rivet carrying strip 56 which adds stability to the rivets 58 in place within the magazine 52 .
[0042] Referring now to FIGS. 5 to 8 , another embodiment of the magazine of the invention, the preferred embodiment, is there shown generally at numeral 80 . This rivet magazine 80 includes four longitudinal panels 82 which extend longitudinally between transverse end panels 84 . This embodiment 80 , also formed as a unit, includes a central longitudinal passageway 94 and drive engaging apertures 92 formed in each of the end panels 84 .
[0043] The peripheral edges of each end panel 84 are scalloped at 86 between corners 88 thereof and between each of the adjacent longitudinal panels 82 for weight reduction and rivet carrying strip loading and packaging convenience. The flexible strips loaded with rivets as previously described and shown in FIG. 3 are tightly spiral wound around the longitudinal distal edges 96 of each of the longitudinal panels 82 such that, even with the scalloped portions 86 , each of the end panels 84 provide some support for retaining the heads 62 of each rivet 58 held by the tightly wound flexible rivet carrying strip within the envelope defined by the magazine 80 .
[0044] To prevent the tightly wound flexible rivet carrying strip from inadvertently slipping off of the distal longitudinal edge 96 of one or more of the longitudinal panels 82 , the tips or corners 88 of each of the end panels 84 extend radially outwardly beyond the distal edge of each longitudinal panel 82 as best seen in FIG. 6 at 90 . Thus, when a fully loaded magazine is jostled or handled roughly, the flexible rivet carrying strip 56 is much less likely to inadvertently slip from the distal margins of each of the longitudinal panels 82 .
[0045] Still another embodiment of the magazine of the invention is shown generally at numeral 100 in FIGS. 9 and 10 . In this embodiment 100 of the magazine, similar longitudinal panels 102 are provided in orthogonal orientation one to another and strengthened in that relationship by end panels 104 . These end panels 104 include drive apertures 108 for receiving a mating drive shaft which slidably engages through a longitudinally extending a longitudinally extending clearance passage 110 .
[0046] To insure that the flexible rivet carrying strip (not shown in these drawings) is prevented from slipping off of the distal edges 112 of each of the longitudinal panels 102 , overhang tabs 106 are also provided which extend radially outwardly at 114 a distance sufficient to prevent slippage of the flexible rivet carrying strip therefrom.
[0047] In FIG. 11 , still another yet more economical embodiment of the magazine of the invention is there shown generally at numeral 120 . In this embodiment 120 , longitudinally extending longitudinal panels 122 orthogonally oriented one to another and radially extending about an imaginary center line of the magazine as with respect to all of the other embodiments described hereinabove, are also provided. A small stabilizing end panel 124 is disposed centrally against each end margin of the longitudinal panels 122 , the entire magazine 120 being formed as a unit of molded plastic material. A drive aperture 130 is disposed in each of the end panels 124 in alignment with a central passageway 132 while radially extending overhang tabs 126 providing a slight overhang at 134 , prevent the flexible rivet-carrying strip from sliding from its wound positioning around the distal longitudinal edges 128 of each of the longitudinal panels 122 .
[0048] Note in this embodiment 120 that the reinforcing end panels 124 are only for providing a drive aperture 130 and for reinforcing the orientation of the end panels 122 so that they do not substantially flex when the loaded flexible rivet-carrying strip is wound therearound. That is to say that the stability of the rivets held between each adjacent longitudinal panel 122 is maintained and the rivet heads are kept from substantial movement outside of the end profile of the magazine 120 by the biased effect of the rivets against the side walls of the longitudinal panels 122 created by the flexing of the flexible rivet-carrying strip by the biasing of the entire rivet against the sides of each of the longitudinal panels 122 as previously described.
[0049] Referring now to FIGS. 12 to 17 , the preferred embodiment of the magazine is there shown generally at numeral 140 formed as a single molded plastic unit including four longitudinal panels 144 longitudinally extending between transverse end plates 142 thereof. An elongated longitudinally extending central passageway 146 is tapered toward the central portion thereof as best seen in FIG. 14 to accommodate and to releasably, yet lockingly engage onto a support shaft 160 which is described more fully herebelow.
[0050] To insure that the MYLAR carrying strip 56 shown in phantom in FIG. 15 carrying rivets 58 does not slip from its wound ready-for-use position around each longitudinally extending edge 144 a of each of the panels 144 , each the distal end portions 148 of each of the end panels 142 extend radially slightly beyond the corresponding edge 144 a.
[0051] As best seen in FIG. 15 , this embodiment 140 also includes molded elongated slender carrying strip attaching pins 150 which are positioned on and extend at a slight inward angle to tangent from at least one of the panels 144 . These pins 150 are positioned in close proximity to one or both of the end panels 142 and at a specified distance radially inwardly from the corresponding longitudinal distal edge 144 a . Pin 150 is sized to be snuggly inserted into an empty aperture formed into the lead portion of the carrying strip 156 which is then pulled taught at 64 to bend around the distal edge 144 a to begin the carrying strip winding process of loading the rivets 60 onto the magazine 140 . By slightly tipping the pins 150 inwardly, a self-locking benefit is derived when the carrying strip wrapping process begins. In this embodiment 140 , the transverse perimeter measurement around the distal edges is about 12%″ so that the rivet spacing on the carrying strip is about 1.9″
[0052] The support shaft 160 is best seen in FIGS. 16 and 17 and is formed in two main rigid components, a tapered outer shaft 162 and an inner shaft 174 . The outer shaft 162 matches the tapered passageway 146 best seen in FIG. 14 and is of sufficiently shallow angle of taper so as to be self-locking when tapped into the position shown in FIG. 12 . However, to further insure the releasable attachment to avoid inadvertent disengagement between the support shaft 160 and the magazine 140 when in use, a machined micro finish of 125 microns is applied to the outer surface of the outer member 162 for additional frictional engagement into the tapered passageway 146 . Note that other forms of surface finishing such as bead blasting, knurling and the like may be applied for this enhanced releasable attachment feature.
[0053] The inner shaft 174 is held in position by a threaded fastener 172 which exerts pressure against a spring or crush washer 176 positioned between an enlarged head 164 of the outer shaft 162 and an enlarged flange 168 of the inner shaft 174 . By this arrangement, by adjusting the tightness of threaded fastener 172 , which variably compresses the spring washer 176 , relative resistance to frictional rotation between the outer tapered member 162 and the threaded proximal end 170 which remains stationary and locked into the rivet setting tool is accomplished. The threaded proximal end 170 threadably engages into a mating female thread formed into a side portion of the rivet setting tool housing as described in U.S. Pat. No. 5,136,873 which has previously been incorporated by reference to support the magazine 140 .
[0054] While the instant invention has been shown and described herein in what are conceived to be the most practical and preferred embodiments, it is recognized that departures may be made therefrom within the scope of the invention, which is therefore not to be limited to the details disclosed herein, but is to be afforded the full scope of the claims so as to embrace any and all equivalent apparatus and articles.
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A magazine for holding a quantity of blind rivets ready for use in an automatic rivet setting tool. The rivets are connected together in spaced relation along the length of an elongated rivet carrying strip or ribbon of flexible material by having a distal portion of each mandrel inserted or pierced therethrough. The magazine includes longitudinal panels connected together in a preferably even, spaced, radially extending arrangement forming a spool. The longitudinal panels each define an outer distal longitudinal edge, all of which are preferably substantially parallel one to another and to a central spool axis. Each rivet carried on the flexible strip, when the flexible strip is spiral-wound around said longitudinal distal edges, is positioned in somewhat radially oriented fashion between adjacent longitudinal panels with the head of each rivet positioned inwardly toward the spool axis.
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This application claims the benefit of provisional 60/281,964 filed on Apr. 6, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to decorticated and fibrillated bast fibers as reinforcement for polymeric, thermoplastic, and thermoset composites.
2. Description of the Related Art
A polymer matrix composite (PMC) is defined as a matrix of plastic resins reinforced by fibers or other reinforcements with a discernible aspect ratio of length to diameter. Materials used to reinforce resins to provide superior strength, stiffness, impact resistance relative to weight include primarily glass, carbon, boron, aramids and cellulosic, or organic fibers. The fibrous reinforcements with a relatively high aspect ratios are distinctly different from fillers which are primarily in particulate or powdered form. Fillers for plastics include calcium carbonate, talc, mica, wollastonite, fly ash and other inorganic or organic compounds. The polymers may be either thermoset or thermoplastic resins and include polyesters, vinyl esters, epoxies, polyvinylchloride (PVC) and polyolefins such as polypropylene (PP) and low/medium/ high density polyethylene (LDPE, MDPE, HDPE).
The superior properties of the reinforced plastics makes them particularly useful for load bearing and structural applications. Polyolefins currently account for approximately 11.92 billion pounds of material, over 51% of the potential market. The total global annual consumption of reinforced plastics surpassed 23 billion pounds in 1999, and continues to grow at an overall rate of 5.4% per year. While both continuous and short fibers are used as reinforcement, a particular need is evident for the use of short lignocellulosic bast fibers such as flax, kenaf, jute, ramie, sisal, and hemp.
Natural bast fibers such as hemp, jute, flax, kenaf and sisal, have been used for tens of thousands of years to make paper, textiles, cordage and other products essential to human existence. Recently, there has been a resurgent interest in utilizing agricultural products as feedstock for industrial application. This trend is driven by several key factors, among them: 1) Reduction of dependence upon forest products and foreign petroleum; 2) Need to find alternatives to farm subsidies to support rural communities; 3) Elimination of air pollution caused by burning waste straw; 4) Desire to utilize more sustainable, less toxic natural resources.
In 1996, German environmental legislation mandated that cars must be able to be recycled. While the European automobile manufacturers found that they could successfully recover and recycle steel and rubber materials, they could do little with the glass fiber reinforced plastics used throughout vehicle interiors.
By combining natural fibers with polypropylene fibers in to non-woven mat products, then heating and pressing these mats into three-dimensional shapes, manufacturers could effectively produce interior trim components such as door panels, seat backs, package trays and instrument panels. Automobile manufacturers found that these natural fiber composites achieved a number of important benefits, including improved impact strength, significant weight reduction, lower manufacturing costs, greater dimensional stability, better acoustical performance, reduced waste generation, ability to recycle products, and safer work environments.
Flax ( Linum usitatissimum L.) is grown as a commercial crop in Canada and the U.S. and harvested primarily for oil seed. Flax oil yields high quality solvents and lubricants such as linseed oil, and building materials such as linoleum flooring. Once harvested, the flax stalk becomes waste field straw. Because this straw cannot typically be plowed under, it poses a significant waste management problem for growers. The traditional disposal method is to burn it in the field, but this practice generates significant environmental and human health problems. Every 100,000 acres of flax straw burned produces the equivalent annual emissions of approximately 43,000 cars, or over 2 million pounds of green house gasses.
The traditional process for preparing the straw for reinforcement involves decortication. During decortication, the ‘shive’ core from the plant is removed and the fibers from the ‘bark’ of the plant is extracted. These long fibers, typically 4 to 6 inches in length are then used to prepare a non-woven, or needle punched mat with other polymeric fibers for use in compression molded parts.
For many years there has been a significant effort in research laboratories in North America, Europe and Asia to develop process technologies to effectively exploit the reinforcement properties of bast fibers in plastics. While a number of technologies have worked on a laboratory scale, the only commercial application of bast fibers has been in non-woven mats in compression molded automotive parts as described above. Since compression molding constitutes only about 20% of the installed base, the focus of research efforts has been to develop other methods to address a much larger market sector.
Every attempt in the past has resulted in problems similar to that quoted in U.S. Pat. No. 6,114,416 where the bast decorticated fiber due to its low bulk density ‘balls up’. Other terms used to describe the phenomenon is ‘clumping’, ‘matting’ or ‘hanging together’ of the fibers during compounding. The result of this has been an uneven and inconsistent distribution of the fiber in the resin matrix in the final product with areas that are resin rich and those that resin starved (fiber rich). Also, the surface finish of the parts is not smooth due to the effect of ‘clumping. Additionally, as reported in U.S. Pat. No. 6,114,416, the percent of bast fiber by weight that may be added to the resin is also very limited, typically much less than 10% by weight beyond which compounding, and molding of the composite specimen is not possible.
A prior method of fibrillation of bast fibers includes steam explosion. The STEX (steam explosion) process uses hydrolysis at elevated temperatures as its main method of removing unwanted constituents of flax, especially pectins, hemicellulose, and lignin. The processes described in the technical literature generally soak the flax with aqueous solutions prior to steam explosion. The thoroughly wet flax has adherent water, the acidity of which has been adjusted to the alkaline side in an attempt to reduce the degradation of the cellulose. A typical successful STEX process exposes the flax to 200 C. temperatures for 10 to 20 minutes. After quick release of the pressure, the steam-exploded flax usually is washed with an alkaline solution.
The effect of this procedure leads to a product that is high in cellulose percentage because most of the other polymers have been removed. Nevertheless, the composition of the cellulose has changed due to partial hydrolysis of this glucose polymer. The key indication of this damage is the degree of polymerization (DP) of the cellulose. Flax cellulose has DP of 1000 to 2000 glucose units. The reduction in DP depends on the severity of the conditions under which the STEX takes place. If the severity exceeds 3.0, the degradation is so drastic that the product is worthless. The most sophisticated STEX processes have a severity of about 2.7 which still provides a strong, useful product. Nevertheless, about 20% to 50% of the DP will be lost to associated hydrolytic action.
SUMMARY OF THE INVENTION
Through a combination of special processes, decorticated bast fibers are converted to a unique fibrillated state of matter, herein termed Fibex (FIBEX™), that overcomes all the difficulties in the stated above during compounding and molding. Fibex fibrillated bast fibers, also have superior characteristics over prior bast fibers.
While waste flax straw has been used as for demonstration of the invention, the general methodology covers all bast fiber materials listed above including flax, hemp, kenaf, jute, sisal, ramie, and similar bast fibers and lignocellulosic fibers. FIG. 1 shows the relative strengths of various pure bast fibers. As shown, flax is one of the strongest of the natural fibers.
The invention, in one form, comprises a fibrillated bast fiber composition including a decorticated bast fibers of which at least approximately 90% of the fibers have a cross-sectional area of less than approximately 700 micrometers squared.
The invention, in another, comprises form a fibrillated bast fiber composition including decorticated bast fibers which have been fibrillated without auto-hydrolysis, such that the fibrillated fibers have a molecular weight at least 75% of the molecular weight of the pre-fibrillated decorticated fibers.
The invention, in yet another form, comprises a fibrillated bast fiber composition including decorticated bast fibers which have been fibrillated without auto-hydrolysis such that the fibrillated fibers have a molecular weight at least 90% of the molecular weight of the pre-fibrillated decorticated fibers.
The invention, in still another form, is a process of forming a bast fiber composition comprising providing decorticated bast fibers; fibrillating the decorticated bast fibers utilizing mechanical impact; and admixing the fibrillated bast fibers with a polymeric resin. The fibrillating step, in the preferred form comprises the application of ultrasonic energy to the decorticated bast fibers. The application of ultrasonic energy in one form of the invention is conducted through liquid to said decorticated bast fibers.
One advantage of the present invention is having a much finer fiber that conventional decorticated materials as seen the scanning electron micrographs, FIGS. 2 a and 2 b.
Another advantage of the present invention is that significantly greater surface area for bonding with the resin for the same quantity as compared to decorticated materials, as shown in FIG. 4 .
Another advantage of the present invention is that effective wetting and dispersion during compounding with polymeric resins up to 50% by weight loading in the polymers.
Yet another advantage of the present invention is the availability, due to the prevention of clumping, of development of standard compounded pellets for ease of storage, transportation and handling.
Still another advantage of the present invention is the injection molding of specimens without any problems with ‘clumping’ or balling up of fibers. Further, injection molding of parts using conventional equipment may be utilized and is now possible.
Yet another advantage of the present invention is a significant increases in stiffness and strength of the formed composites. Significant benefits in strength and stiffness to weight ratios approaching those of glass reinforced materials have been shown.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a graph indicating the strength of various natural fibers showing flax fiber to be the strongest;
FIG. 2 is a Scanning Electron Micrograph of (a) decorticated flax fiber (25×) and (b) Fibex fiber of one form of the invention (100×);
FIG. 3 is typical surface of molded specimen with decorticated fiber demonstrating ‘clumping’ or ‘balling up’ of fiber during compounding and molding (prior art);
FIG. 4 is a cross sectional area comparison of decorticated fiber and the Fibex material of one form of the invention;
FIG. 5 is a photograph of one form of Fibex reinforced polypropylene pellets;
FIG. 6 is a photograph of injection molded specimens with Fibex (40% by weight) reinforced polypropylene pellets of showing smooth surface without any ‘balling up’ of fibers;
FIG. 7 is a photo of injection molded part (hemispherical shell from a double cavity mold) at 30% Fibex fiber loading showing even dispersion of fiber in invention composite resin;
FIG. 8 is a graph showing a comparison of strength (a) and stiffness (b) of Fibex reinforced polypropylene with other reinforcements and fillers;
FIG. 9 is a graph showing a comparison of strength (a) and stiffness (b) to weight ratio of Fibex reinforced polypropylene with other reinforcements and fillers; and
FIG. 10 a and FIG. 10 b are photographs of fibers (a) before and (b) after ultrasonic processing.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
Unlike other fiber processing technologies applied to bast fibers such as steam explosion (STEX), Fibex does not rely upon the use of solvents, chemicals, microbes or enzymes. As a result, there is no chemical residue. Products made with Fibex will not off-gas volatile organic compounds (VOC's) or emit strong odors commonly associated with flax. The mechanism by which Fibex is made differs fundamentally from the mechanism of the STEX process that is now practiced in Europe. The result is therefore a different composition of matter. Fibex and STEX cellulosic fibers are different compositions of matter when made from the same sample of flax. The compositional differences arise from differences in their manufacturing procedures.
During the STEX process, pretreatment is necessary in addition to STEX. The pretreatments use one or more of the following: alkaline solutions, surfactants, metal salts, complexing agents, and acid buffers. All of them act in aqueous environments and are intended to hydrolyze and/or dissolve hemicellulose and pectins without much damage to the cellulose polymer in the bast fiber.
The STEX process is an autohydrolysis process aimed at depolymerizing carbohydrates other than cellulose. In general, the hydrolysis cleaves the polymer chain at the hemiacetal functional groups. It involves cleavage of carbon-to-oxygen bonds. It is operated in a temperature/pH range known to leave cellulose mostly undisturbed while attacking hemicellulose, lignin, and pectins. That is, the temperature is well under the Tg of cellulose and well above the Tg of the other polymers. The end of the process involves release of pressure in which 10 bar to 15 bar pressure is reduced to one bar, suddenly. This mechanical action helps to free the partly depolymerized and solubilized substances from the cellulose fiber.
In contrast, Fibex processing is a primarily mechanical technology in which the unwanted flax constituents are abraded or scraped from the underlying cellulose. Although water is not rigorously excluded, no water or alkali is necessarily added for Fibex processing. The process does not feature hydrolysis. Brief periods of intensive heating occur as part of the mechanical action. There may be some chemical action under these conditions. The mechanical forces may press some of the non cellulosic material into the cellulose fibers to form thin coatings or even graft polymers. Depending on the Fibex processing conditions that are selected, there may be some decrease in DP of the order of 5% to 15% due to fracture of the polymer chains which is a radical chemical reaction, not a hydrolytic reaction.
It follows from the above description that the differences in composition of these two products (STEX and Fibex) can be determined by standard analytical methods. Fibex fibers will have a lower percentage of cellulose that STEX fibers will have. Fibex cellulose will have a distinctly higher DP than STEX fibers will have. Detailed analysis of samples of the two types of fibers will show differences in the chemical compositions of the residual films that cling to the cellulose framework.
In addition to these differences in composition, differences in the polymer morphology can be detected. STEX fibers are likely to show a higher percentage of crystallinity in its cellulose than is found with Fibex. The prolonged heating at elevated temperature and hydrolysis reactions provide the opportunity for the STEX product to move toward the most thermodynamically stable (crystalline) form. Fibex processing does not provide this opportunity due to its quick mechanical action. Based on such differences, Fibex and STEX products are distinctly different compositions of matter.
The present invention of fibrillated bast type fibers, Fibex production, uses any number of processes, all of which are likely to involve mechanical or shock waves. The preferred process, an ultrasonic process, is one possible method of dispersing the fiber, uses a burst of energy from transducers that operate in an aqueous, air, fluid, or other environment, in which cavitation phenomena are clearly present. The implosion of the tiny bubbles or other particles abrade the hemicellulose and pectin sheath off of the raw cellulose bast fiber.
EXAMPLE
An experiment was designed to apply ultrasonic energy to selectively break the weaker inter-fiber bonds of flax bast without breaking the main fibers by appropriate levels and modalities of ultrasonic energy.
The key ultrasonic processing parameters are:
Ultrasonic vibration amplitude at the active face of the applicator;
Ultrasonic horn design;
Ultrasonic frequency;
Active surface area of the horn;
Treatment time;
Fiber-to-water weight ratio;
Initial state or condition of the decorticated fibers
Total treatment volume of the water;
Differing Water treatments (e.g., “alkaline water, 5-μm filtered water, alkaline 5-μm filtered water, tap water etc.”); and
Post processing of the fibers (e.g., air drying at room temperature).
A Dukane Corporation 20-kHz ultrasonic power supply with automatic power control was used for all tests. The vibration amplitude of the converter was 20 μm peak-to-peak (pp). Since the power supply is power controlled, this vibration amplitude is a constant at all power settings. A booster with a mechanical gain or amplification of 2.5 was used to amplify the vibration to 50-μm pp. Several types of “horns” or mechanical resonant amplifiers were tried for adequate mixing as well as amplification and control of the vibration amplitude. Visual observations were used for all feedback on performance. An axis-symmetric ultrasonic horn with a gain of 2 and an active surface diameter of 1 inch, was found to perform the best and was used for all subsequent tests. Therefore, the net amplitude at the active surface is 100-μm pp.
Several trials indicated that a water-to-fiber weight ratio of 400 appears to work the best, when the total weight of water was 200 gm. For each experiment carefully weighed 0.5 gm of dry fiber were added to 200 gm of 5-μm filtered water. Treatment times of 5, 10, 15, 20, 30 and 60 seconds at power settings of 5, 15 and 25 on the ultrasonic generator were utilized. For commercial success, the objective was to investigate good performance with minimum power and time. This led to the selection of treatment time of 20 seconds at the minimum power setting of 5. At these settings, decorticated fibers were place in the ultrasonic field fibrillated to yield sufficient quantities of Fibex for characterization. FIGS. 10 a and 10 b are photographs of the fibers before and after treatment. The fibers were subsequently air dried prior to further evaluation.
The trials indicated that:
1. Ultrasonic fibrillation of decorticated bast fibers in the water medium is very effective;
2. Commercially available 20-kHz, 1-kW ultrasonic power supply was adequate;
3. The treatment time of 20 seconds was sufficient at the minimum power setting value of 5.
The fibrillated Fibex material from any of the mechanical wave processing methods can be used to compound with polymers using appropriate coupling agents to promote adhesion between the fibers and the resin. In the first case the Fibex was compounded with and 18 melt flow index (MFI) polypropylene homopolymer (Aristech 180M) using a standard roll mill at 420 F. A maleated polypropylene (MAPP Polybond 3200) was used as the coupling agent. The compound consisted of 30 to 40% by weight Fibex and 1 to 4% by weight MAPP with the balance being the PP homopolymer. The resulting compound was injection molded into standard specimens for evaluating density (per ASTM 638), tensile properties (per ASTM 6), flexural properties, and Izod Impact. The results obtained using Fibex as compared to other data from the literature for flax shives as well as other fillers and reinforcements is shown in FIGS. 8 and 9. As seen in FIG. 8, both the tensile and flexural strength of the new Fibex fibrillated fiber and compound is far superior to all other reinforcements and approach those of glass fibers in PP resins. The results are even more pronounced when compared on a strength to weight ratio basis in FIG. 9 .
The method of formulating Fibex fibers and Fibex composites includes:
1. Decortication of the bast fibers from raw materials;
2. Fibrillation, decorticated bast fibers with mechanical impact forces; and
3. In the preferred form, application of sufficient ultrasonic energy to remove the cellulose polymers from the other constituents. The ultrasonic process may occur in different regimes of power, frequency, container designs, and treatment time. The method then includes taking the fibrillated fibers and compounding same with polymeric thermoplastics (such as, PP, HDPE, LDPE, PVC, Nylon, SAN, Polyurethanes, Polystyrenes) or thermoset (polyesters, vinyl esters, epoxies, etc.), in particular resins that have processing temperatures below 325° C. The method of creation further includes the use of MAPP based coupling agents, or alternate coupling agents between the Fibex fibrillated fibers and the polymeric resins, such as acrylic acid coupling agents, silanes, aminosilanes, and isocynates. Such use of the above coupling agents increase the strength of the resin composition.
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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A decorticated bast fiber such as from flax that is particularly suitable as a reinforcement for polymeric resins, thermoplastic, and thermoset composites. The invention specifically overcomes past difficulties involving compounding and injection molding of composite specimens with bast fiber reinforcements. In one form, ultrasonic energy is applied to decorticated bast fibers to cause fibrillation.
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BACKGROUND OF THE INVENTION
This invention relates generally to crib toys and more particularly to a mechanized crib toy adapted to rock on the rail of a crib.
There are many known crib toys for amusing and entertaining a child. Many of these toys include musical devices which are mechanically actuated in any number of different ways. An example of such a device is shown in U.S. Pat. No. 4,285,159, issued Aug. 28, 1981, which discloses a RAIL RUNNER (trademark of Mattel, Inc.) toy train containing a music box adapted to move the train back and forth along a crib rail.
None of the above mentioned prior art devices discloses a mechanized crib toy having a music box adapted to rock the toy on the rail of a crib.
SUMMARY OF THE INVENTION
The present invention relates to a crib toy having an hollow outer shell with a mechanism including a spring-wound music box contained internally thereof. The output shaft of the mechanism is connected through a suitable gearing arrangement and a sliding coupling means to a clamp for mounting the entire toy on a crib rail. Therefore, when the motor of the mechanism is actuated, music will be played and the toy will be rocked. The gear ratio of the gearing arrangement is specifically designed and coordinated with turning of the output shaft to rock the toy, through the sliding coupling means, at a predetermined frequency. In a preferred embodiment of the invention, the hollow outer shell, is molded in the shape of a pony or rocking horse.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made to the accompanying drawings wherein:
FIG. 1 is a perspective view of the crib toy of the present invention mounted on the rail of a baby's crib;
FIG. 2 is a front plan view of the crib toy of FIG. 1;
FIG. 3 is a sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3;
FIGS. 5 and 6 are enlarged partial sectional views taken along lines 5--5 and 6--6 of FIG. 4, respectively, showing the short rockers and centering pins;
FIG. 7 is an exploded perspective view showing the clamping means for mounting the crib toy of the present invention on a rail;
FIG. 8 is a partial sectional view showing the music box and the crib toy in an upward rocking position; and
FIG. 9 is a partial sectional view similar to that shown in FIG. 8 with the music box and the crib toy in a different or downward rocking position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the attached drawings in which like reference numerals refer to like elements throughout the several views, there shown is the shell 10 of a child's toy. The shell may be molded out of any suitable material to emulate any desired object and is preferably in the form of a pony or rocking horse. The shell 10 may be one piece, or contain a left housing 12 and a right housing 14, as viewed in FIG. 2 of the drawings. As shown in FIGS. 1 and 3, the pony includes a head 16 at the right end thereof. A winding element or key 18, preferably in the form of a bunny rider, is mounted to the left of the head 16. The bunny passes through hole 17 formed in a simulated saddle 20 carried on the back 22 of the pony. The pony also includes a simulated mane 24 and tail 26 held in a known manner between the two halves 12 and 14.
The bunny 18 is adapted to wind up or rotate a spring motor (not shown) held within a housing 19 which also contains a musical mechanism adapted to play a lullaby or tune, in a manner well known in the art. In turn, the musical mechanism is adapted to rock the pony, as described more fully hereinafter. The two halves 12 and 14 of the pony are preferably molded with depending legs 28 having rockers 30 with a downwardly facing U-shaped channel 32 formed therebetween. The U-shaped channel allows the pony to be placed in position upon any type of thin wall member 34, such as a crib rail or the like. If the shell has two halves, they are joined together along a seam 36, as is well known in the art. In addition, the rockers 30 allow the pony to be used as a floor toy.
As is shown more clearly in FIGS. 3 through 9 of the drawings, a clamp 38 having two halves 40, 42 is used for securely holding the rocking horse to various size rails. The clamp includes spring biased holding members 44, 46 resiliently held against the sides of various sized rails by means of leaf springs 48, 50 formed as arc or triangular shaped members (see FIG. 7).
With the two halves 40, 42 of the clamp 38 joined together, an upper planar surface 52 is formed having an integral centering block 54. As is clearly shown in FIGS. 5 and 6, each of the right and left housings 12 and 14 is provided with a short rocker 56 and a centering pin 58 on the interior surface thereof. The short rockers 56 are designed with a radius which allows the pony to rock at a predetermined frequency or period. In addition, the short rockers 56 always allow the pony to return smoothly to the central rest position, as shown in FIGS. 1-5 of the drawings, if not mechanically rocked, as explained more fully below. The radius of the short rockers 56 is measured from the center of gravity of the pony, marked with a circle 59, shown in FIGS. 3, 8 and 9.
With the shell of the pony mounted over the clamp 38, the centering pins 58 on each side of the shell, engage in openings 60 formed at each end of the centering block 54. The short rockers 56 rest on the top surface of lips 61 preferably formed integral with and extending from planar surface 52. In this manner, the pony 10 may be rocked on short rockers 56 acting against the top surface of lips 61.
As shown in FIGS. 3, 8 and 9, a wire 62 having an end 64 slidingly coupled to clamp 38 through means of a vertically extending tab 66 formed integrally with clamp half 40 is used to mechanically rock the pony. The other end 68 of wire 62 is securely connected to a link 70 driven by a crank or eccentric 72. The eccentric is turned by a gear train 74 driven by an output shaft 18, shown in phanton line in FIG. 4, extending from within the housing 19. The ouput shaft is turned by the spring driven motor and the music box assembly in a manner similar to that disclosed in U.S. Pat. No. 4,285,159, the description of which operation is incorporated herein by reference.
Gear train 74 includes a gear 71 attached to the output shaft 18. Gear 71 drives a larger gear 75 through a spur gear 73 joined coaxially therewith. Gear 75 drives the crank or eccentric 72 through a coaxially formed spur gear 77. The size of and number of teeth on the individual gears 71, 73, 75, and 77 varies, depending on the speed of the output shaft, the radius of the short rockers 56, and the frequency or rate at which it is desired to rock the pony when mounted on a rail.
The overall gear ratio of the gear train 74 is coordinated to the speed of the output shaft and the radius of the short rockers to allow the pony to be rocked at what may be termed its "resonant frequency". In other words, the pony will be continuously rocked at a fairly constant rate, which rate is approximately the same as the speed of rotation of the entire gear train 74. In the preferred embodiment, the radius of each of the short rockers 56 is chosen to allow the pony to rock at one cycle per second, i.e., the same frequency as the speed of rotation of the gear train.
In operation, after the bunny 18 is turned to wind the spring motor within the housing, the spring motor will commence operation to play the music box melody. The music box mechanism will also turn the output shaft 18 thereby driving the gear train 74 at its predetermined speed. The gear train will drive the crank or eccentric 72 to move link 70. Because the link is connected or fixed at one end 76 to the housing 19, and includes a slot 79, a pin 81 of the crank 72 will drive the link in an oscillating, upward and downward motion, as shown by the arrow 78 in FIG. 4 of the drawings. As the gear train rotates, the crank or eccentric 72 will be moved downwardly thereby driving the link 70 downwardly. The link 70 will in turn drive the end 68 of wire 62 downwardly and allow it to move in the downward direction, to thereby force the pony to rock upwardly on rockers 56, as shown by arrow 80 in FIG. 8 of the drawings. End 64 of wire 62 will slide within tab 66. When the link moves upwardly, the end 68 of the wire 62 will have pressure released therefrom and end 64 will slide to the rear, to thereby allow the pony to rock downwardly on short rockers 56 in the direction of the arrow 82, shown in FIG. 9 of the drawings. In this manner, it can be seen that the pony will rock, but will slow down due to friction. However, as the music box continues to play, the gear train will continuously apply a push through wire 62 to the rocking pony in a predetermined frequency along with the melody. This push will rock the pony and amuse a child watching the rocking pony mounted on a rail or the like.
The mechanical rocking movement of the pony may be envisioned as somewhat akin to the pushing of a child on a swing. As the pony is rocking back toward its central rest position, much like a swing with a child in it being given a push before the swing reaches the natural end of its backswing, the rocking pony receives a small push or jolt from the link and wire. This small push or jolt assists the continuous rocking motion without forcing it too much.
Thus, though there has been shown and described a preferred embodiment of the invention, other embodiments and configurations will be obvious to those skilled in the art without departing from the spirit and scope of the invention.
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A crib toy in the shape of a rocking pony having an outer shell with a downwardly facing U-shaped aperture contained therein. The U-shaped aperture contains a clamp adapted to fit over different sized crib rails to securely clamp the pony thereto. The shell contains a mechanism having an output shaft which drives a gear train for rocking the pony through a slideable connecting means, while music is also played by the mechanism.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a convertible washing machine having a tub tiltable from a vertical position to a horizontal position to selectively perform the pulsator type washing and the drum type washing, and more particularly to an apparatus for and method of determining a tilt angle of the tub in such a convertible washing machine, capable of controlling the tub to be positioned at various tilt angles such as 90° corresponding to the vertical position, 0° corresponding to the horizontal position and 45°, thereby enabling the pulsator type washing, the drum type washing and the small load washing.
2. Description of the Prior Art
A "convertible washing machine" means a washing machine having a tub tiltable through an angle ranged from 0° to 90° with respect to a tub shaft so that it can performs conventional pulsator type washing at a tub tilt angle of 90° corresponding to the vertical position of the tub and a conventional drum type washing at a tub tilt angle of 0° corresponding to the horizontal position of the tub.
FIG. 1 is a partially-broken elevational view of conventional convertible washing machine. In FIG. 1, the reference numeral 1 denotes an outer case, 2 an outdoor, 3 a cover, 4 a base plate, 5 a rear cover, 6 a damper, 7 a pulsator motor, 8 a drum pulley, 9 a pulsator pulley, 10 a damper bracket, 11 a tub, 12 a drum motor, 13 a bearing housing, 14 a tub shaft, 15 a worm gear, 16 and 16' switches, 16a and 16a' respective leads of switches 16 and 16', 17 a worm motor, and 18 a worm.
As shown in FIG. 2, the worm gear 15 has a pair of stoppers 20 and 20' respectively formed at its opposite ends, and a pair of mounting holes 19 and 19' perforated through its inner portion having no gear tooth.
The worm gear 15 is fixedly mounted to the bearing housing 13 by means of the mounting holes 19 and 19'. The worm motor 17 is fixedly mounted to one side portion of the tub 11. To the worm motor 17, the worm 18 is rotatably coupled.
A tub tilting operation and a tub tilt angle sensing operation performed in the conventional convertible washing machine will now be described.
As the worm motor 17 drives under a condition that the tub 11 is kept at its vertical position corresponding to the tub tilt angle of 90°, as shown in FIG. 1, the worm 18 rotates by the drive force of the worm motor 17.
By the rotation of the worm 18, the tub 11 rotates about the tub shaft 14 toward its horizontal position because the worm 18 is engaged with the worm gear 19 fixedly mounted to the bearing housing 13.
Once the tub 11 rotates through an angle of 90°, that is, when it is positioned at its horizontal position corresponding to the tub tilt angle of 0°, one end of the worm 18 pushes the corresponding switch lead 16a', thereby causing the worm motor 17 to stop.
When the tub 11 is desired to return from its horizontal position (0°to its vertical position (90°), the worm motor 17 drives reversely. By the reverse drive force of the worm motor 17, the tub 11 rotates toward its vertical position in the same manner as mentioned above.
When the tub 11 reaches its vertical position (90°), the other end of the worm 18 pushes the corresponding switch lead 16', thereby causing the worm motor 17 to stop.
However, this tub tilt angle sensing device equipped in the conventional convertible washing machine has several problems as follows.
First, the switches 16 and 16' and the stoppers 20 and 20' of worm gear 15 may be easily damaged because this conventional tub tilt angle sensing device is constructed to physically push switches 16 and 16', respectively, by both ends of the worm 18. Even after the worm motor 17 stops, the rotation of the tub 11 is continues due to the inertia of the rotating tub 11, thereby causing the worm 18 to strike against the leads 16' forcefully and 16a'. This causes damage to not only the switches 16 and 16', but also the stoppers 20 and 20' of worm gear 15.
Second, it is difficult to always maintain the tub at a desired tub tilt angle. Where the quantity of clothes to be washed is small, the washing operation is often carried out under a condition that the tub is maintained at a tilted position by an angle of about 45° so as to reduce the amount of washing water. In this case, however, it is difficult to always maintain the tub at a desired tub tilt angle.
Third, it is impossible to detect whether the current tub position corresponds to the horizontal position (0°) or the vertical position (90°) when the electric power once cut off is applied again.
SUMMARY OF THE INVENTION
Therefore, an object of the invention is to provide an apparatus for determining a tilt angle of a tub in a convertible washing machine, capable of determining the tub tilt angle without any mechanically-damageable striking of elements.
Another object of the invention is to provide an apparatus for and a method of determining a tilt angle of a tub in a convertible washing machine, capable of controlling the tub to be maintained not only at a horizontal position (0°) or a vertical position (90°), but also at a 45°-tilted position, thereby enabling the pulsator type washing, the drum type washing and the small load washing.
Another object of the invention is to provide an apparatus for and a method of determining a tilt angle of a tub in a convertible washing machine, capable of returning the tub to its intended position when the tub unintentionally deviates due to the weight thereof or vibration during an operation of the washing machine.
Another object of the invention is to provide a method for determining a tilt angle of a tub in a convertible washing machine, capable of detecting the tilted condition of the tub at an initial state at which electric power is initially applied to the convertible washing machine, and further capable of rotating the tub to a specific initial position, for example, a vertical position.
In accordance with one aspect, the present invention provides in a convertible washing machine capable of both drum type washing and pulsator type washing, an apparatus for determining a tilt angle of a tub among 90°, 45° and 0°, comprising: means fixed to said tub and having a first and a second moving ear for rotating corresponding to said tub when said tub rotates, said first and said second moving ear formed in series with a predetermined angle; means fixed to a base of said convertible washing machine regardless of said rotation of said tub and having a first and a second stationary ear for providing a reference point to said rotation of said moving ears, said first and said second stationary ear formed in series with said predetermined angle; means having a first sensor supported by said first stationary ear and a second sensor supported by said second stationary ear, for detecting whether each of said stationary ears is fully covered by an optional one of said moving ears as said tub rotates; and means for determining a tilt angle of said tub on the basis of said detection.
In accordance with another aspect, the present invention provides in a convertible washing machine capable of both drum type washing and pulsator type washing, which comprises means fixed to said tub and having a first and a second moving ear for rotating corresponding to said tub when said tub rotates, said first and said second moving ear formed in series with a predetermined angle and each having an outwardly extending ear portion of a predetermined width, means fixed to a base regardless of said rotation of said tub and having a first and a second stationary ear for providing a reference point to said rotation of said moving ears, said first and said second stationary ear formed in series with said predetermined angle, means having a first sensor supported by said first stationary ear and a second sensor supported by said second stationary ear, for detecting whether each of said stationary ears is fully covered by an optional one of said moving ears as said tub rotates, and means for determining a tilt angle of said tub on the basis of said detection, a method of determining a tilt angle of said tub when power is initially applied to said convertible washing machine, comprising the steps of: detecting whether each of said first sensor and said second sensor is at an ON state or an OFF state at an initial state when electric power is initially applied to said convertible washing machine, said ON state corresponding to a state at which each of said stationary ears is fully covered by an optional one of said moving ears; rotating said tub toward said first sensor by driving a worm motor for a predetermined time when said first sensor and said second sensor have been detected at said initial state to be at ON state and OFF state, respectively, checking whether both of said first sensor and said second sensor come to be at ON state, checking whether a predetermined time has elapsed when both of said first sensor and said second sensor have not come to be at ON state, determining said tilt angle of said tub at said initial state as 45°-N° and the current hilt angle of said tub as 90° when both of said first sensor and said second sensor have come to be at ON state before said predetermined time elapses, and determining said tilt angle of said tub at said initial state as 90° or 90°+α° and the current tilt angle of said tub as 90°+α° when both of said first sensor and said second sensor have not come to at ON state until said predetermined time elapses, said predetermined time corresponding to a time taken for an outwardly extending ear portion of each of said moving ears to pass through each of said first and second sensors, said N being an angle corresponding to the width of said outwardly extending ear portion, and α corresponding to a predetermined clearance for preventing said moving ears from coming into contact with other elements when said tub is positioned at its 0°-tilted position or its 90°-tilted position; determining both said tilt angle of said tub at said initial state and said current tilt angle of said tub as 45° when both of said first sensor and said second sensor have been detected at said initial state to be at ON state; rotating said tub toward said first sensor by driving said worm motor until said first sensor comes to be at ON state when both of said first sensor and said second sensor have been detected at said initial state to be at OFF state, further rotating said tub toward said first sensor by driving said worm motor for said predetermined time when said first sensor has come to be at ON state while checking whether both of said first sensor and said second sensor comes to be at ON state, determining said tilt angle of said tub at said initial state as an angle of more than 0°, but less than 45° and said current tilt angle of said tub as 45° when both of said first sensor and said second sensor have come to be at ON state before said predetermined time elapses, and determining said tilt angle of said tub at said initial state as an angle of more than 45°, but less than 90° and said current tilt angle of said tub as 90°+α° when both of said first sensor and said second sensor have not come to be at ON state until said predetermined time elapses; and rotating said tub toward said first sensor by driving said worm motor until said first sensor comes to be at ON state when said first sensor and said second sensor have been detected at said initial state to be at OFF state and ON state, respectively, further rotating said tub toward said first sensor by driving said worm motor for said predetermined time when said first sensor has come to be at ON state while checking whether both of said first sensor and said second sensor come to be at ON state, determining said tilt angle of said tub at said initial state as 0° or 0°+α° and said current tilt angle of said tub as 45° when both of said first sensor and said second sensor have come to be at ON state before said predetermined time elapses, and determining said tilt angle of said tub at said initial state as 45°+N° and said current tilt angle of said tub as 90°+α° when both of said first sensor and said second sensor have not come to be at ON state until said predetermined time elapses.
In accordance with the present invention, the present invention provides in a convertible washing machine capable of both drum type washing and pulsator type washing, which comprises means fixed to said tub and having a first and a second moving ear for rotating corresponding to said tub when said tub rotates, said first and said second moving ear formed in series with a predetermined angle and each having an outwardly extending ear portion of a predetermined width, means fixed to a base regardless of said rotation of said tub and having a first and a second stationary ear for providing a reference point to said rotation of said moving ears, said first and said second stationary ear formed in series with said predetermined angle, means having a first sensor supported by said first stationary ear and a second sensor supported by said second stationary ear, for detecting whether each of said stationary ears is fully covered by an optional one of said moving ears as said tub rotates, and means for determining a tilt angle of said tub on the basis of said detection, a method of correcting an undesired angle change of said tub due to vibration when said convertible washing machine operates, comprising the steps of: continuously checking during an operation of said convertible washing machine whether said first sensor and said second sensor are at ON state and OFF state, respectively, corresponding to a vertical position of said tub, stopping said worm motor when said first sensor and said second sensor have been detected to be at ON state and OFF state, respectively, checking whether said first sensor comes to be at OFF state when said first sensor and said second sensor have not been detected to be at ON state and OFF state, respectively, and rotating said tub toward said first sensor by driving said worm motor until said first sensor comes to be at ON state when said first sensor has been detected to be at OFF state, said ON state corresponding to a state at which each of said stationary ears is fully covered by an optional one of said moving ears; continuously checking during an operation of said convertible washing machine whether said first sensor and said second sensor are at OFF state and ON state, respectively, corresponding to a horizontal position of said tub, stopping said worm motor when said first sensor and said second sensor have been detected to be at OFF state and ON state, respectively, checking whether said second sensor comes to be at OFF state when said first sensor and said second sensor have not been detected to be at OFF state and ON state, respectively, and rotating said tub toward said second sensor by driving said worm motor until said second sensor comes to be at ON state when said second sensor has been detected to be at OFF state; and continuously checking whether both of said first sensor and said second sensor are at ON state corresponding to a 45-tilted position of said tub, stopping said worm motor when both of said first sensor and said second sensor have been detected to be at ON state, checking whether said first sensor comes to be at OFF state when both of said first sensor and said second sensor have not been detected to be at ON state, rotating said tub toward said first sensor by driving said worm motor until said first sensor comes to be at ON state when said first sensor has been detected to be at OFF state, checking whether said second sensor comes to be at OFF state when said first sensor has not been detected to be at OFF state, and rotating said tub toward said second sensor by driving said worm motor until said second sensor comes to be at ON state when said second sensor has been detected to be at OFF state.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and aspects of the invention will become apparent from the following description of embodiments with reference to the accompanying drawings in which:
FIG. 1 is a partially-broken elevational view of a conventional convertible washing machine;
FIG. 2 is a tub tilt angle sensing device equipped in the conventional convertible washing machine shown in FIG. 1;
FIG. 3 is a partially-broken elevational view of a convertible washing machine equipped with an apparatus for determining a tilt angle of a tub in accordance with the present invention;
FIG. 4 is a front view of an internal construction of the convertible washing machine shown in FIG. 13;
FIG. 5A is a front view of the tub tilt angle determining apparatus in accordance with the present invention;
FIG. 5B is a schematic view of a photosensor actuating member of the tub ti It angle determining apparatus in accordance with the present invention;
FIG. 6 is an exploded perspective view of the tub tilt angle determining apparatus in accordance with the present invention;
FIG. 7 is a sectional view of the tub tilt angle determining apparatus in accordance with the present invention;
FIG. 8 is a circuit diagram of the tub tilt angle determining apparatus in accordance with the present invention;
FIG. 9A to 9C are flowcharts respectively illustrating a method of maintaining the tilt angle of a tub in a convertible washer in accordance with the present invention;
FIGS. 10A and 10B are flowcharts respectively illustrating a method of discriminating the tilted position of a tub at an initial state at which electric power is initially applied to a convertible washing machine; and
FIGS. 11A to 11D are flowcharts respectively illustrating control operations of the tub tilt angle determining apparatus for rotating the tub from various positions to desired tilted positions in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 3 and 4, a convertible washing machine is illustrated which is equipped with an apparatus for determining a tilt angle of a tub in accordance with the present invention. In FIGS. 3 and 4, elements corresponding to those in FIGS. 1 and 2 are denoted by the same reference numerals.
As shown in FIGS. 3 and 4, the convertible washing machine comprises an outer case 1 and a tub 11 disposed in the outer case 1. A plurality of dampers 6 are fixedly mounted to a base plate 4 of the outer case 1 to vertically extend from the base plate 4. The dampers 6 support a pair of damper brackets 10 at their upper ends.
A bearing housing 13 is fixedly mounted to the upper portion of each damper bracket 10. The bearing housing 13 serves to support each corresponding end of a tub shaft 14 provided at the tub 11.
The tub tilt angle determining apparatus of the present invention comprises a pair of photosensors 21 and 22 fixedly mounted to the bearing housing 13, and a photosensor actuating member 23 fixedly mounted to the tub shaft 14 to rotate together with the rotating tub 11 and transmit the rotation of the tub 11 to the photosensors 21 and 22.
The first photosensor 21 and the second photosensor 22 fixedly mounted on the circumferential surface of the bearing housing 13 are circumferentially spaced a predetermined angle θ from each other, as shown in FIG. 5A. The first photosensor 21 has a photoshield groove 21a whereas the second photosensor 22 has a photoshield groove 22a (see FIG. 6-7) .
The photosensor actuating member 23 has a pair of ear-shaped photoshield portions 23a and 23b circumferentially spaced a predetermined angle θ from each other, as shown in FIG. 5B. The photoshield portions 23a and 23b of photosensor actuating member 23 are positioned to pass through the photoshield grooves 21a and 22a of photosensors 21 and 22 during the rotation of the photosensor actuating member 23.
The photoshield portions 23a and 23b may be regarded as moving ears. In this case, the photoshield grooves 21a and 22a may be regarded as stationary ears for providing a reference point to the rotation of the photoshield portions 23a and 23b, that is, the moving ears.
In the illustrated embodiment of the present invention, the angle θ is 45° because the range of angles to be controlled is 0° to 90°.
Although the mounting of the photosensors 21 and 22 to the bearing housing 13 may be achieved by use of various mounting means, it is preferable to use the following means in accordance with an embodiment of the present invention.
As shown in FIGS. 5A, 5B and 7, a sensor bracket 24 is fixed to a cylindrical portion 13a of the bearing housing 13 by means of a plurality of set screws 25. The sensor bracket 24 has a pair of sensor mounting portions 24a and 24b downwardly bent. The photosensors 21 and 22 are fixedly mounted to respective lower surfaces of the sensor mounting portions 24a and 24b of the sensor bracket 24. To respective upper surfaces of the sensor mounting portions 24a and 24b, photosensor circuit boards 28 and 27 are attached.
Taking into consideration the angle θ defined between the photosensors 21 and 22, the sensor mounting portions 24a and 24b supporting the photosensors 21 and 22 are spaced from each other by an angle corresponding to the angle θ.
The photosensor actuating member 23 which has a cylindrical shape is fitted around one end of the tub shaft 14 and fixed by means of a plurality of set screws 28. The photoshield portions 23a and 23b are provided at the outer circumferential surface of the photosensor actuating member 23.
As shown in FIG. 6, the bearing housing 13 has an arc-shaped guide slot 13b receiving the photoshield portions 23a and 23b. The guide slot 13b has a circumferential length allowing the photoshield portions 23a and 23b to rotate through a predetermined angle.
The photoshield portions 23a and 23b of the photosensor actuating member 23 have such a large width that they have outward protrusions or ear portions circumferentially extending away from each other and beyond the photosensors 21 and 22, respectively, when they are aligned with the photosensors 21 and 22, respectively, at the 45°-tilted position of the tub 11. The construction of the photoshield portions 23a and 23b is needed to continuously maintain the tilted state of the tub 11 and sense the tilt angle of the tub 11 at an initial state at which electric power is initially applied to said convertible washing machine, as will be described hereinafter.
When the photoshield portions 23a and 23b are positioned in the photoshield grooves 21a and 21b, respectively, they shield between respective light emitting elements of the photosensors 21 and 22 and respective corresponding light receiving elements of the photosensors 21.
The guide slot 13b of bearing housing 13 should have such a circumferential length that it does not come into contact with the photoshield portions 23a and 23b when the tub 11 rotates through an angle ranged from 0° to 90°, but physically restricts a further rotation of the tub 11 beyond the angle range of 0° to 90°.
To this end, it is desirable to maintain a predetermined clearance between facing end surfaces of the guide slot 13b and each corresponding one of the photoshield portions 23a and 23b when the tub 11 is positioned at its 0°-tilted position and its 90°-tilted position.
That is, the guide slot 13b should have a circumferential length corresponding to the following angle A:
A=135°+2N°+α
wherein,
N: an angle corresponding to a half of the width of each of photoshield portions 23a and 23b; and
α: an angle corresponding to the predetermined clearance.
The photosensor actuating member 23 has a rib 23c having a thickness larger than those of the photoshield portions 23a and 23b so as to prevent possible damage of the photoshield portions 23a and 23b when the photoshield portions 23a and 23b selectively come into contact with corresponding end surfaces or stoppers 13c and 13d of the guide slot 13b.
In FIGS. 3 and 7, the reference numeral 29 denotes a bearing, 30 a stop ring, 31 a pulsator, 32 a drum, 33 a lift, and 34 a door.
In the pulsator type washing of the convertible washing machine having the above-mentioned construction, the pulsator 31 is rotated by the drive force of the pulsator motor 7 under a condition the tub 11 is vertically positioned, that is, at the tub tilt angle of 90°. For the drum type washing, the drum 32 is rotated by the drive force of the drum motor 12 under a condition that, the tub 11 is horizontally positioned, that is, at the tub tilt angle of 0°.
Where the quantity of clothes to be washed is small, a washing may be carried out in the same manner as in the pulsator type washing under a condition that the tub 11 is tilted 45°. In this case, an economical washing is achieved.
In al the washing types, charging of clothes to be washed is achieved by opening the outdoor 2 and the door 34 at the 90°-tilted position of the tub 11 and then putting the clothes into the opened tub 11.
Operation of the tub tilt angle determining apparatus of the present invention, which is applied to the convertible washing machine, will now be described in conjunction with FIGS. 5A to 11D.
As shown in FIG. 8, each of the photosensors 21 and 22 which are also denoted by respective reference characters P 1 and P 2 are constituted by a light emitting diode and a light receiving diode.
When the photoshield portions 23a and 23b pass through respective photoshield grooves 21a and 22a of the photosensors 21 and 22 during a rotation of the tub 11 and shield respective light receiving diodes of the photosensors 21 and 22 from respective corresponding light emitting diodes, the photosensors 21 and 22 supply predetermined signals to a microcomputer. Based on the received signals, the microcomputer controls the worm motor 17 so that the rotation angle of the tub 11 can be controlled.
In accordance with the illustrated embodiment of the present invention, the photosensors 21 and 22 have appropriate alignment relations with the photoshield portions 23a and 23b of the photosensor actuating member 23. As shown in FIGS. 5A and 5B, the first photosensor 21 is aligned with the second photoshield portion 23b when the tub 11 is positioned at its 90°-tilted position. When the tub 11 is positioned at its 45°-tilted position, the first photosensor 21 and the second photosensor 22 are aligned with the first photoshield portion 23a and the second photoshield portion 23b, respectively. At the 0°-tilted position of the tub 11, the second photosensor 22 is aligned with the first photoshield portion 23a.
Of course, the alignment relations among the photosensors and the photoshield portions may be varied, depending on the engineering design used.
FIGS. 9A to 9C are flowcharts illustrating a control operation for returning the tub 11 unintentionally rotated due to the weight thereof or vibration in operation of the washing machine, to its originally tilted position. In the following description, the state "P 1 =ON" means that the first photosensor 21 has been shielded by one of the photoshield portions 23a and 23b. The state "P 2 =ON" means that the second photosensor 22 has been shielded by one of the photoshield portions 23a and 23b.
FIG. 9A is a flowchart illustrating a control operation for maintaining the tub 11 at its vertical position, namely, its 90°-tilted position. This control operation will now be described in conjunction with FIG. 9A.
When the convertible washing machine operates at the vertical position of the tub 11, that is, under a condition that P 1 and P 2 are at ON state and OFF state, respectively, a checking is continuously made about whether P 1 has come to be at OFF state. Where the state "P 1 =OFF" has not been detected, a determination is made that the tub 11 has not been moved yet. However, when the state "P 1 =OFF" has been detected, the worm motor 17 rotate the tub 11 in the right direction, namely, clockwise or toward P 1 when viewed in FIG. 6 until P 1 achieves an ON state. The reason for rotating the tub in right direction is because the tub 11 is allowed by the right-side stopper to rotate only in left direction, namely, toward its horizontal position when it is positioned at its vertical position.
FIG. 9B is a flowchart illustrating a control operation for maintaining the tub 11 at its horizontal position, namely, its 0°-tilted position. This control operation will now be described in conjunction with FIG. 9B.
When the convertible washing machine operates at the horizontal position of the tub 11, that is, under a condition that P 1 and P 2 are at OFF state and ON state, respectively, a checking is continuously made about whether P 2 achieves an OFF state. Where the state "P 2 =OFF" has not been detected, a determination is made that the tub 11 has not been moved yet. However, when the state "P 2 =OFF" has been detected, the worm motor 17 drives to rotate the tub 11 in left direction, namely, counter-clockwise or toward P 2 when viewed in FIG. 6 until P 2 achieves ON state. The reason of rotating the tub in left direction is because the tub 11 is allowed by the left-side stopper to rotate only in right direction, namely, toward its vertical position when it is positioned at its horizontal position.
FIG. 9C is a flowchart illustrating a control operation for maintaining the tub 11 at its 45°-tilted position. This control operation will now be described in conjunction with FIG. 9C.
When the convertible washing machine operates under a condition that both of P 1 and P 2 are at ON state, a checking is continuously made about whether both of P 1 and P 2 achieved an ON state. Where the state "P 1 and P 2 =ON" has been detected, a determination is made that the tub 11 has not been moved yet. However, when the state "P 1 and P 2 =ON" has not been detected, a discrimination is made about whether P 1 has come to be at OFF state. When the state "P 1 =OFF" has been detected, the worm motor 17 drives to rotate the tub 11 in left direction until both of P 1 and P 2 come to be at ON state. Where the state "P 1 =OFF" has not been detected, a discrimination is made about whether P 2 has come to be at OFF state. Thereafter, the worm motor 17 drives to rotate the tub 11 in right direction until both of P 1 and P.sub. 2 come to be at ON state.
As mentioned above and as illustrated in FIG. 5B, the photoshield portions 23a and 23b of the photosensor actuating member 23 have a larger width than the photosensors 21 and 22 by a protrusion outwardly and circumferentially extended. Because of the constructions of the photoshield portions 23a and 23b, when P 1 switches to an OFF state from an ON state due to a slight movement of the tub 11 caused by vibrations during an operation of the convertible washing machine, it can be interpreted that the tub 11 has been rotated a little in right direction. Similarly, when P 2 switches to an OFF state from an ON state due to a slight movement of the tub 11 caused by vibrations during an operation of the convertible washing machine, it can be interpreted that the tub 11 has been rotated a little in left direction.
On the other hand, when the power supplied to the convertible washing machine is cut off, a memory equipped in the microcomputer for storing a present angle of the tub 11 is reset. To this end, when the electric power is applied to the convertible washing machine again, it is required to discriminate the tilt angle of the tub at the initial state of the power application so as to rotate the tub 11 to the position corresponding to the washing mode selected by the user.
In order to accomplish this operation, the outward protrusions of photoshield portions 23a and 23b of the photosensor actuating member 23 are also utilized in accordance with the illustrated embodiment of the present invention.
In other words, the initial position of the tub is detected by slightly rotating the tub in right direction or in left direction at an initial state at which electric power is initially applied to said convertible washing machine, and then sensing ON/OFF states of the photosensors 21 and 22 again, in accordance with the present invention.
For the simplicity of description, each outward protrusion of the photoshield portions 23a and 23b is assumed to have a width corresponding to the width of the corresponding photosensor so that each of the photoshield portions 23a and 23b may have a width corresponding to two times the width of each of the photosensors 21 and 22.
Now, the operation for discriminating the tilted position of the tub at an initial state at which electric power is initially applied to said convertible washing machine will be described, in conjunction with FIGS. 10A and 10B.
It is noted that the procedure illustrated in FIGS. 10A and 10B include the steps performed until the tub 11 is positioned at its vertical position (90°) after completion of the discrimination about the position of the tub 11, for the simplicity of description.
The ON/OFF states of the photosensors 21 and 22, namely, P 1 and P 2 discriminated at the initial state of electric power application will include four cases as follows:
P.sub.1 =ON and P.sub.2 =OFF; (1)
P.sub.1 =ON and P.sub.2 =ON; (2)
P.sub.1 =OFF and P.sub.2 =OFF; and (3)
P.sub.1 =OFF, P.sub.2 =ON. (4)
Primarily, the first case "P 1 =ON and P 2 =OFF" will be described.
The first case "P 1 =ON and P 2 =OFF" will correspond to one of the following cases:
(1-A) when P 1 is covered by the outward protrusion of the first, photoshield portion 23a, that is, when the tilt angle of the tub 11 at the initial state of electric power application corresponds to the angle of 45°-N°;
(1-B) when P 1 is covered by the second photoshield portion 23b, that is, when the tilt angle of the tub 11 at the initial state of electric power application corresponds to the angle of 90°; and
(1-C) when P 1 is covered by the outward protrusion of the second photoshield portion 23b, that is, when the tilt angle of the tub 11 at the initial state of electric power application corresponds to the angle of 90°+N°.
The case (1-C) does not occur because the tub 11 can not rotate in right direction beyond its 90°-tilted position, at which the rib 23c of the photosensor actuating member 23 is in contact with the stopper 13c of the guide slot 13b, even when the driving of the worm motor 17 is continued.
In either case, the worm motor 17 is driven for a predetermined time to rotate the tub 11 in the right direction. Then, a check is made whether both of P 1 and P 2 have achieved an ON state. By this checking, both the initial state and the current state of the tub 11 can be discriminated.
In this case, the predetermined time means the time taken for the tub 11 to rotate through an angle corresponding to the width of the outward protrusion of each of the photoshield portions 23a and 23b. The right direction means the direction that the tub 11 rotates toward its vertical position (90°) or the first photosensor 21.
When both of P 1 and P 2 have achieved an ON state after the driving of worm motor 17 for the predetermined time, a determination is made that the position or the tilt angle of the tub 11 at the initial state of electric power application corresponds to the case (1-A) wherein P 1 is covered by the outward protrusion of the first photoshield portion 23a and the tilt angle of the tub corresponds to the angle of 45°-N°. Simultaneously, a determination is also made that the current position of the tub 11 corresponds to the 45°-tilted position.
Then, the worm motor 17 is further driven to rotate the tub 11 in right direction until P 1 achieves an OFF state and then an ON state, thereby causing the tilt angle of the tub 11 to be changed from 45° to 90°.
Where the state "P 1 =ON and P 2 =ON" is not detected even after the driving of worm motor 17 for the predetermined time, a determination is made that the initial position or the initial tilt angle of the tub 11 corresponds to the case (1-B) wherein P 1 is covered by the second photoshield portion 23b and the initial tilt angle of the tub 11 corresponds to the angle of 90° or to the case (1-C) wherein P 1 is covered by the outward protrusion of the second photoshield portion 23b and the initial tilt angle of the tub 11 corresponds to the angle of 90°+α°. Simultaneously, a determination is also made that the current position of the tub 11 corresponds to the vertical position, namely the 90°-tilted position. As mentioned above, the angle of a is the predetermined clearance between facing end surfaces of the guide slot 13b and the photoshield portions 23a when the tub 11 is positioned at its 90°-tilted position.
In other words, since the tub I 1 has al ready been positioned at the 90°-tilted position or the 90°+α°-tilted position, the state "P 1 =ON and P 2 =ON" does not occur even when the worm motor 17 is driven for the predetermined time to rotate the tub 11 in right direction.
In this case, the continued driving of worm motor 17 cause the rotation of tub 11 no longer because the rib 23c of the photosensor actuating member 23 is in contact with the stopper 13c of the guide slot 13b.
Next, the second case wherein the state "P 1 =ON and P 2 =ON" is detected at the initial state of electric power application will be described.
In the second case, both the initial position and the current of the tub 11 correspond to the 45°-tilted position. Accordingly, the worm motor 17 is driven to rotate the tub 11 in right direction until P 1 achieves an OFF state and then at ON state, thereby causing the tub 11 to be positioned at the 90°-tilted position, in similar to the case (1-A) of the first case.
Next, the third case wherein the state "P 1 =OFF and P 2 =OFF" is detected at the initial state of electric power application will be described.
The third case "P 1 =OFF and P 2 =OFF" will correspond to one of the following cases:
(3-A ) when P 1 is positioned between the first photoshield portion 23a and the second photoshield portion 23b; and
(3-B) when P 2 is positioned between the first photoshield portion 23a and the second photoshield portion 23b.
in this third case, the worm motor 17 is driven to rotate the tub 11 in right direction until P 1 achieves at ON state.
This state "P 1 =ON" corresponds to one of the following cases:
(3-A-a) when P 1 is covered by the second photoshield portion 23b, that is, when the tilt angle of the tub 11 corresponds to the angle of 90°, by the rotation of tub 11 in right direction from the state of the case (3-A); and
(3-B-a) when P 1 is covered by the outward protrusion of the first photoshield portion 23a, that is, when the tilt angle of the tub 11 corresponds to the angle of less than 45°, by the rotation of tub 11 in right direction from the state of the case (3-B).
These cases (3-A-a) and (3-B-a) correspond to the cases (A-1) and (A-2) of the first case (A), respectively. It is, therefore, possible to distinguish the case (3-A-a) from the case (3-B-a) by driving the worm motor 17 for the predetermined time and then detecting whether both of P 1 and P 2 have come to be at ON state.
In other words, when both of P 1 and P 2 achieves an ON state after the driving of worm motor 17 for the predetermined time, a determination is made that the position or the tilt angle of the tub 11 at the initial state of electric power application corresponds to an angle of more than 0°, but less than 45°. Simultaneously, a determination is also made that the current position of the tub 11 corresponds to the 45°-tilted position.
Then, the worm motor 17 is further driven to rotate the tub 11 in right direction until P 1 achieves an OFF state and then at ON state, thereby causing the tilt angle of the tub 11 to be an angle of more than 45°, but less than 90°.
Where the state "P 1 =ON and P 2 =ON" is not detected even after the driving of worm motor 17 for the predetermined time, a determination is made that the initial position or the initial tilt angle of the tub 11 corresponds to an angle of more than 45°, but less than 90°. Simultaneously, a determination is also made that the current position of the tub 11 corresponds to an angle of 90°+N°.
Finally, the fourth case wherein the state "P 1 =OFF and P 2 =ON" is detected at the initial state of electric power application will be described.
The fourth case "P 1 =OFF and P 2 =ON" will correspond to one of the following cases:
(4-A) when P 2 is covered by the outward protrusion of the first photoshield portion 23a, that is, when the tilt angle of the tub 11 at the initial state of electric power application corresponds to the angle of 0°-N°;
(4-B) when P 2 is covered by the first photoshield portion 23a, that is, when the tilt angle of the tub 11 at the initial state of electric power application corresponds to the angle of 0°; and
(4-C) when P 2 is covered by the outward protrusion of the second photoshield portion 23b, that is, when the tilt angle of the tub 11 at the initial state of electric power application corresponds to the angle of 45°+N°.
In either case, the worm motor 17 is driven for a predetermined time to rotate the tub 11 in right direction until P 1 achieves an ON state.
This state "P 1 =ON" corresponds to one of the following cases:
(4-A-a or 4-B-a) when P 1 is covered by the outward protrusion of the first photoshield portion 23a, that is, when the tilt angle of the tub 11 corresponds to the angle of 45°-N°, by the rotation of tub 11 in right direction from the state of the case (4-A) or the case (4-B); and
(4-B-a) when P 1 is covered by the second photoshield portion 23b, that is, when the tilt angle of the tub 11 corresponds to the angle of 90°, by the rotation of tub 11 in right direction from the state of the case (4-C).
These cases (4-A-a or 4-B-a) and (4-C-a) correspond to the cases (A-1) and (A-2) of the first case (A), respectively. It is, therefore, possible to distinguish the cases (4-A-a), (4-B-a) and (4-C-a) from one another by driving the worm motor 17 for a predetermined time and then discriminating about whether both of P 1 and P 2 have achieves an ON state.
When both of P 1 and P 2 have achieves an ON state after the driving of worm motor 17 for the predetermined time, a determination is made that the position of the tub 11 at the initial state of electric power application corresponds to one of the cases (4-A) or (4-B). This is because the current state means that the outward protrusion of the first photoshield portion 23a has just passed through P 1 , but P 1 is fully covered by the first photoshield portion 23a by the rotation of tub 11. That is, this precedent state corresponds to the case (4-A-a or 4-B-a). On the other hand, when the state "P 1 =ON and P 2 =ON" is not detected even after the driving of worm motor 17 for the predetermined time, a determination is made that the position of the tub 11 corresponds to the case (4-C). This is because the current state means that the rib 23c of the photosensor actuating member 23 has already been in contact with the stopper 13c of the guide slot 13b, so that the tub 11 can rotate in right direction no longer even though the driving of the worm motor 17 continues. That is, this precedent state corresponds to the case (4-C-a).
In the former case (4-A ) or (4-B ), the worm motor 17 is continuously driven to rotate the tub 11 in right direction until P 1 achieves an OFF state and then at ON state, thereby causing the tub 11 to be positioned at the 90°-tilted position, in similar to the case (1-A) of the first case. On the other hand, the worm motor 17 is stopped in the latter case (4-C) because the rib 23c of the photosensor actuating member 23 has already been in contact with the stopper 13c of the guide slot 13b.
FIGS. 11A to 11B are flowcharts respectively illustrating operations for rotating the tub 11 from 90°-, 45°- and 0°-tilted positions to desired tilted positions. These operations can be sufficiently understood by referring to the above description made in conjunction with FIGS. 10A and 10B and thus their detailed description will be omitted.
Although the preferred embodiments of the invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
In the embodiment illustrated in FIGS. 10A and 10B, the tub is once rotated in right direction (when viewed in FIG. 5B) after completion of the detection for its initial position so that it can be positioned at its 90°-tilted position. On the contrary, the tub may be once rotated in left direction (when viewed in FIG. 5B) after completion of the detection for its initial position so that it can be positioned at its 0°-tilted position.
Although the 90°-tilted position of the tub has been assumed to be obtained when the first photosensor is fully covered by the second photoshield portion, it can be assumed to be obtained when the second photosensor is fully covered by the first photoshield portion.
In accordance still another embodiment, a plurality of photoshield portions and a plurality of photosensors may be used, even although two photoshield portions and two photosensors are used for carrying out control operations at 90°-, 45°- and 0°-tilted tub positions in the illustrated embodiments. In this case, control operations at more various tub tilt angles can be accomplished. Where photoshield portions and photosensors are arranged within 45° such that each photoshield portion and each photosensor is positioned at every 5° position, the tub can be controlled by every 5° within a range of 0° to 90°.
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An apparatus for controlling a tilt angle of a tub in a convertible washing machine which converts between drum type washing and pulsator type washing. The convertible washing machine includes a tub shaft which rotates the tub, and a tilt angle motor for changing a tilt angle of the tub to effect conversion of the convertible washing machine between drum type washing and pulsator type washing. The apparatus includes a structure which rotates with the tub and includes at least first and second projections. At least first and second reference structures are fixed to the convertible washing machine such that the first and second reference structures are stationary when the tub rotates. The first reference structure detects when one of the first and second projections is at a first predetermined position, and the second reference structure detects when one of the first and second projections is at a second predetermined position.
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[0001] CROSS-REFERENCES TO RELATED APPLICATIONS
[0002] This application claims the benefit, under 35 U.S.C. § 119(e)(1), of U.S. Provisional Application No. 60/186,005, (TI-29942PS), filed Mar. 1, 2000.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] The present embodiments relate to wireless communication systems and are more particularly directed to a wireless frequency hopping system with a receiver having a filtered adaptive slicer.
[0005] Wireless networks are becoming increasingly popular, and there has been improvement in many aspects of such networks. Various improvements relate to the use of a wireless network for a variety of devices that are typically within fairly close distances of one another, such as in the range of 10 meters or less. In the current state of the art, such a network is sometimes referred to as a personal area network (“PAN”) and it may include, by way of example, a keyboard and a printer, each of which communicates in a wireless manner with a mutual computer that is also part of the PAN. Other wireless devices (e.g., personal organizers, cell phones, and still others) also may be implemented to communicate at either the PAN level or at much greater distances. In any event, the term network is used in this document to describe a system consisting of an organized group of any of various types of intercommunicating devices.
[0006] Devices within a wireless network may communicate using one of various different protocols or the like, where one currently popular approach is known in the art as spread spectrum frequency hopping and is sometimes referred to more simply as frequency hopping. In frequency hopping, a network transmitter transmits different packets of information at different frequencies such as in an effort to reduce the chance that the packets will interfere or “collide” with packets transmitted at different frequencies by a transmitter in a different network. The change between frequencies, that is, from one frequency to another, is said to be a “hop” between the frequencies. Thus, the transmitter has a corresponding frequency hopping sequence which specifies the various different frequency bands along which the transmissions are sent. The receiver likewise is informed of and operates in response to the frequency hopping sequence so as to properly receive and demodulate the transmissions. The goal of such an approach is that each packet from a first network is transmitted at a frequency which neither overlaps nor is near enough to a frequency at which a second network is transmitting. Further in this regard, some systems transmit each successive single packet, commonly referred to as a time slot and having a duration of 625 microseconds, at a different frequency; thus, the transmitter is “hopping” to a different frequency for each packet, where the so-called Bluetooth protocol is an example of such a system. Bluetooth is a fairly new standard for radio transmissions in the 2.4 GHz ISM (Industrial, Scientific, and Medical) band, and it uses frequency hopping across a certain number of carrier frequencies, where the number of total carrier frequencies is presently set by standards which differ in various geographies. Alternatively, others systems (e.g., IEEE 802.11) transmit a first set of multiple packets at a first frequency, and then hop to a second frequency to transmit a second set of multiple packets, and so forth for numerous different sets of packets at numerous different respective frequencies.
[0007] While frequency hopping has proven itself as a beneficial protocol in wireless networks, it also has certain limitations and drawbacks due to frequency variations in both the transmission and receipt of a packet. For example, for a packet communicated in a Bluetooth communication at a carrier frequency of 2.4 GHz, each bit in that packet represents either one of two binary values based on an additional change in a modulation frequency equal to ± a value which is commonly 160 kHz, but based on implementation this value of 160 kHz could be in a range of 140 to 175 kHz. For the sake of a consistent example, in this document the change in modulation frequency is assumed to be equal to 160 kHz. Thus, for a first binary value (e.g., 1), the bit is ideally modulated at a carrier frequency of 2.4 GHz+160 kHz, whereas for a second binary value (e.g., 0), the bit is ideally modulated at a frequency of 2.4 GHz-160 kHz. This change in frequency of ±160 kHz is sometimes referred to in the art as a frequency offset In any event, error in the transmitting station's clock can cause a variation up to ±75 kHz, and error in the receiver station's clock can cause a variation up to ±50 kHz. Thus, there is the potential of a total of ±125 kHz (i.e., ±75 kHz ±50 kHz) in frequency variation in a communication between the transmitter and receiver, which therefore is a considerably large value relative to the frequency offset of 160 kHz. Clearly, therefore, a technique must exist to reduce the effect of the frequency variation so as to properly demodulate the actual data encoded by the frequency offset of 160 kHz.
[0008] In a Bluetooth system, techniques are implemented to address the frequency variations described above and they typically are performed at the same time as synchronization. Specifically, after an initial synchronization between the Bluetooth master and slave, each receiver is configured to re-synchronize itself to a transmitter's clock at the beginning of receipt of each packet from that transmitter. More particularly, the transmitter inserts a channel access code (“CAC”) at the beginning of each packet so that the receiver can use the CAC to re-synchronize itself to the transmitter's clock. The CAC consists of a preamble pattern (e.g., 1010 or 0101) followed by a 64-bit synchronization word. The receiver includes circuitry to thereby detect the CAC, which itself also introduces a ±10 bit uncertainty as to the exact location or occurrence of the CAC. As the CAC is being properly detected, the receiver also includes circuitry, as further detailed later, to correct for the frequency variations in both the transmission and receipt of the packet. Thus, once the receiver detects the CAC and also determines the frequency variation, the receiver is considered synchronized to the transmitter and can decipher the remaining data in the packet following the CAC by determining the frequency offset for each bit (i.e., either +160 KHz or −160 kHz), where this deciphering operation is assisted by the frequency variation determination made while the CAC was processed.
[0009] While the preceding approach has provided satisfactory synchronization results in frequency hopping wireless communication systems, it is observed in connection with the present inventive embodiments that such an approach also may be improved. Specifically and as also detailed later, the prior art includes a receiver for performing the synchronization and frequency variation detection functions, where the latter function is performed in part by an adaptive slicer circuit. The adaptive slicer circuit endeavors to reduce the effect of frequency variation in the received signal by determining a direct current (“DC”) voltage offset adjustment to be made to the DC voltage which is derived from the received frequency modulated signal. However, the present inventors have observed that this approach is susceptible to error due to the presence of noise in the processed signal. Indeed, such noise results in an estimated 0.8 dB loss for the performance of the receiver's adaptive slicer as compared to an ideal slicer which would know the input DC offset exactly. Accordingly, there exists a need to improve upon this performance drawback, and this need is addressed by the preferred embodiments described below.
BRIEF SUMMARY OF THE INVENTION
[0010] In the preferred embodiment, there is a wireless communication network comprising a wireless receiver. The wireless receiver comprises at least a first antenna for receiving packets, wherein each of the received packets comprises a plurality of bits and each of the plurality of bits is modulated by a frequency offset. The wireless receiver also comprises circuitry for demodulating each received packet in response to a frequency band in a hopping sequence, wherein the hopping sequence comprises a sequence of frequency bands. The wireless receiver also comprises circuitry for detecting the frequency offset of each of the plurality of bits and converting the frequency offset of each of the plurality of bits into a corresponding DC voltage for each of the plurality of bits. Still further, the wireless receiver comprises circuitry for sampling the DC voltage for each of the plurality of bits and providing a DC offset voltage for each of the plurality of bits, and it also comprises circuitry for providing a filtered DC offset voltage by filtering the DC offset voltage. Lastly, the wireless receiver also comprises circuitry for providing a digital value corresponding to each of the plurality of bits in response to the corresponding DC voltage for each of the plurality of bits as adjusted in response to the filtered DC offset voltage. Other circuits, systems, and methods are also disclosed and claimed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0011] [0011]FIG. 1 illustrates a diagram of a wireless communications system by way of an example in which the preferred embodiments may be implemented.
[0012] [0012]FIG. 2 illustrates a block diagram of the preferred embodiment filter used in connection with the adaptive slicer of the receiver in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0013] [0013]FIG. 1 illustrates a wireless network 10 in which the network devices communicate with one another along a wireless medium using frequency hopping and as an example in which the preferred embodiments may be implemented. Network 10 preferably implements the Bluetooth protocol, which as known in the art defines a master/slave relationship between Bluetooth devices in a network. Network 10 includes two wireless communication devices 12 and 14 by way of example, where one skilled in the art will appreciate from the remaining discussion that numerous other devices may be included in the network. Each device 12 and 14 includes a respective antenna AT 12 and AT 14 for communication of frequency hopping packets between the devices. Devices 12 and 14 may represent various different wireless devices, such as voice communication devices in a cellular telephone system or computers and computer-peripherals in a personal area network (“PAN”). Also, in the preferred embodiment, communication devices 12 and 14 are preferably transceivers, while they alternatively could be only one of either a transmitter or a receiver. For the sake of example, assume that device 12 is a Bluetooth master while device 14 is a Bluetooth slave. Also to simplify the remaining illustration, it is assumed that device 12 is a transmitting device while device 14 is a receiving device; thus, for the remainder of this document, these devices are referred to as transmitter 12 and receiver 14 , respectively. Lastly, note that either or both of transmitter 12 and receiver 14 may be residing in mobile devices, such as would be the case for a cellular phone or a transportable computing device or peripheral.
[0014] For purposes of operation, in general both transmitter 12 and receiver 14 include sufficient transceiver circuitry to communicate packets between one another in a wireless fashion and according to a frequency hopping protocol (e.g., Bluetooth). The term “packet” (and variations thereof) is used in this document as synonymous with a block of information sent in a finite period of time, where subsequent such packets are sent at other corresponding time periods. This block of information may take on various forms, and the block sometimes includes different information types such as a preamble or other type of control information, followed by user information which is sometimes also referred to as user data. Further, the overall packet may be referred to in the art by other names, such as a frame, and these other information blocks are also intended as included within the term “packet” for purposes of defining the present inventive scope. In any event, some of this circuitry is illustrated and discussed below to better appreciate the preferred embodiments. However, various other circuitry is known in the wireless art and, therefore, it is neither illustrated nor discussed in detail. For the sake of simplifying the discussion, each of transmitter 12 and receiver 14 is discussed separately below.
[0015] Transmitter 12 alone is constructed according to the prior art, but its operation in connection with receiver 14 improves the overall performance of network 10 as detailed later. Turning first to transmitter 12 , it includes information bits B i , which may be produced from various circuits (not shown), and bits B i are connected to an input of a packet generator 16 . Packet generator 16 parses the bits into the appropriate groups and encodes the bits into a packet format, which thereby includes within that format a preamble as detailed earlier in the Background Of The Invention section of this document. Thus, packet generator 16 inserts the previously-described channel access code (“CAC”) into the packet format and follows it with the appropriate data as provided by bits B i .
[0016] The output of packet generator 16 is connected as an input to a mixer circuit 18 . Mixer circuit 18 also receives a mixing signal as a second input. In the example of a Bluetooth network, the mixing signal is the 2.4 GHz carrier frequency plus any carrier frequency adjustment for the hopping band along which the packet is to be transmitted. In the example of Bluetooth communications, typically each hopping band is 1 MHz wide. Thus, the actual carrier frequency may be 2.402 GHz plus an additional integer times 1 MHz, where the integer is determined by the frequency hopping sequence such that the present band indicated by the sequence is added to the 2.402 GHz carrier frequency. Accordingly, the carrier frequency is 2.402GHz+S(1 MHz), where S represents the band along which the present packet is to be communicated. Note that in Bluetooth the number of bands, S, are typically established by standards, such as a total of 79 bands in the United States and most of Europe (except Spain and France) or a total of 23 bands in Spain, France, and Japan. For the United States example, therefore, the mixing signal input to mixer circuit 18 will be between 2.402 GHz and 2.480 GHz (i.e., 2.402GHz+(79-1)(1MHz)=2.480 GHz). In addition to the preceding, mixer circuit 18 also frequency modulates each bit within the packet according to the value of the bit, whereby if the bit is a logical low (e.g., binary 0) then the carrier frequency is decreased by 160 kHz, and if the bit is a logical high (e.g., binary 1) then the carrier frequency is increased by 160 kHz.
[0017] The output of mixer circuit 18 is connected as an input to a power amplifier 20 . Power amplifier 20 increases the power applied to the signal to raise it to the appropriate level for wireless communication. Thus, after the amplification is applied in this regard, the packet is transmitted by transmitter 12 via its antenna AT 12 . Accordingly, the packet and other like-transmitted packets may be received by a receiver, including receiver 14 as detailed below.
[0018] Receiver 14 receives radio frequency communications at its antenna AT 14 and those communications therefore include packets transmitted by transmitter 12 . These communications are connected to a frequency demodulator path designated generally at 22 and which includes four blocks known in the art: a low noise amplifier and mixer 24 , an intermediate frequency (“IF”) limiter 26 , a frequency modulation (“FM”) discriminator 28 , and a baseband filter 30 . Since these blocks are known in the art they are only briefly discussed here. Low noise amplifier and mixer 24 amplifies the input signal from antenna AT 14 due to the attenuation of that signal as it traveled in the wireless medium, and preferably amplifier and mixer 24 is constructed of sufficient circuitry so as to minimize the introduction of additional noise into the signal due to the amplification. In addition, low noise amplifier and mixer 24 receives the hopping sequence as an input and thereby removes that level of modulation from the incoming signal. The result is an amplified and intermediate frequency level output which is connected from amplifier 24 to IF limiter 26 , and which in the preferred embodiment is on the order of 4 MHz plus the frequency offset (i.e., ±160 kHz). Since network 10 is a frequency modulation system, then signal amplitude is not critical insofar as representing data; thus, IF limiter 26 normalizes the amplitude of the signal so that the signal may be processed further. Also due to the lack of importance of amplitude in such a system, note that no automatic gain control (“AGC”) circuitry is required in receiver 14 . In any event, the amplitude-normalized signal is then connected to FM discriminator 28 . FM discriminator 28 and baseband filter 30 together convert the frequency offset in the incoming signal into a corresponding DC voltage. More particularly, FM discriminator 28 performs a multiplication of the signal with a delay version of itself and the result thereby provides a baseband signal along with various harmonics; further, baseband filter 30 removes the harmonics, thereby leaving only the DC voltage corresponding to the frequency offset. Ideally, therefore, if the frequency offset is ±160 kHz, then the output of baseband filter 30 is a first DC voltage representing a high binary signal, whereas if the if the frequency offset is −160 kHz, then the output of baseband filter 30 is a second DC voltage representing a low binary signal.
[0019] The preceding operation, particularly with respect to the output of baseband filter 30 , describes an ideal output of one of two DC voltages. In actuality, however, the output of baseband filter 30 is further influenced by any variation in either the transmitter or receiver clock frequency which, as described above in the Background Of The Invention section of this document, may in fact exceed the frequency swing caused by the frequency offset. To compensate for these additional factors, the output of baseband filter 30 is connected as an input to an adaptive slicer 32 , and it is also connected to a 1-bit analog-to-digtal converter (“ADC”) 34 , both of which are used in the prior art. However, in the preferred embodiment, adaptive slicer 32 works in a novel manner insofar as its signal is further processed by way of a filter 36 connected between adaptive slicer 32 and 1-bit ADC 34 , thereby achieving improved performance as further detailed below.
[0020] Looking first to adaptive slicer 32 in the manner that it is the same as in the prior art, it preferably implements two capacitors, where a first capacitor stores a DC voltage, V H , from baseband filter 30 corresponding to a high binary value while a second capacitor stores a DC voltage, V L , from baseband filter 30 corresponding to a low binary value. In an ideal situation where there is no frequency variation and hence, no DC voltage contribution by such frequency error, then V H and V L are complementary voltages (i.e., symmetric about zero); thus, assume by way of example for an ideal case that V H =1.0 volt while V L =−1.0 volt. In response to the voltages stored on its two capacitors, adaptive slicer 32 determines a DC offset voltage. Thus, for a bit in a packet at a time instant t, let this DC offset voltage be represented as ε(t), and it is determined according to the following Equation 1:
ɛ ( t ) = V H + V L 2 Equation 1
[0021] From Equation 1, therefore, in the ideal case where V H and V L are complementary voltages, then the DC offset equals 0 volts.
[0022] However, recall that frequency errors such as in the clock of transmitter 12 and receiver 14 may arise, and when these fluctuations are processed through frequency demodulator path 22 , then the results from baseband filter 30 are DC voltages other than the ideal cases of V H =1.0 volt and V L =−1.0 volt. As a different example, therefore, assume that the frequency variations on average cause a higher frequency signal to be received than is ideal. As a result, V H and V L are increased, and by way of example assume that V H =1.2 volt while V L =−0.8 volt. By applying these values to Equation 1, then adaptive slicer 32 makes a different DC offset voltage determination as shown in the following Equation 2:
ɛ ( t ) = V H + V L 2 = 1.2 + ( - 0.8 ) 2 = 0.2 volts Equation 2
[0023] From Equation 2, under the prior art the 0.2 volt output from the prior art adaptive slicer is connected directly as an offset to a prior art analog-to-digital converter (“ADC”). In response, in the next time instant (i.e., t+τ), the ADC subtracts this offset value from the remaining voltage provided by baseband filter 30 and the result is converted by the ADC into a digital counterpart value. However, as discussed earlier in the Background Of The Invention section of this document, the present inventors have observed that the performance of such an approach may be improved, as is achieved in the preferred embodiment as further discussed below.
[0024] Adaptive slicer 32 operates as discussed above with respect to Equation 1, that is, to accumulate voltages on capacitors and determine an offset from the accumulated high and low voltages. Next, recall that the output of adaptive slicer 32 is not directly connected to an ADC as in the prior art but, instead, it is connected as an input to filter 36 . In the preferred embodiment, filter 36 is a first order filter and has a structure which is now described further in connection with FIG. 2.
[0025] [0025]FIG. 2 illustrates a functional block diagram of the preferred embodiment for filter 36 . Filter 36 has an input 36 i connected to receive the output, ε(t), from adaptive slicer 32 . Input 36 i is connected to a one-sample delay element 50 , and the output of delay element 50 is connected as an addend to an adder 52 . The output of adder 52 is connected as a multiplicand input to a mulitplier 54 . A second multiplicand input to mulitplier 54 is a filtering coefficient μ, where preferably 0<μ<1 as detailed below. The output 54 o of mulitplier 54 is connected as an addend input to an adder 56 . The output of adder 56 provides the output signal, ν(t) , of filter 36 along an output 36 o . The output signal, ν(t), is also fed back as an input to a one-sample delay element 58 . The output of one-sample delay element 58 is connected as a second addend input to adder 56 and its negative value is also connected as a second addend input to adder 52 .
[0026] The operation of filter 36 may be appreciated from the illustration of FIG. 2 and is further characterized by the following Equation 3:
ν(t)=ν( t−τ )+με( t−τ )−ν(t− 96 )) Equation 3
[0027] Equation 3, as well as the operation of filter 36 , may be confirmed by tracing the various signals through the illustration of FIG. 2, starting from the input 36 i of filter 36 . Thus, input 36 i passes through one-sample delay element 50 , which thereby produces an output which may be designated as ε(t−τ) due to the delay by one sample. Also, since the output of delay element 58 delays the ν(t) output by one sample, then it may be designated as ν(t−τ) and the negative of this value, −ν(t−τ), is added by adder 52 to the ε(t−τ) output from one-sample delay element 50 . Accordingly, the output 52 o of adder 52 is as shown in the following Equation 4:
output 52 o =(ε(t−τ)−ν(t−τ)) Equation 4
[0028] Next, the output from Equation 4 is multiplied by multiplier 54 times the filtering coefficient, μ; thus, the output 54 o of multiplier 54 is as shown in the following Equation 5:
output54 o =μ(ε(t−τ)−ν(t−τ)) Equation 5
[0029] Finally, output 54 o is added to the delayed output from delay element 58 , thereby producing the total result for ν(t) as shown above in Equation 3. Given the preceding, one skilled in the art should appreciate that the filtering operation of filter 36 operates to further attenuate the effects of any noise included in the ε(t) output from adaptive slicer 32 which is connected to filter 36 , and this operation and its benefits are further explored below.
[0030] Returning to FIG. 1, the signal ν(t) from filter 36 is output to 1-bit ADC 34 which recall also receives the DC voltage output from baseband filter 30 . In response, ADC 34 subtracts ν(t) as an offset from the voltage then being output by baseband filter 30 , and then ADC 34 converts the result of this subtraction to a digital output value. Looking at these operations by way of example, recall the case as illustrated in Equation 2 above wherein V H =1.2 volt and V L =−0.8 volt. Thus, in a given time instance n, suppose that baseband filter 30 outputs V H (whereas as an alternative it could output V L ) to ADC 34 and to adaptive slicer 32 . Also in the present example, adaptive slicer 32 in response determines a value on the order of ε(t)=0.2, which is then connected to filter 36 . Filter 36 then operates as illustrated above with respect to Equation 3, so that in the next instance of t (i.e., t+τ) a filtered offset value ν(t+τ) is provided to ADC 34 , and that offset is subtracted from the then-output value from baseband filter 30 . As a result of these operations, the effect of noise present in the output ε(t) of adapter slicer 32 is reduced. Indeed, in the preferred embodiment and as further detailed below, an improvement on the order of 0.3 dB has been simulated as compared to a prior art approach wherein the output of the adaptive slicer is directly connected to an ADC. Recalling that the prior art gives rise to an approximate 0.8 dB loss as compared to an ideal slicer configuration, there is a 37.5 percent (i.e., 0.3/0.8) increase in performance as between the 0.8 dB prior art value and the 0.3 dB improvement by the preferred embodiment. In any event, once ADC 34 operates as described above, it outputs the converted digital value to a timing recovery correlator 38 . Timing recovery correlator 38 operates according to the prior art, that is, it runs in the baseband and endeavors to identify where the signal is operating in time. Finally, note that the preceding operations are preferably performed by receiver 14 during receipt of the CAC at the beginning of a packet received by receiver 14 . Thus, once the corrective values for that packet, including the offset from filter 36 , are established in connection with the CAC bits of the packet, those values are preferably applied by receiver 14 to the remaining data (including user data) in that packet. In an alternative embodiment, the preceding process may be repeated later during the same packet to provide an updated DC offset voltage with that updated value then used with respect to subsequent bits in the packet. As still another alternative, the process could be continuous throughout the processing of the packet so that a continuously updated DC offset voltage is obtained and applied to packet bits then being processed. In any of these approaches, when a new packet is received, the preceding process repeats with respect to the CAC in that packet and so forth for subsequent communications.
[0031] Having illustrated in FIG. 2 a preferred embodiment of a filter 36 and having demonstrated how its operation achieves the functionality demonstrated by Equation 3, note that such an embodiment necessarily requires a value for the filtering coefficient μ to achieve its beneficial performance. As introduced earlier, recall that in the preferred embodiment that 0<μ<1. The actual value of μ in this range between zero and one may be established in various manners, such as through simulations and with empirical data. For example, in one embodiment, μ may be set to a single value between zero and one. As another example, however, in an alternative embodiment μ the filtering coefficient changes among a plurality of different values, each of which is between zero and one, and such that each different value is reduced for successive bits received in a single received packet. More particularly in this case, the following Table 1 illustrates receipt of a total of 184 bits, with three different values of μ are implemented by filter 36 as applied to three different respective sets of bits within those 184 bits:
TABLE 1 μ Bits 0.004 first 52 Bits 0.001 next 40 bits 0.00025 remaining bits in packet
[0032] According to Table 1, it may be seen that for a first set of 52 bits in a packet a value of μ=0.004 is used by filter 36 , followed by a value of μ=0.001 for a successive and second set of 40 bits, followed lastly by a value of μ=0.00025 for a successive and third set of bits that complete the packet. Thus, in this alternative, note various attributes. First, the value of μ is initially at a given value as applied to a first set of bits and then is reduced for additional bits (i.e., in one or more additional sets of bits). Second, in the approach of Table 1, each reduction of μ represents a 25 percent reduction in the value of μ in comparison to the immediately-preceding value of μ. Both of these attributes were found in combination to provide the 0.3 dB net gain for the filtered adaptive slicer output ν(t) as mentioned above, and thereby show themselves to be desirable for implementing filter 36 .
[0033] In addition to the preceding, note that the operation of network 10 in various respects may be in the manner of communications between frequency hopping wireless devices known to one skilled in the art. Since such operation is known it is not explored further herein. However, it is noted that the overall operation is further enhanced by implementing with such communications the methodology of the preferred embodiment as detailed above.
[0034] From the above, it may be appreciated that the preferred embodiments provide a wireless frequency hopping system including a transmitter and receiver, where network communications are improved. This improvement arises in that the receiver achieves better demodulation and synchronization performance over the prior art in connection with its adaptive slicing and analog-to-digital conversion values which arise in response to frequency variations such as from variations in the transmitter or receiver clock frequency. Moreover, the alternatives provided above demonstrate considerable flexibility in the inventive scope, and indeed still additional alternatives are contemplated. For example, while certain example values have been given for the value of μ those values may be adjusted given various additional considerations by one skilled in the art. As another example, while the preferred embodiments may be used with the Bluetooth protocol, other frequency hopping wireless protocols may implement various of the preceding teachings. Nonetheless, Bluetooth may well become a very prevalent protocol and, for this reason, the preferred embodiment specifically contemplates a Bluetooth implementation. As a final example, while filter 36 is shown to be a first order filter in one preferred embodiment, in an alternative embodiment filter 36 is a second order filter. Indeed, the first order approach is preferred when the frequency error is expected to be relatively constant which is often the case in a frequency hopping network, but nonetheless a second order filter would be more desirable for embodiments wherein there is a relatively quick drift or change in frequency errors. In any event, therefore, while the present embodiments have been described in detail, the preceding further demonstrates that various substitutions, modifications or alterations could be made to the descriptions set forth above without departing from the inventive scope which is defined by the following claims.
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A wireless communication network comprising a wireless receiver. The wireless receiver comprises at least a first antenna for receiving packets, wherein each of the received packets comprises a plurality of bits and each of the plurality of bits is modulated by a frequency offset. The wireless receiver also comprises circuitry for cycling through a hopping sequence, wherein the hopping sequence comprises a sequence of frequency bands and circuitry for demodulating each received packet in response to a frequency band in the hopping sequence. The wireless receiver also comprises circuitry for detecting the frequency offset of each of the plurality of bits and converting the frequency offset of each of the plurality of bits into a corresponding DC voltage for each of the plurality of bits. Still further, the wireless receiver comprises circuitry for sampling the DC voltage for each of the plurality of bits and providing a DC offset voltage for each of the plurality of bits, and it also comprises circuitry for providing a filtered DC offset voltage by filtering the DC offset voltage. Lastly, the wireless receiver also comprises circuitry for providing a digital value corresponding to each of the plurality of bits in response to the corresponding DC voltage for each of the plurality of bits as adjusted in response to the filtered DC offset voltage.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part application of Ser. No. 07/639,216 filed on Jan. 9, 1991 now U.S. Pat. No. 5,084,084 which is a continuation-in-part application of Ser. No. 07/549,140 filed on Jul. 6, 1990, now abandoned.
BACKGROUND OF THE INVENTION
the present invention relates to novel uracil derivatives and herbicides having an selectivity and containing the uracil derivatives as active ingredients.
A large variety of herbicides have been prepared and practically used for protecting important crop plants such as rice, soybean, wheat, corn, cotton, beet, etc., from weeds and for enhancing productivity of these crop plant. The herbicides may be roughly classified into the following three types according to the locality of application: 1 herbicides for upland cropping, 2 herbicides for paddy field and 3 herbicides for non-arable land. Each kind of herbicides can be further classified into subclasses such as soil incorporation treatment type, pre-emergence treatment type and post-emergence treatment type (foilage treatment) according to the method of application.
With increase of global population in recent years, there is no denying the fact that productivity of principal crop plants gives a serious influence to food economy of each country, and thus enhancement of productivity of principal crop plants is now a matter of paramount importance. In fact, for the people engaged in farming, it is still more necessary to develop herbicides which are capable of economical and efficient killing or controlling of growth of weeds which do harm to cultivation of crop plants.
As such herbicides, there are demanded the ones which can meet the following requirements:
(1) Herbicidal effect is high with small amount of application. (It is necessary, especially from the viewpoint of environmental protection, to kill the weeds by application of as small as amount of herbicide as possible.)
(2) Residual effect is appropriate. (Recently, the problem is pointed out that the chemicals retaining their effect in soil for a long time could give damage to the next crop plants. It is thus important that the chemicals keep an appropriate residual effect after application).
(3) Weeds are killed quickly after application. (It is made possible to perform seeding and transplantation of the next crop plant in a short time after chemicals treatment.)
(4) The number of times of herbicide treatment (application) required is small. (It is of much account for the farmers that the number of times of weed-controlling work be minimized.)
(5) Weeds killed or controlled by one of herbicide is of wide range. (It is desirable that different weeds such as broad-leaved weeds, graminaceous weeds and perennial weeds can be killed or controlled by application of one of herbicides.)
(6) The application method is diversified. (The herbicidal effect is intensified when it can be applied in various ways, such as soil treatment, foliage treatment, etc.)
(7) No damage to crop plants is given. (In a cultivated field where both crop plants and weeds co-exist, it is desirable that weeds alone are killed selectively by a herbicide.)
Nevertheless, there is yet available no herbicide which can meet all of the above requirements.
It is known that certain compounds of uracil derivatives have a herbicidal activity. For instance, in the Pesticide Manual, 8th Ed., p. 89 (published by The British Crop Protection Council, 1987), Bromacil as one the herbicides having uracil skeleton is disclosed.
There are also known the following hetero-ring derivatives which can serve as active ingredient for herbicides:
(1) 3-Aryluracil-alkyl, alkenyl and alkinylenol ethers represented by the following general formula: ##STR1## wherein R 1 represents C 1-8 alkyl, C 2-6 alkenyl, C 2-6 alkynyl, C 2-8 alkoxyalkyl or n ##STR2## R 2 represents halogen or cyano, R 3 represents hydrogen or halogen, R 4 represents hydrogen, fluorine or C 1-4 alkyl, R 5 represents C 1-4 alkyl or C 1-4 haloalkyl, or R 4 and R 5 may combine to represent tri- or tetra-methylene (in which R 6 and R 7 represent independently C 1-4 aklyl, and m is 1 or 2), and X is O, O--C(O), O--C(O)--O or C(O)--O (Japanese Patent Application Laid-Open (Kokai) No. 64-107967).
(2) Compounds represented by the following general formula: ##STR3## wherein R 1 represents hydrogen, C 1-4 alkyl, C 1-4 haloalkyl, formyl or C 2-6 alkanonyl, R 2 represents ether or a residue containing (thio)carbonyloxy or sulfonyloxy, the residue being directly linked to benzene nucleus A through oxygen atom, R 3 represents halogen or cyano, R 4 represents hydrogen or halogen, R 5 represents hydrogen, halogen or C 1-4 alkyl, and R 6 represents C 1-4 alkyl or C 1-4 haloalkyl, or R 5 and R 6 may be combined together to represent tri- or tetrametylene, and salts of the compounds of the said formula wherein R 1 is hydrogen (Japanese Patent Application Laid-Open (Kokai) No. 63-41466).
(3) Compounds represented by the following formula: ##STR4## wherein R 1 represents hydrogen, C 1-4 alkyl, C 2-4 alkenyl, C 2-4 alkynyl, C 2-6 alkoxyalkyl, formyl, C 2-6 alkanoyl or C 2-6 alkoxycarbonyl; R 2 represents hydrogen, C 1-6 alkyl, C 2-4 alkenyl, C 2-4 alkynyl or C 2-6 alkoxyalkyl; R 3 represents halogen or nitro; R 4 represents hydrogen or halogen; R 5 represents hydrogen, halogen, C 1-4 alkyl, chloromethyl, bromomethyl, hydroxymethyl (C 1-5 alkoxy)methyl, (C 1-5 alkylthio)methyl, cyano, nitro or thiocyanato; R 6 represents hydrogen, C 1-4 alkyl or C 1-4 fluoroalkyl, or R 5 and R 6 are combined to represent trior tetramethylene, in which one of the said methylene groups may be substituted with oxygen or sulfur, or these groups may be substituted with C 1-3 alkyl; and X represents oxygen or sulfur, in which (i) when R 5 is fluorine, R 6 is C 1-4 alkyl or C 1-4 fluoroalkyl, and (ii) when R 5 is cyano, R 6 is hydrogen or C 1-4 alkyl, and X is oxygen, and salts of the compounds of the said formula wherein R 1 and/or R 2 represent (s) hydrogen (Japanese Patent application Laid-Open (Kokai) No. 61-221178).
(4) Herbicidal compounds having the general formula: ##STR5## wherein X is hydrogen or hydroxy, R 1 is hydrogen or halo and R 2 is alkyl, cycloalkyl, phenyl, alkenyl, and substituted derivatives of the above (U.S. Pat. No. 3,981,715).
(5) Herbicidal compounds having the general formula: ##STR6## wherein X is hydrogen or hydroxy, R 1 is hydrogen or halo and R 2 is alkyl, cycloalkyl, phenyl, alkenyl, and substituted derivatives of the above (U.S. Pat. No. 3,869,457).
(6) Compounds of formula (I): ##STR7## wherein R 1 represents hydrogen, C 1-4 alkyl, C 3-4 alkenyl, C 3-4 alkynyl, C 1-4 haloalkyl, R 2 represents ##STR8## or, when R 1 represents haloalkyl, hydrogen, C 1-8 alkyl, C 2-8 alkenyl, C 2-8 alkynyl or C 2-8 alkoxyalkyl, R 3 represents halogen or cyano, R 4 represents hydrogen or halogen and R 5 represents hydrogen, fluorine or C 1-4 haloalkyl, as well as their enol ethers and salts (WO 88/10254).
Keen request is heard for the presentation of a herbicide which can meet the above-mentioned requirements (1)-(7), namely a herbicide which shows selectivity in potency, with no fear of giving any damage to crop plants (crop injury), exhibits excellent herbicidal effect at low dosage against a vide variety of weeds, and is also capable of exhibiting desired effect in both soil treatment and foliage treatment.
As a result of the present inventor's further studies, it has been found that uracil derivatives having a methyl group at 1-position of the uracil ring, a trifluoromethyl group at 6-position thereof and a phenyl group at 3-position thereof which has a NHSO 2 D 26 group at 5-position of the benzene ring, a halogen atom at 4-position thereof and a hydrogen atom or a halogen atom at 2-position thereof, have a penetrative translocation activity and a high herbicidal activity at a very low dosage, and show, particularly, no phytotoxicity against soybean. Based on the finding, the present invention has been attained.
SUMMARY OF THE INVENTION
In a first aspect of the present invention, there is provided uracil derivatives represented by the formula (I): ##STR9## wherein R 7 represents hydrogen or halogen, R 8 represents halogen and D 26 represents Cl-4 alkyl or Cl-3 haloalkyl.
In a second aspect of the present invention, there is provided a herbicidal composition comprising a herbicidally effective amount of uracil derivatives as defined in the first aspect and a herbicidally acceptable carrier or diluent therefor.
DETAILED DESCRIPTION OF THE INVENTION
Among the uracil derivatives represented by the formula (I), uracil derivatives wherein R 7 represents hydrogen, fluorine or chlorine and R 8 represents chlorine are preferred for the object of the present invention.
Among the uracil derivatives represented by the formula (I), uracil derivative wherein R 7 represents hydrogen, fluorine or chlorine, R 8 represents chlorine and D 26 represents methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, sec-butyl, t-butyl, trifluoroethyl, chloro-n-propyl are more preferable.
The uracil derivatives of the present invention can be synthesized according to the following reaction schemes: ##STR10## [wherein R 7 , R 8 and D 26 are the same meaning as defined above, G 1 represents C 1-4 alkyl, G 2 represents C 1-4 alkyl or phenyl, R' represents hydrogen, C 1-4 alkyl or phenyl and Hal represents halogen]
(1) In Scheme 1, phenyl isocyanate (VI) is reacted with β-aminoacrylic ester (V) to form an uracil derivative (I') at the first stage, and after isolating the said derivative (I') or without isolationthereof, the 1-position of the uracil ring thereof is methylated to produce an uracil derivative of the formula (I) at the second stage.
Reaction in the first stage
Usually phenyl isocyanate (VI) is used in an amount of 0.5 to 1.5 equivalents, preferably 0.8 to 1.2 equivalents to β-aminoacrylic ester (V).
The reaction can proceed without solvent, but usually a solvent is used to accelerate the reaction. As the solvents usable for the said purpose in the reaction, aliphatic hydrocarbons such as hexane, heptane, ligroine and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and chlorobenzene; halogenated hydrocarbons such as chloroform and methylene chloride; ethers such as diethyl ether, dioxane and tetrahydrofuran; ketones such as acetone and methyl ethyl ketone; nitriles such as acetonitrile and isobutyronitrile; tertiary amines such as pyridine and N,N-diethylaniline; acid amides such as N,N-dimethylacetamide, N,N-dimethylformamide and N-methylpyrrolidone; sulfur-containing compounds such as dimethyl sulfoxide and sulfolane; water; and mixtures thereof may be exemplified. Among them, the aliphatic hydrocarbons, the aromatic hydrocarbons, the acid amides, the sulfur-containing compounds and mixtures thereof are preferred.
The reaction can proceed without base, but usually a base is used in an amount of 0.5 to 10 equivalents, preferably 1.0 to 3.0 equivalents to β-aminoacrylic ester (V). As the base, there can be used, for instance, organic bases containing nitrogen such as pyridine, triethylamine, N,N-dimethylaniline, N,N-diethylaniline, 4-(N,N-dimethylamino)pyridine and 1,4-diazabicyclo[2,2,2]octane; inorganic bases such as sodium hydride, potassium hydride, sodium hydroxide, potassium hydroxide, sodium carbonate and potassium carbonate; and metal alcoholates such as sodium methoxide, sodium ethoxide and potassium-tert-butoxide. Among them, sodium hydride, sodium hydroxide and potassium hydroxide are preferred.
Reaction temperature is usually from -70° to 200° C., preferably from -30° C. to reflux temperature of the reaction mixture.
Reaction time is usually 5 minutes to 72 hours, preferably 10 minutes to 12 hours.
After the reaction is completed, the derivative (I') can be isolated by making the reaction product acidic with a mineral acid such as hydrochloric acid or an organic acid such as acetic acid, trifluoroacetic acid, p-toluenesulfonic acid or the like.
Reaction in the second stage
In the second stage of reaction, the derivative (I') is methylated by using a methylating agent in an amount of 0.5 to 10 equivalents, preferably 0.8 to 5.0 equivalents to the derivative (I'). As the methylating agent, there can be used, for instance, dimethylsulfuric acid, and methyl halides such as methyl chloride, methyl bromide and methyl iodide.
The reaction can proceed without solvent, but usually a solvent is used to accelerate the reaction. As the solvents usable for the said purpose in the above reaction, aliphatic hydrocarbons such as hexane, heptane, ligroine and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and chlorobenzene; halogenated hydrocarbons such as chloroform and methylene chloride; ethers such as diethyl ether, dioxane and tetrahydrofuran; ketones such as acetone and methyl ethyl ketone; nitriles such as acetonitrile and isobutyronitrile; tertiary amines such as pyridine and N,N-diethylaniline; acid amides such as N,N-dimethylacetomide, N,N-dimethylformamide and N-methylpyrrolidone; sulfur-containing compounds such as dimethyl sulfoxide and sulfolane; water and mixtures thereof may be exemplified. Among them, the aliphatic hydrocarbons, the aromatic hydrocarbons, the ethers, the ketones, the nitriles, the acid amides, the sulfur-containing compounds and mixtures thereof are preferred.
In the above reaction, usually a base is used in an amount of 0.5 to 10 equivalents, preferably 0.8 to 3.0 equivalents to the derivative (I'). As the base, there can be used organic bases containing nitrogen such as pyridine, triethylamine, N,N-dimethylaniline, N,N-diethylaniline, 4-(N,N-dimethylamino)pyridine and 1,4-diazabicyclo[2,2,2]octane; and inorganic bases such as sodium hydride, potassium hydride, sodium hydroxide, potassium hydroxide, sodium carbonate and potassium carbonate. Among them, such inorganic bases as sodium hydride and potassium carbonate are preferred.
Reaction temperature is usually from -30° to 150° C., preferably from -10° C. to reflux temperature of the reaction mixture.
Reaction time is usually 10 minutes to 96 hours, preferably 30 minutes to 48 hours.
(2) According to Scheme 2, N-phenyl carbamate (VII) is reacted with β-aminoacrylic ester (V) to form an uracil derivative (I') at the first stage, and after isolating the derivative (I') or without isolation thereof, the 1-position of the uracil ring thereof is methylated to produce an uracil derivative of the formula (I) at the second stage.
Reaction in the first stage
Usually N-phenyl carbamate (VII) is used in an
amount of 0.5 to 1.5 equivalents, preferably 0.8 to 1.2 equivalents to β-aminoacrylic ester (V).
Usually a solvent is required to be present in the reaction. As the solvent, there can be used, for instance, aliphatic hydrocarbons such as hexane, heptane, ligroine and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and chlorobenzene; halogenated hydrocarbons such as chloroform and methylene chloride; ethers such as diethyl ether, dioxane and tetrahydrofuran; ketones such as acetone and methyl ethyl ketone; nitriles such as acetonitrile and isobutyronitrile; tertiary amines such as pyridine and N,N-diethylaniline; acid amides such as N,N-dimethylacetamide, N,N-dimethylformamide and N-methylpyrrolidone; sulfur-containing compounds such as dimethyl sulfoxide and sulfolane; alcohols such as methanol, ethanol, propanol and butanol; water; and mixtures thereof. Among them, the aliphatic hydrocarbons, the aromatic hydrocarbons, the acid amides, the sulfur-containing compounds and mixtures thereof are preferred.
In the above reaction, usually a base is used in an amount of 0.5 to 10 equivalents, preferably 1.0 to 3.0 equivalents to β-aminoacrylic ester (V). The bases usable in the above reaction include organic bases containing nitrogen such as pyridine, triethylamine, N,N-dimethylaniline, N,N-diethylanilin, 4-(N,N-dimethylamino)pyridine and 1,4-diazabicyclo[2,2,2]octane; inorganic bases such as sodium hydride, potassium hydride, sodium hydroxide, potassium hydroxide, sodium carbonate and potassium carbonate; metal alcoholates such as sodium methoxide, sodium ethoxide and potassium-tert-butoxide; and metal alkyl mercaptides such as sodium methyl mercaptide and sodium ethyl mercaptide. Among them, inorganic bases such as sodium hydride and metal alcoholates such as sodium methoxide are preferred.
The reaction is carried out at a temperature of usually from 0° to 200° C., preferably from room temperature to reflux temperature of the reaction mixture.
Reaction time is usually 10 minutes to 24 hours, preferably 30 minutes to 24 hours.
After the completion of the reaction, the derivative (I') can be isolated from the reaction mixture by acidifying it with a mineral acid such as hydrochloric acid or an organic acid such as acetic acid, trifluoroacetic acid and p-toluenesulfonic acid.
Reaction in the second stage
Methylation of the derivative (I') can be effectuated under the same reaction conditions as in the second stage of Scheme 1.
(3) In Scheme 3, phenyl isocyanate (VI) is reacted with N-methyl-β-aminoacrylic ester (VIII) to produce an uracil derivative of the formula (I) in a single stage. It is possible to employ the same reaction conditions as used in Scheme 1.
(4) In Scheme 4,N-phenyl carbamate (VII) is reacted with N-methyl-β-aminoacrylic ester (VIII) to produce an uracil derivative of the formula (I) in a single stage. The reaction can be performed under the same reaction conditions as used in Scheme 2.
(5) In Scheme 5, a sulfonylhalide (X-a) or a sulfonic anhydride (X-b) is reacted with an aminated compound (IX) to produce an uracil derivative of the formula (I) in a single stage.
Usually the sulfonylhalide (X-a) or sulfonic anhydride (X-b) is used in amount of 0.3 to 10 equivalents, preferably 0.5˜2.0 equivalents to the aminated compound (IX).
The reaction can proceed without solvent, but usually a solvent is used to accelerate the reaction. As the solvents usable for the said purpose in the reaction, aliphatic hydrocarbons such as hexane, heptane, ligroine and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and chlorobenzene; halogenated hydrocarbons such as chloroform and methylene chloride; ethers such as diethyl ether, dioxane and tetrahydrofuran; ketones such as acetone and methyl ethyl ketone; nitriles such as acetonitrile and isobutyronitrile; tertiary amines such as pyridine and N,N-diethylaniline; acid amides such as N,N-dimethylacetamide, N,N-dimethylformamide and N-methylpyrrolidone; sulfur-containing compounds such as dimethyl sulfoxide and sulfolane; and mixtures thereof.
The reaction can proceed without base, but usually a base is used in an amount of 0.3 to 10 equivalents to the aminated compound (IX). Also, the base may be used in large excess as the solvent. As the base, there can be used, for instance, organic bases containing nitrogen such as pyridine, triethylamine, N,N-dimethylaniline, N,N-diethylaniline, 4-(N,N-dimethylamine)pyridine and 1,4-diazabicyclo[2,2,2]octane; inorganic bases such as sodium hydride, potassium hydride, sodium hydroxide, potassium hydroxide, sodium carbonate and potassium carbonate; and metal alcoholates such as sodium methoxide, sodium ethoxide and potassium-tert-butoxide. Among them, the organic bases containing nitrogen and the inorganic bases are preferred.
Reaction temperature is usually from -30° to 160° C., preferably from -10° to 130° C.
Reaction time is usually 10 minutes to 48 hours, preferably 30 minutes to 24 hours.
(6) In Scheme 6, an aminated compound (IX) is reacted with an acylating agent to form an acylated amino compound (IX-a) at the first stage; after isolating the acylated amino compound (IX-a) or without isolation thereof, the acylated amino compound (IX-a) is sulfonylated to produce an N-acylsulfamoylated compound (IX-b) in the second stage; and after isolating the N-acylsulfamoylated compound (IX-b) or without isolation thereof, the N-acylsulfamoylated compound (IX-b) is deacylated to produce an uracil derivative of the formula (I) at the third stage.
Reaction in the first stage
Usually an acylating agent is used in an amount of 0.5 to 5.0 equivalents, preferably 0.8 to 2.0 equivalents to the aminated compound (IX). As the acylating agent, acetyl chloride, benzoyl chloride, acetic anhydride and formic acid are usable and acetic anhydride is preferable.
The reaction can proceed without solvent, but usually a solvent is used to accelerate the reaction. As the solvents usable for the said purpose in the reaction, aliphatic hydrocarbons such as hexane, heptane, ligroine and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and chlorobenzene; halogenated hydrocarbons such as chloroform and methylene chloride; tertiary amines such as pyridine and N,N-diethylaniline; acid amides such as N,N-dimethylacetamide, N,N-dimethylformamide and N-methylpyrrolidone; sulfur-containing compounds such as dimethyl sulfoxide and sulfolane; organic acids such as formic acid, acetic acid and butyric acid; and mixtures thereof may be exemplified. Among them, the aliphatic hydrocarbons, the aromatic hydrocarbons, the halogenated hydrocarbons and the organic acid are preferred.
The reaction can proceed without base, but usually a base is used in an amount of 0.5 to 5.0 equivalents, preferably 0.8 to 2.0 equivalents to the aminated compound (IX). As the base, there can be used, for instance, organic bases containing nitrogen such as pyridine, triethylamine, N,N-dimethylaniline, N,N-diethylaniline, 4-(N,N dimethylamino)pyridine and 1,4-diazabicyclo[2,2,2]octane; inorganic bases such as sodium hydride, potassium hydride, sodium hydroxide, potassium hydroxide, sodium carbonate and potassium carbonate; and acetic acid salts such as sodium acetate and potassium acetate.
Reaction temperature is usually from -30° to 200° C., preferably from 0° to 130° C.
Reaction time is usually 10 minutes to 24 hours, preferably 30 minutes to 6 hours.
Reaction in the second stage
In the second stage of reaction, an acylated amino compound (IX-a) is sulfonylated by using a sulfonylating agent in an amount of 0.5 to 5.0 equivalents, preferably 0.8 to 2.0 equivalents to the acylated amino compound (IX-a). As the sulfonylating agent, there can be used, for instance, sulfonylhalide represented by the formula: Hal-SO 2 D 26 (X-a) and sulfonic anhydride represented by the formula: D 26 SO 2 --O--SO 2 D 26 (X-b).
The reaction can proceed without solvent, but usually a solvent is used to accelerate the reaction. As the solvents usable for the said purpose in the above reaction, aliphatic hydrocarbons such as hexane, heptane, ligroine and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and chlorobenzene; halogenated hydrocarbons such as chloroform and methylene chloride; ethers such as diethyl ether, dioxane and tetrahydrofuran; ketones such as acetone and methyl ethyl ketone; nitriles such as acetonitrile and isobutyronitrile; tertiary amines such as pyridine and N,N-diethylaniline; acid amides such as N,N-dimethylacetamide, N,N-dimethylformamide and N-methylpyrrolidone; sulfur-containing compounds such as dimethyl sulfoxide and sulfolane; and mixtures thereof may be exemplified.
In the above reaction, usually a base is used in an amount of 0.5 to 5.0 equivalents, preferably 0.8 to 2.0 equivalents to the acylated amino compound (IX-a). As the base, there can be used organic bases containing nitrogen such as pyridine, triethylamine, N,N-dimethylaniline, N,N-diethylaniline, 4-(N,N-dimethylamino)pyridine and 1,4-diazabicyclo[2,2,2]octane; inorganic bases such as sodium hydride, potassium carbonate and potassium carbonate and metal alcoholates such as sodium methoxide, sodium ethoxide and potassium-tert-butoxide. Among them, the organic bases containing nitrogen and inorganic bases are preferred.
Reaction temperature is usually from -30° to 160° C., preferably from -10° to 130° C.
Reaction time is usually 30 minutes to 48 hours, preferably 1 to 12 hours.
Reaction in the third stage
Usually water, alkalis or acids is used in amount of 0.5 to 3.0 equivalents, preferably 0.8 to 2.0 equivalents to the N-acylsulfamoylated compound (IX-b).
As the alkalis, inorganic bases such as sodium hydride, potassium hydride, sodium hydroxide, potassium hydroxide, sodium carbonate and potassium carbonate; and metal alcoholates such as sodium methoxide, sodium ethoxide and potassium-tert-butoxide may be exemplified. Among them, the inorganic bases are preferred.
As the acids, inorganic acids such as hydrochloric acid and sulfuric acid; and organic acids such as acetic acid and trifluoroacetic acid may be exemplified.
The reaction can proceed without solvent, but usually a solvent is used to accelerate the reaction. As the solvent, there can be used, for instance, aliphatic hydrocarbons such as hexane, heptane, ligroine and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and chlorobenzene; halogenated hydrocarbons such as chloroform and methylene chloride; alcohols such as methanol and ethanol; ethers such as diethyl ether, dioxane and tetrahydrofuran; ketones such acetone and methyl ethyl ketone; nitriles such as acetonitrile and isobutyronitrile; tertiary amines such as pyridine, triethylamine, N,N-dimethylaniline and N,N-diethylaniline; acid amides such as N,N-dimethylacetomide, N,N-dimethylformamide and N-methylpyrrolidone; organic acids such as formic acid, acetic acid and butyric acid; water; and mixtures thereof. Among them, the alcohols, the ethers, the ketones, the tertiary amines, the acid amides, the organic acids and water are preferred.
The reaction is carried out at a temperature of usually from -30° to 130° C., preferably from -10° to 100° C.
Reaction time is usually 10 minutes to 48 hours, preferably 30 minutes to 24 hours.
(7) In Scheme 7, an aminated compound (IX) is sulfonylated to produce a disulfonylaminated compound (IX-c) in the first stage; and after isolating the disulfonylaminated compound (IX-c) or without isolation thereof, the disulfonylaminated compound (IX-c) is hydrolyzed to produce an uracil derivative of the formula (I) at the second stage.
Reaction in the first stage
Usually a sulfonylhalide (X-a) or sulfonic anhydride (X-b) is used in an amount of 1.0 to 20 equivalents, preferably 2.0 to 5.0 equivalents to the aminated compound (IX).
The reaction can proceed without solvent, but usually a solvent is used to accelerate the reaction. As the solvents usable for the said purpose in the reaction, aliphatic hydrocarbons such as hexane, heptane, ligroine and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and chlorobenzene; halogenated hydrocarbons such as chloroform and methylene chloride; ethers such as diethyl ether, dioxane and tetrahydrofuran; ketones such as acetone and methyl ethyl isobutyronitrile; tertiary amines such as pyridine and N,N-diethylaniline; acid amides such as dimethylacetamide, N,N-dimethylformamide and N-methylpyrrolidone; sulfur-containing compounds such as dimethyl sulfoxide and sulfolane; and mixtures thereof may be exemplified.
The reaction can proceed without base, but usually a base is used in an amount of 1.0 to 10 equivalents, preferably 2.0 to 3.0 equivalents to the aminated compound (IX). As the base, there can be used, for instance, organic bases containing nitrogen such as pyridine, triethylamine, N,N-dimethylaniline, N,N-diethylaniline, 4-(N,N-dimethylamino)pyridine and 1,4-diazabicyclo[2,2,2]octane; inorganic bases such as sodium hydride, potassium hydride, sodium hydroxide, potassium hydroxide, sodium carbonate and potassium carbonate; and metal alcoholates such as sodium methoxide, sodium ethoxide and potassium-tert-butoxide. Among them, the organic bases containing nitrogen and inorganic bases are preferred.
The reaction is carried out at a temperature of usually from -30° to 160° C., preferably from -10° to 130° C.
Reaction time is usually 30 minutes to 60 hours, preferably 1 to 30 hours.
Reaction in the second stage
Water, alkalis or acids is used in an amount of 0.5 to 3.0 equivalents, preferably 0.8 to 2.0 equivalents to the disulfonylaminated compound (IX-c) in order to hydrolyze it.
As the alkalis, inorganic bases such as sodium hydride, potassium hydride, sodium hydroxide, potassium hydroxide, sodium carbonate and potassium carbonate; and metal alcoholates such as sodium methoxide, potassium methoxide and potassium-tert-butoxide may be exemplified. Among them, the inorganic bases are preferred.
As the acids, inorganic acids such as hydrochloric acid and sulfuric acid; and organic acids such as acetic acid and trifluoroacetic acid may be exemplified.
The reaction can proceed without solvent, but usually a solvent is used to accelerate the reaction. As the solvents usable for the said purpose in the reaction, aliphatic hydrocarbons such as hexane, heptane, ligroine and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and chlorobenzene; halogenated hydrocarbons such as chloroform and methylene chloride; alcohols such as methanol and ethanol; ethers such as diethyl ether, dioxane and tetrahydrofuran; ketones such as acetone and methyl ethyl ketone; nitriles such as acetonitrile and isobutyronitrile; tertiary amines such as pyridine, trimethylamine, N,N-dimethylaniline, N,N-diethylaniline 4-(N,N-dimethylamino)pyridine and 1,4-diazabicyclo[2,2,2]octane; acid amides such as N,N-dimethylacetamide, N,N-dimethylformamide and N-methylpyrrolidone; organic acids such as formic acid, acetic acid and butyric acid; water; and mixtures thereof may be exemplified. Among them, the alcohols, the ethers, the ketones, the tertiary amines, the acid amides, the organic acids, and water are preferred.
The reaction is carried out at a temperature of usually rom -30° to 160° C., preferably -10° to 130° C.
Reaction time is usually 5 minutes to 48 hours preferably 30 minutes to 24 hours.
The uracil derivatives of the present invention can be applied as a herbicide for upland field, paddy fields and non-arable land through either soil treatment or foliage treatment. Also, they show high herbicidal activities at a low dosage against, for instance, cropland weeds of broad-leaved weeds of Solananceae weeds such as Solanum nigrum and Datura stramonium, Malvaceae weeds such as Abutilon theophrasti and Side spinosa, Convolvulaceae weeds such as Ipomoea spps. of Ipomoea purpurea, and Calystegia spps., Amaranghaceae weeds such as Amaranthus lividus and Amaranthus retroflexus, Compositae weeds such as Xanthium pensylvanicum, Ambrosia artemisiaefolia, Helianthus annuus, Galinsoga ciliata, Cirsium arvense, Senecio vulgaris, Erigeron annus and Bidens pilosa, Cruciferae weeds such as Rorippa indica, Sinapis arvensis and Capsella Bursapastris, Polygonaceae weeds such as Polygonum Blume and Polygonum convolvulus, Portulacaceae weeds such as Portulaca oleracea, Chenopodiaceae weeds such as Chenopodium album, Chenopodium ficifolium and Kochias coparia, Caryophyllaceae weeds such as Stellaria media, Scrophulariaceae weeds such as Veronic persica, Commelinaceae weeds such as Commelina communis, Labiatae weeds such as Lamium amplexicaule and Lamium purpureum, Euphorbiaceae weeds such as Euphorbia supina and Euphorbia maculata, Rubiaceae weeds such as Galium spurium, Galium aparine and Rubiaakane,; Violaceae weeds such as Viola arvensis, and Leguminosae weeds such Sesbania exaltata and Cassis obtusifolia; Graminaceous weeds such as Sorgham bicolor, Panicum dichotomiflorum, Sorghus halepense, Echinochloa crus-galli, Digitaria adscendens, Avena fatua, Eleusine indica, Setaria viridis and Alopecurus aegualis; Cyperaceous weeds such as Cyperus rotundus and Cyperus esculentus; and paddy weeds of Alismataceae weeds such as Alisma canaliculatum, Sagittaria trifolia and Sagittaria pygmaea, cyperaceae weeds such as Cyperus difformis, Cyperus serotinus, Scirpus juncoides and Eleocharis kuroguwai, Scrothulariaceae weeds such as Lindemia pyxidaria, Potenderiaceae weeds such as Monochoria Vaginalis, Potamogetonaceae weeds such as Potamogeton distinctus, Lythraceae weeds such as Rotala indica and Gramineae weeds such as Echinochloa crus-galli. It is also quite remarkable that the uracil derivatives of the present invention do not harm to the important crops such as wheat, corn, barley, soybean, rice. Especially, since the uracil derivatives of the present invention show no phytotoxicity against soybean through either soil treatment or soil incorporation treatment, and high herbicidal activities at a very low dosage against weeds of Abutilon theophrasti, Xanthium pensylvanicum, Ipomoea spps. of Ipomoea purpurea, Calystegia spps., Amaranthus retroflexus, Polygonum Blume, Polygonum convolvulus, Portulaca oleracea, Chenopodium album, Datura stramonium, Ambrosia artemisiaefolia, Bidens pilosa, Side spinosa, Sebsania exaltata and Solanum nigrum.
Further, the uracil derivatives of the present invention are also useful as a defoliant.
In use of the compounds of present invention as a herbicide, they are usually mixed with a carrier, for example, a solid carrier such as clay, talc, bentonite, diatomaceous earth and white carbon (fine silica powder), or a liquid carrier such as water alcohols (isopropanol, butanol, benzyl alcohol, furfuryl alcohol, etc.), aromatic hydrocarbons (toluene, xylene, etc.), ethers (anisole, etc.) ketones (cyclohexanone, isophorone, etc.), esters (butyl acetate, etc.), acid amides (N-methylpyrrolidone, etc.) and halogenated carbons (chlorobenzene, etc.). Also, if necessary, they may be added with a suitable adjuvant such as surfactant, emulsifier, dispersant, penetrating agent, spreader, thickener, anti-freezing agent, coagulation preventing agent, stabilizer and the like, and can be offered to practical use in various forms of formulation such as liquid formulation, emulsifiable concentrate, wettable powder, dry flowable, flowable, dust and granule.
In a herbicidal composition of the present invention, an amount of an active ingredient of the uracil derivative of the present invention is in the range of 01. to 90 parts by weight and an amount of a herbicidal acceptable carrier or diluent is in the range of 10 to 99.9 parts by weight, based on 100 parts by weight of the herbicidal composition.
More particularly, preferable composition ratios (based on 100 parts by weight of the herbicidal composition) of the uracil derivative of the present invention in each formulation are set forth below.
______________________________________Wettable PowderThe uracil derivative of 5 to 80 parts by weightthe present inventionSolid carrier 10 to 85 parts by weightSurfactant 1 to 10 parts by weightOther carrier 1 to 5 parts by weight(For example, coagulation preventing agent, etc.)Emulsifiable ConcentrateThe uracil derivative of 1˜30 parts by weightthe present inventionLiquid carrier 30˜95 parts by weightSurfactant 5˜15 parts by weightFlowableThe uracil derivative of 5˜70 parts by weightthe present inventionLiquid carrier 15˜65 parts by weightSurfactant 5˜12 parts by weightOther carrier 5˜30 parts by wei9ht(For example, anti-freezing agent, thickener, etc.)Granular Wettable Powder (Dry Flowable)The uracil derivative of 20˜90 parts by weightthe present inventionSolid carrier 10˜60 parts by weightSurfactant 1˜20 parts by weightGranulesThe uracil derivative of 0.1˜10 parts by weightthe present inventionSolid carrier 90˜99.99 parts by weightOther carrier 1˜5 parts by weight______________________________________
The compounds of present invention may be mixed, if necessary, with other kinds of herbicide, various kinds of insecticide, fungicide, plant growth regulating agent, synergism agent and the like in the course of preparation or at the time of application of the formulation.
As the kinds of herbicide that can be mixed with the compounds of present invention in use thereof, there can be mentioned, for instance, the compounds described in Farm Chemicals Handbook, 1990.
Especially, in case applying the compound of the present invention to soybean, as the preferable compound which may be mixed with the compound of the present invention, trifluralin, pendimethalin, alachlor, metolachor, metribuzin, linuron, chlorimuron ethyl, imazaquin, imazethapyr, dinoseb, bifenox and clomazone may be examplified.
The application rate of the compound of the present invention is variable depending on the place of application, time of application, method of application, kind of crop to be treated, etc., but it is usually appropriate to apply the compound of the present invention in an amount of about 0.0001 to 10 kg/ha, preferably 0.001 to 5 kg/ha measured as the amount of active ingredient.
The uracil derivatives of the present invention have an excellent penetrative translocation activity and a very high herbicidal activity at a very low dosage, and show no phytotoxicity against soybean, and can be applied through either soil treatment or soil incorporation treatment against a wise variety of weeds.
EXAMPLES
The present invention is explained in more detail in the following Examples, however, it should be recognized that the scope of the present invention is not restricted to these examples.
EXAMPLE 1
Synthesis of 3-(4-chloro-3-ethanesulfonylaminophenyl)-1-methyl-6-trifluoromethyl-2,4 (1H,3H)-pyrimidinedione (Compound 2) ##STR11##
0.50 g of 3-(3-amino-4-chlorophenyl)-1-methyl-6-trifluoromethyl-2,4(1H,3H)-pyrimidimedione was dissolved in 5 ml of pyridine. To the obtained solution, 0.16 ml of ethanesulfonylchloride was added dropwise at a temperature of no higher than 5° C. and the mixed solution was stirred for 2 hours. After the reaction was completed, pyridine was distilled off and the residue was dissolved in ethyl acetate. The solution was washed with water, dilute hydrochloric acid and a saturated sodium chloride aqueous solution, and dried over anhydrous sodium sulfate, and then ethyl acetate was distilled off to obtain a crude product. The obtained product was washed with diisopropyl ether to obtain 0.37 g of the objective product as light brown crystals.
EXAMPLE 2
Synthesis of 3-(4-chloro-2-fluoro-5-isopropylsulfonylaminophenyl)-1-methyl-6-trifluoromethyl-2,4 (1H,3H)-pyrimidinedione (Compound 5) ##STR12##
2.00 g of 3-(5-amino-4-chloro-2-fluorophenyl)-1-methyl-6-trifluoromethyl-2,4 (1H,3H)-pyrimidinedione was dissolved in 5 ml of benzene. To the obtained solution, 0.61 ml of acetic anhydride was added an the resultant solution was refluxed for one hour. After distilling off benzene, the obtained crude product was washed with hexane to obtain 3-(5-acetylamino-4-chloro-2-fluorophenyl) -1-methyl-6-trifluoromethyl-2,4(1H,3H)-pyrimidinedione as white crystals.
m.p.: 263°˜266° C.
1 H-NMR(d 6 -DMSO) δ(ppm): 2.15(3H,s), 3,47(3H,s), 6.54(1H,s), 7.70(1H,d,J=9Hz), 7,90(1H,d,J=8Hz), 9.56(1H,br s) ##STR13##
to a suspension of 0.11 g of sodium hydride (oil, purity: 60%) in 10 ml of tetrahydrofuran, 1.00 g of the obtained 3-(5-acetylamino-4-chloro-2-fluorophenyl)-1-methyl-6-trifluoromethyl-2,4 (1H,3H)-pyrimidinedione was added at a temperature of 0° C. and then 0.30 ml of isopropylsulfonylchloride was added dropwise to the resultant suspension. After stirring for 2 hrs, the reaction mixture was poured into ice water and extracted with ethyl acetate. The extract of the ethyl acetate layer was washed with a saturated sodium chloride aqueous solution and dried over anhydrous sodium sulfate. Then ethyl acetate was distilled off to obtain a crude product. The obtained product was purified by preparative thin-layer chromatography (developing solvent: hexane/ethyl acetate=2/1) to obtain 0.54 g of 3-[4-chloro-2-fluoro-5-(N-acetyl) isopropylsulfonylaminophenyl]-1-methyl-6-trifluoromethyl-2,4(1H,3H)-pyrimidinedione as a colorless viscous oil.
1 H-NMR (CDCl 3 ) δ(ppm): 1.45(6H, d,J=7Hz), 1.97(3H,s), 3.47(3H,s), 4,10(1H, qq,J=7Hz), 6,23(1H,s), 7.29(1H,d,J=7Hz), 7.36(1H,d,J=9Hz) ##STR14##
0.47 g the obtained 3-[4-chloro-2-fluoro-5-(N-acetyl) isoporopylsulfonylaminophenyl]-1-methyl-6-trifluoromethyl-2,4(1H,3H)-pyrimidienedione was dissolved in 5 ml of tetrahydrofuran. To the obtained solution, 0.04 g of sodium hydroxide and 0.06 ml of water were added and the mixed solution was stirred for 4 hours. After the reaction was completed, the reaction mixture was poured into dilute hydrochloride acid and extracted with ethyl acetate. The extract of the ethyl acetate layer was washed with water and a saturated sodium chloride aqueous solution, and dried over anhydrous sodium sulfate. Then ethyl acetate was distilled off to obtain a crude product. The obtained product was purified by preparative thin-layer chromatography (developing solvent: hexane/ethyl acetate=3/1) to obtain 0.29 g of the objective compound as a colorless viscous oil.
EXAMPLE 3
Synthesis of 3-(2,4-dichloro-5-ethanesulfonylaminophenyl)-1-methyl-6-trifluoromethyl-2,4 (1H,3H)-pyrimidinedione (Compound 9) ##STR15##
To a mixture of 1.00 g of 3-(5-amino-2,4-dichlorophenyl)-1-methyl-6trifluoromethyl-2,4 (1H,3H)-pyrimidinedione, 0.60 g of triethylamine and 10 ml of dichloromethane, 0.56 g of ethanesulfonylchloride was added at a temperature of not more than 5° C. The resultant mixture was stirred overnight. After washing twice the reaction mixture with water, the reaction mixture was washed with a saturated sodium chloride aqueous solution and dried over anhydrous sodium sulfate. The dichloromethane was distilled off to obtain a crude product. The obtained product was washed with diisopropylether to obtain 1.40 g of 3-[5-bis (ethanesulfonyl)amino-2,4-dichlorophenyl]-1-methyl-6-trifluoromethyl-2,4(1H,3H)-pyrimidinedione as light yellow crystals.
m.p.: 221°˜223° C.
1 H-NMR(d 6 -DMSO) δ(ppm): 1.48)6H,t,J=7Hz), 3,49(3H,s), 3.61(4H,q,J=7Hz), 6,27(1H,s), 7.56(1H,s), 7.67(1H,s) ##STR16##
To 8 ml of dioxane, 0.80 g of the obtained 3-[5-bis (ethanesulfonyl)amino-2,4-dichlorophenyl]-1-methyl-6-trifluoromethyl-2,4 (1H,3H)-pyrimidinedione was dissolved and 0.12 g of sodium hydroxide (93%) and 2 ml of water were added to the obtained solution. After the mixed solution was stirred for 4 hours, a dilute hydrochloric acid was added thereto in order to acidify the resultant solution. The reaction mixture was extracted with ethyl acetate. The obtained extract of the ethyl acetate layer was washed with water and a saturated sodium chloride aqueous solution, and dried over anhydrous sodium sulfate. Then ethyl acetate was distilled off to obtain a crude product. The obtained product was purified by preparative thin-layer chromatography (developing solvent: hexane/ethyl acetate=3/2) to obtain 0.46 g of the objective product as white crystals.
REFERENCE EXAMPLE 1
Synthesis of 3-[5-bis(methanesulfonyl)amino-4-chloro-2-fluorophenyl]-1-methyl-6-trifluoromethyl-2,4 (1H,3H)-pyrimidinedione (Intermediate) ##STR17##
To a mixture of 1.00 g of 3-(5-amino-4-chloro-2-fluorophenyl)-1-methyl-6-trifluoromethyl-2,4 (1H,3H)-pyrimidinedione, 0.63 g of triethylamine and 10 ml of dichloromethane, 0.48 g of methanesulfonylchloride was added at a temperature of not more than 5° C. The resultant mixture was stirred overnight. After washing twice the reaction mixture with water, the reaction mixture was washed with a saturated sodium chloride aqueous solution and dried over anhydrous sodium sulfate. The dichloromethane was distilled off to obtain a crude product. The obtained product was washed with diisopropylether to obtain 1.36 g of the objective product as white crystals. m.p.: 282°˜285° C.
1 H-NMR(d 6 -DMSO) δ(ppm): 3.54(6H,s), 4.22(3H,s), 6.48(1H,s), 7.79(1H,d,J=9Hz), 7.98(1H,d,J=7Hz)
REFERENCE EXAMPLE 2
Synthesis of 3-[5-bis(methanosulfonyl)amino-2,4-dichlorophenyl]-1-methyl-6-trifluoromethyl-2,4 (1H,3H)-pyrimidinedione (Intermediate) ##STR18##
To a mixture of 1.00 g of 3-(5-amino-2,4-dichlorophenyl)-1-methyl-6trifluoromethyl-2,4 (1H,3H)-pyrimidicedione, 0.60 g of triethylamine and 10 ml of dichloromethane, 0.46 g of methanesulfonylchloride was added at a temperature of not more than 5° C. The resultant mixture was stirred overnight. After washing twice the reaction mixture with water, the reaction mixture was washed with a saturated sodium chloride aqueous solution and dried over anhydrous sodium sulfate. The dichloromethane was distilled off to obtain a crude product. The obtained product was washed with diisopropylether to obtain 1.40 g of the objective product as white crystals.
m.p.: not less than 300° C.
1 H-NMR(d 6 -DMSO) δ(ppm): 3.50(6H,s), 4.20(3H,s), 6.35(1H,s), 7.55(1H,s), 7.65(1H,s)
The uracil derivatives of the present invention synthesized according to the above Examples and synthesized by following the similar procedures to the above Examples or Schemes are shown in Table 1, and the physical properties of these compounds are shown in Table 2.
Further, the uracil derivative of the present invention synthesized according to the above Examples and synthesized by following the similar procedures to the above Examples or Schemes are shown in Table 3. The compounds obtainable in accordance with the present invention, however, are not limited to those shown in the following tables.
TABLE 1______________________________________Com-poundNo. Structure______________________________________ ##STR19##2 ##STR20##3 ##STR21##4 ##STR22##5 ##STR23##6 ##STR24##7 ##STR25##8 ##STR26##9 ##STR27##10 ##STR28##11 ##STR29##12 ##STR30##13 ##STR31##______________________________________
TABLE 2__________________________________________________________________________ .sup.1 H-NMR δ (ppm) PhysicalCompound No. [solvent] Properties__________________________________________________________________________1 2.94(3H, s), 3.45(3H, s), m.p.: 174˜177° C. 6.21(1H, s), 6.68˜7.00(1H, m), 7.07˜7.59(3H, m) [d.sub.6 -DMSO]2 1.33(3H, t, J=7Hz), 3.12(2H, q, J=7Hz), m.p.: 177˜180° C. 3.52(3H, s), 6.25(1H, s), 6.71˜7.17(2H, m), 7.26˜7.64(2H, m) [d.sub.6 -DMSO]3 2.95(3H, s), 3.43(3H, s), 6.29(1H, s), m.p.: 168˜171° C. 7.39(1H, d, J=9Hz), 7.44(1H, d, J=7Hz), 9.28(1H, br s) [d.sub.6 -DMSO]4 1.32(3H, t, J=7Hz), 3.06(2H, q, J=7Hz), m.p.: 165˜167° C. 3.43(3H, s), 6.23(1H, s), 7.29(1H, d, J=9Hz), 7.41(1H, d, J=7Hz), 9.11(1H, br s) [d.sub.6 -DMSO]5 1.34(6H, d, J=7Hz), 3.22(1H, qq, J=7Hz), viscous oil 3.48(3H, s), 6.22(1H, s), 6.90(1H, br s), 7.17(1H, d, J=9Hz), 7.56(1H, d, J=7Hz) [CDCl.sub.3 ]6 1.00(3H, t, J=7Hz), 1.25˜2.19(2H, m), m.p.: 113˜115° C. 2.80˜3.28(2H, m), 3.54(3H, s), 6.35(1H, s), 7.16(1H, br s), 7.40(1H, d, J=9Hz), 7.70(1H, d, J=7Hz) [CDCl.sub.3 ]7 0.70˜2.19(7H, m), 2.88˜3.24(2H, m), m.p.: 115˜117° C. 3.49(3H, s), 6.22(1H, s), 6.91(1H, br s), 7.20(1H, d, J=8Hz), 7.50(1H, d, J=7Hz) [CDCl.sub.3 ]8 3.06(3H, s), 3.50(3H, s), 6.42(1H, s), m.p.: 172˜173° C. 7.62(1H, s), 7.74(1H, s), 10.00(br s) [d.sub.6 -DMSO]9 1.31(3H, t, J=7Hz), 3.10(2H, q, J=7Hz), m.p.: 152.5˜153.5° C. 3.52(3H, s), 6.34(1H, s), 7.21(1H, s), 7.59(1H, s), 7.66(1H, s) [CDCl.sub.3 ]10 3.46(3H, s), 3.94(2H, q, J=9Hz), m.p.: 181˜184° C. 5.15(1H, br s), 6.23(1H, s), 7.25(1H, d, J=9Hz), 7.40(1H, d, J=7Hz) [CDCl.sub.3 ]11 2.05-2.45(2H, m), 3.21(2H, t, J=8Hz), vitrified 3.47(3H, s), 3.61(2H, t, J=8Hz), 6.32(1H, s), 7.35(1H, d, J=8Hz), 7.36(1H, br s), 7.60(1H, d, J=7Hz) [CDCl.sub.3 ]12 1.34(3H, t, J=7Hz), ), 3.05(2H, q, J=7Hz), m.p.: 183˜186° C. 3.47(3H, br s), 6.22(1H, s), 6.99(1H, dd, J=10Hz), 7.35(1H, dd, J=8Hz), 9.32(1H, br s), [d.sub.6 -DMSO]13 1.35(3H, t, J=7Hz), ), 3.11(2H, q, J=7Hz), m.p.: 136˜140° C. 3.54(3H, br s), 6.34(1H, s), 6.86(1H, br s), 7.50(1H, d, J=9Hz), 7.67(1H, d, J=7Hz), [CDCl.sub.3 ]__________________________________________________________________________
TABLE 3______________________________________ ##STR32##R.sup.7 R.sup.8 D.sup.26______________________________________H Cl CH.sub.3H Cl CH.sub.2 CH.sub.3H Cl CH.sub.2 CH.sub.2 CH.sub.3H Cl CH(CH.sub.3).sub.2H Cl CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3H Cl CH(CH.sub.3)CH.sub.2 CH.sub.3H Cl CH.sub.2 CH(CH.sub.3).sub.2H Cl C(CH.sub.3).sub.3H Cl CH.sub.2 CF.sub.3H Cl CH.sub.2 CH.sub.2 CH.sub.2 ClCl Cl CH.sub.3Cl Cl CH.sub.2 CH.sub.3Cl Cl CH.sub.2 CH.sub.2 CH.sub.3Cl Cl CH(CH.sub.3).sub.2Cl Cl CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3Cl Cl CH(CH.sub.3)CH.sub.2 CH.sub.3Cl Cl CH.sub.2 CH(CH.sub.3).sub.2Cl Cl C(CH.sub.3).sub.3Cl Cl CH.sub.2 CF.sub.3Cl Cl CH.sub.2 CH.sub.2 CH.sub.2 ClF Cl CH.sub.3F Cl CH.sub.2 CH.sub.3F Cl CH.sub.2 CH.sub.2 CH.sub.3F Cl CH(CH.sub.3).sub.2F Cl CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3F Cl CH(CH.sub.3)CH.sub.2 CH.sub.3F Cl CH.sub.2 CH(CH.sub.3).sub.2F Cl C(CH.sub.3).sub.3F Cl CH.sub.2 CF.sub.3F Cl CH.sub.2 CH.sub.2 CH.sub.2 ClF F CH.sub.3F F CH.sub.2 CH.sub.3F F CH.sub.2 CH.sub.2 CH.sub.3F F CH(CH.sub.3).sub.2F F CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3F F CH(CH.sub.3)CH.sub.2 CH.sub.3F F CH.sub.2 CH(CH.sub.3).sub.2F F C(CH.sub.3).sub.3F F CH.sub.2 CF.sub.3F F CH.sub.2 CH.sub.2 CH.sub.2 ClH F CH.sub.3H F CH.sub.2 CH.sub.3H F CH.sub.2 CH.sub.2 CH.sub.3H F CH(CH.sub.3).sub.2H F CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3H F CH(CH.sub.3)CH.sub. 2 CH.sub.3H F CH.sub.2 CH(CH.sub.3).sub.2H F C(CH.sub.3).sub.3H F CH.sub.2 CF.sub.3H F CH.sub.2 CH.sub.2 CH.sub.2 ClF Br CH.sub.3F Br CH.sub.2 CH.sub.3F Br CH.sub.2 CH.sub.2 CH.sub.3F Br CH(CH.sub.3).sub.2F Br CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3F Br CH(CH.sub.3)CH.sub.2 CH.sub.3F Br CH.sub.2 CH(CH.sub.3).sub.2F Br C(CH.sub.3).sub.3F Br CH.sub.2 CF.sub.3F Br CH.sub.2 CH.sub.2 CH.sub.2 ClH Br CH.sub.3H Br CH.sub.2 CH.sub.3H Br CH.sub.2 CH.sub.2 CH.sub.3H Br CH(CH.sub.3).sub.2H Br CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3H Br CH(CH.sub.3)CH.sub.2 CH.sub.3H Br CH.sub.2 CH(CH.sub.3).sub.2H Br C(CH.sub.3).sub.3H Br CH.sub.2 CF.sub.3H Br CH.sub.2 CH.sub.2 CH.sub.2 ClCl Br CH.sub.3Cl Br CH.sub.2 CH.sub.3Cl Br CH.sub.2 CH.sub.2 CH.sub.3Cl Br CH(CH.sub.3).sub.2Cl Br CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3Cl Br CH(CH.sub.3)CH.sub.2 CH.sub.3Cl Br CH.sub.2 CH(CH.sub.3).sub.2Cl Br C(CH.sub.3).sub.3Cl Br CH.sub.2 CF.sub.3Cl Br CH.sub.2 CH.sub.2 CH.sub.2 Cl______________________________________
Shown below are the examples of formulations using the compounds of the present invention. It should be understood, however, that the formulations coming within the concept of the present invention are not limited to those shown below. In the following descriptions of Formulation Examples, all "parts" are by weight unless otherwise noted.
FORMULATION EXAMPLE 1
Wettable powder
______________________________________Compound 3 of the present invention 50 partsZeeklite PFP (kaolin type clay, mfd. by 43 partsZeeklite Industries Co., Ltd.)Sorpol 5050 (anionic surfactant, mfd. 2 partsby Toho Chemical Co., Ltd.)Runox 1000 C (anionic surfactant, mfd. 3 partsby Toho Chemical Co., Ltd.)Carplex #80 (anti-freezing agent) (white 2 partscarbon, mfd. by Shionogi Pharm. Co., Ltd.)______________________________________
The above substances are uniformly mixed and ground to form a wettable powder.
FORMULATION EXAMPLE 2
Emulsifiable concentrate
______________________________________Compound 3 of the present invention 3 partsXylene 76 partsIsophorone 15 partsSorpol 3005 X (mixture of nonionic 6 partssurfactant and anionic surfactant,mfd. by Toho Chemical Co., Ltd.)______________________________________
The above substances are uniformly mixed to prepare an emulsifiable concentrate.
FORMULATION EXAMPLE 3
Flowable
______________________________________Compound 3 of the present invention 35 partsAgrizole S-711 (nonionic surfactant, 8 partsmfd. by Kao Corp.)Runox 1000 C (anionic surfactant, mfd. 0.5 partsby Toho Chemical Co., Ltd.)1% Rodopol water (thickener, mfd. by 20 partsRohone-Poulenc)Ethylene glycol (anti-freezing agent) 8 partsWater 28.5 parts______________________________________
The above substances are uniformly mixed to prepare a flowable.
FORMULATION EXAMPLE 4
Granules
______________________________________Compound 3 of the present invention 0.1 partsBentonite 55.0 partsTalc 44.9 parts______________________________________
The above substances are uniformly mixed and ground, then kneaded with stirring by adding a small amount of water, granulated by an extrusion granulator and dried to form granules.
FORMULATION EXAMPLE 5
Granular wettable powder (dry flowable)
______________________________________Compound 3 of the present invention 75 partsIsobam No. 1 (anionic surfactant, mfd. 10 partsby Kuraray Isoprene Chemical Co., Ltd.)Vanilex N (anionic surfactant, mfd. 5 partsby Sanyo Kokusaku Pulp K. K.)Carplex #80 (white carbon, mfd. by 10 partsShionogi Pharm. Co., Ltd.)______________________________________
The above substances are uniformly mixed and pulverized to form a dry flowable.
FORMULATION EXAMPLE 6
Wettable powder
______________________________________Compound 4 of the present invention 50 partsZeeklite PFP (kaolin type clay, mfd. by 43 partsZeeklite Industries Co., Ltd.)Sorpol 5050 (anionic surfactant, mfd. 2 partsby Toho Chemical Co., Ltd.)Runox 1000 C (anionic surfactant, mfd. 3 partsby Toho Chemical Co., Ltd.)Carplex #80 (anti-freezing agent) (white 2 partscarbon, mfd. by Shionogi Pharm. Co., Ltd.)______________________________________
The above substances are uniformly mixed and ground to form a wettable powder.
FORMULATION EXAMPLE 7
Emulsifiable concentrate
______________________________________Compound 4 of the present invention 3 partsXylene 76 partsIsophorone 15 partsSorpol 3005 X (mixture of nonionic 6 partssurfactant and anionic surfactant,mfd. by Toho Chemical Co., Ltd.)______________________________________
The above substances are uniformly mixed to prepare an emulsifiable concentrate.
FORMULATION EXAMPLE 8
Flowable
______________________________________Compound 4 of the present invention 35 partsAgrizole S-711 (nonionic surfactant, 8 partsmfd. by Kao Corp.)Runox 1000 C (anionic surfactant, mfd. 0.5 partsby Toho Chemical Co., Ltd.)1% Rodopol water (thickener, mfd. by 20 partsRohone-Poulenc)Ethylene glycol (anti-freezing agent) 8 partsWater 28.5 parts______________________________________
The above substances are uniformly mixed to prepare a flowable.
FORMULATION EXAMPLE 9
Granules
______________________________________Compound 4 of the present invention 0.1 partsBentonite 55.0 partsTalc 44.9 parts______________________________________
The above substances are uniformly mixed and ground, then kneaded with stirring by adding a small amount of water, granulated by an extrusion granulator and dried to form granules.
FORMULATION EXAMPLE 10
Granular wettable powder (dry flowable)
______________________________________Compound 4 of the present invention 75 partsIsobam No. l (anionic surfactant, mfd. 10 partsby Kuraray Isoprene Chemical Co., Ltd.)Vanilex N (anionic surfactant, mfd. 5 partsby Sanyo Kokusaku Pulp K. K.)Carplex #80 (white carbon, mfd. by 10 partsShionogi Pharm. Co., Ltd.)______________________________________
The above substances are uniformly mixed and pulverized to form a dry flowable.
In practical use of the above formulations, in the case of wettable powder, emulsifiable concentrate, flowable and granular wettable powder, they ar diluted 50 to 1,000 times with water and then applied so that the active ingredient will be supplied at a rate of 0.0001 to 10 kg per hectare.
The utility of the compounds of the present invention as an active ingredient of herbicides will be clearly appreciated from the results of the test examples described below.
TEST EXAMPLE 1
Test on herbicidal effect by soil treatment
Sterilized diluvial soil was placed in a 15 cm × 22 cm × 6 cm plastic case. Then the seeds of barnyardgrass (Echinochloa crus-galli), crabgrass (Digitaria adscendens), annual sedge (Cyperus microiria), black nightshade (Solanum nigrum), hairly galinsoga (Galinsoga ciliate), fieldcress (Rorippa indica), rice (Oryza sativa), corn (Zea mays), wheat (Triticum aestivum), soybean (Glycine max) and cotton (Cossipium herbaceum) were sown mixedly in the case and covered up about 1 cm with soil, and then a test liquid herbicide was sprayed uniformly over the soil surface by a small-sized sprayer so that the active ingredient would be supplied at the predetermined rate. Each test liquid herbicide was prepared by diluting with water a formulation prepared according to the relevant Formulation Examples described above. Three weeks after application (spraying) of the test liquid herbicide, its herbicidal effects on said various species of weeds and crops were examined and evaluated according to the following standard ratings. The results are shown in Table 4.
Standard ratings
5: Growth control rate is more than 90%. (Plants were almost completely withered.)
4: Growth control rate is 70˜90%.
3: Growth control rate is 40˜70%.
2: Growth control rate is 20˜40%.
1: Growth control rate is less than 5%. (Almost non-effective.)
The growth control rate was determined from the following formula after measuring the above-ground plant portion weight in the treated area and that in the nontreated area: ##EQU1##
The underlined symbols in the table represent the following:
N: barnyardgrass (Echinochloa crus-galli)
M: crabgrass (Digitaria adscendens)
K: annual sedge (Cyperus microiria)
H: black nightshade (solanum nigrum)
D: hairly galinsoga (Galinsoga ciliate)
I: fieldcress (Rorippa indicia)
R: rice (Oryza sativa)
T: corn (Zea mays)
W: wheat (Triticum aestivum)
S: soybean (Glycine max)
C: cotton (Cossipium herbaceum)
TABLE 4______________________________________ Appli- Com- cation pound amount No. (g/ha) N M K H D I R T W S C______________________________________1 10 0 0 2 4 5 5 0 0 0 0 0 20 1 1 3 5 5 5 0 0 0 0 0 40 2 2 4 5 5 5 0 0 0 0 1 2 10 0 0 2 3 5 5 0 0 0 0 0 20 1 1 3 4 5 5 0 0 0 0 0 40 2 2 4 5 5 5 0 0 0 0 1 3 10 5 5 5 5 5 5 4 0 0 0 1 20 5 5 5 5 5 5 5 1 0 0 2 40 5 5 5 5 5 5 5 2 1 0 5 4 10 5 3 5 5 5 5 0 0 0 0 2 20 5 4 5 5 5 5 1 0 0 0 4 40 5 5 5 5 5 5 3 0 0 0 5 5 10 4 4 5 5 5 5 1 1 0 0 4 20 5 5 5 5 5 5 2 2 0 0 5 40 5 5 5 5 5 5 4 3 1 0 5 6 10 3 2 5 5 5 5 1 0 0 0 4 20 4 4 5 5 5 5 2 1 0 0 5 40 5 5 5 5 5 5 4 2 1 0 5 7 10 3 4 5 5 5 5 0 0 0 0 2 20 4 5 5 5 5 5 1 1 0 0 3 40 5 5 5 5 5 5 2 2 1 0 4 8 20 5 5 5 5 5 5 4 0 0 0 1 40 5 5 5 5 5 5 5 1 0 0 2 80 5 5 5 5 5 5 5 2 1 0 5 9 20 5 3 5 5 5 5 0 0 0 0 2 40 5 4 5 5 5 5 1 0 0 0 4 80 5 5 5 5 5 5 3 0 0 0 5 10 10 4 4 5 5 5 5 1 1 0 0 3 20 5 5 5 5 5 5 2 2 0 0 4 40 5 5 5 5 5 5 4 3 1 0 5 11 10 4 4 5 5 5 5 0 0 0 0 3 20 5 5 5 5 5 5 2 1 0 0 4 40 5 5 5 5 5 5 3 3 1 0 5 12 20 3 5 5 5 5 5 0 0 0 0 3 40 4 5 5 5 5 5 1 0 0 0 4 80 5 5 5 5 5 5 3 2 1 0 5 13 10 4 4 5 5 5 5 0 0 0 0 0 20 5 5 5 5 5 5 1 0 1 0 2 40 5 5 5 5 5 5 4 1 2 0 4______________________________________
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Disclosed herein is uracil derivatives having a trifluoromethyl group at the 6-position and a phenyl group at the 3-position which has a NHSO 2 D 26 group at 5-position of the benzene ring, halogen atom at 4-position thereof and hydrogen atom or halogen atom at 2-position thereof, which are represented by the formula (I) and showing penetrative translocation activity, a very high herbicidal activity and, particularly, no phytotoxicity against soybean, in which as compared with the conventional herbicidal compounds, the said uracil derivatives can be applied for either soil treatment or soil incorporation treatment, thereby producing a quick and high herbicidal effect even at a very low dosage against a large variety of weeds including perennial weeds, and have the property to residual effect for an appropriate period of time.
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BACKGROUND
[0001] The present invention relates generally to improvements in thermometers and, more particularly, to electronic thermometers for more rapidly obtaining accurate temperature measurements.
[0002] It is common practice in the medical field to determine the body temperature of a patient by means of a temperature sensitive device that not only measures the temperature but also displays that temperature. Such temperature measurements are taken routinely in hospitals and in doctors' offices. One such device is a glass bulb thermometer incorporating a heat responsive mercury column that expands and contracts adjacent a calibrated temperature scale. Typically, the glass thermometer is inserted into the patient, allowed to remain inserted for a sufficient time interval to enable the temperature of the thermometer to stabilize at the body temperature of the patient, and subsequently removed for reading by medical personnel. This time interval is usually on the order of 3 to 8 minutes.
[0003] An electronic thermometer can take one or more minutes in its predictive mode and five or more minutes in its monitoring or direct reading mode. Electronic predictive thermometers have become popular because in their predictive mode, the time for taking the temperature is much less than the mercury thermometer. For busy nursing staffs, time is of the essence. Taking a temperature in one minute is much more desirable than taking a temperature in five minutes. More patients can be served with the faster thermometer and the nursing staff can be more productive.
[0004] Additionally, the more time that a probe must be in a patient's mouth to make a temperature determination, the more likely it is that the probe will not remain in the correct location. This is particularly true with younger patients who tend to be impatient. For patients who cannot be relied upon (by virtue of age or infirmity for example) to properly retain the thermometer for the necessary period of insertion in the body, the physical presence of medical personnel during a relatively long measurement cycle is necessary. Taking a temperature of younger patients in one minute is immensely more desirable than taking the temperature in five minutes. Thus, the predictive electronic thermometer has substantially advanced the art of temperature determination.
[0005] In addition to the above, rapid reuse on other patients is also a goal. However, with reuse, precaution must be taken to avoid the possibility of cross contamination between patients. Consequently, protective covers have been designed for use with the probes of thermometers. The protective cover is designed to completely envelope the portion of the thermometer that comes into contact with the patient. Because the protective cover may then be removed after use of the thermometer, and because the protective cover has protected the thermometer from contact with the patient, the thermometer may be immediately reused by simply applying another protective cover.
[0006] Protective probe covers have been available for predictive electronic thermometers for many years making the thermometer rapidly reusable when properly used with such covers. However, a protective cover adds material between the temperature sensor in the probe of the thermometer and the heat source; i.e., the patient. Additional material between the patient and the sensor can slow down the process of determining the patient's temperature as heat from the patient must first pass through the probe cover before it reaches the sensor. Gains made in permitting immediate reuse of thermometers due to the use of a disposable probe cover may thus be offset by the increasing length of time it takes to obtain a reading, caused by that same probe cover.
[0007] An inherent characteristic of electronic thermometers is that they do not instantaneously measure the temperature of the site to which they are applied. It may take a substantial period of time before the temperature sensitive device stabilizes at the temperature of the site and the temperature indicated by the thermometer is representative of the actual temperature of the body or site measured. This lag is caused by the various components of the measurement system that impede heat flow from the surface of the body or site to the temperature sensor. Some of the components are the sensor tip, the tissue of the body, and any hygienic probe covering applied to the sensor tip to prevent contamination between measurement subjects.
[0008] One approach to shortening the time required for an electronic thermometer to take an accurate reading of a patient's temperature is to preheat the probe tip of the thermometer to a temperature closer to the expected patient's temperature. Such probe tip heaters have been known for many years. However, the heater must have enough power to rapidly raise the temperature of the probe cover along with the probe tip. The probe cover adds further considerations, as, depending on the materials of construction, it may have a high heat capacity requiring more power on the part of the heater to raise its temperature. Failure to provide a heater with enough power will result in a slower increase in the temperature of the probe cover.
[0009] Applying enough heat to the probe tip to raise its temperature and the temperature of the probe cover to a level closer to the patients' temperature will reduce the time required for measurement as there is less difference between the temperature of the probe tip and that of the patient. Shortening the time to obtain the patient's temperature measurement would lessen the risk that the patient would not hold the probe in the correct position for the entire measurement period and requires less time of the attending medical personnel. In addition, the accuracy with which the temperature is predicted improves markedly as the processing and analysis of the data are more accurately performed. This approach has also contributed significantly to the advancement of temperature measurement technology.
[0010] A further consideration is the amount of time needed for the probe to preheat. It is undesirable to take the probe out of its well only to have to hold it for a substantial amount of time until it preheats enough to take the patient's temperature. While there is some advantage in that the probe is not in the patient's mouth while it is preheating, it still requires time of the medical staff to hold the probe until it is preheated.
[0011] While electronic thermometers have advanced the art of thermometry and preheating the probe tips of thermometers is well known, it would be desirable to increase the speed at which the tip may be heated. This would permit faster determination of the patient's temperature. The invention fulfills these needs and others.
SUMMARY OF THE INVENTION
[0012] Briefly and in general terms, the present invention is directed to providing a closed loop system and method for heating the probe of a thermometer. In a more detailed aspect, a closed loop heating system is provided that comprises a sensor mounted to the probe, the sensor configured to sense the temperature of the probe and provide a time varying temperature signal in response to the temperature of the probe, a heater mounted at the probe and responsive to heater control signals to provide heat to the probe, a power source, and a processor connected to the power source, the sensor, and the heater so as to provide a closed loop system in heating the probe, the processor providing a drive level of energy from the power source to the heater to cause the heater to heat the probe, the processor applying an offset to the drive level to the heater, the offset being a non-zero value which is a function of ambient temperature and the power source voltage to more rapidly achieve heating of the probe to a target temperature in a stable controlled fashion.
[0013] In a further detailed aspect, the processor senses the temperature of the probe and if the temperature of the probe is below a first threshold, the processor is configured to apply a larger level of drive energy to the heater to cause the probe to heat faster, and upon reaching the first threshold, the processor reduces the drive of battery energy to the heater in a proportional manner, the threshold being dependent on the drive level offset.
[0014] A method in accordance with aspects of the invention comprises the steps of sensing the temperature of the probe and providing a time varying temperature signal in response to the temperature of the probe, heating the probe in response to heater control signals, and sensing the temperature of the probe and applying heater control signals in a closed loop manner, wherein the heater control signals are applied to the heater at a drive level, and applying an offset to the drive level to the heater, the offset being a non-zero value which is a function of ambient temperature and the power source voltage to more rapidly achieve heating of the probe to a target temperature in a stable controlled fashion.
[0015] These and other features and advantages of the present invention will become apparent from the following more detailed description, when taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a perspective view showing an electronic thermometer probe and probe cover assembly incorporating a probe tip having a temperature sensor and a probe tip heater therein in accordance with aspects of the present invention;
[0017] [0017]FIG. 2 is an end-on view of the distal tip of the thermometer probe shown in FIG. 1 without the probe cover being installed;
[0018] [0018]FIG. 3 is a cross-sectional side view of the distal tip of the thermometer probe shown in FIGS. 1 and 2 taken on lines 3 - 3 of FIG. 2 and in accordance with aspects of the present invention, showing the internal components of the probe tip including the temperature sensor, the probe tip heater, and wire connections;
[0019] [0019]FIG. 4 is a cross-sectional view of the probe and probe cover of FIG. 1 showing the probe cover mounted on the probe and the temperature sensor and probe tip heater;
[0020] [0020]FIG. 5 is a block diagram view of a temperature measurement system incorporating a processor forming a part of the system controlling the temperature of the probe in accordance with aspects of the invention;
[0021] [0021]FIG. 6 is a graph showing the drive level applied to the probe tip heater; and
[0022] [0022]FIG. 7 is a flow or data chart showing the control over the drive level to the probe tip heater shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] In the following description, like reference numerals will be used to refer to like or corresponding elements in the different figures of the drawings.
[0024] Referring now to the drawings, and particularly to FIG. 1, there is shown a thermometer probe 10 and probe cover 12 assembly in accordance with aspects of the present invention that comprises an elongated thermometer probe shaft 14 mounted to a probe housing 16 and an electric cable 18 extending from a temperature sensing element disposed within the distal tip of the shaft (not shown) through the shaft and housing to the data processing portion 19 of the thermometer (shown in block diagram form for convenience) for measuring and displaying 21 the temperature sensed by a temperature sensing element located in the probe 10 . The shaft 14 includes a proximal end 20 mounted within the housing 16 and a distal end 22 with the probe tip 24 mounted thereupon. The elongated probe cover 12 is shaped and sized to fit over the probe shaft 14 and includes an open end 26 to accept the probe shaft into the probe cover and a distal tip 28 to fit snugly and securely over the probe tip 24 .
[0025] Referring now to the end-on view of FIG. 2, there is shown the distal tip 24 . In phantom lines, a probe tip heater 30 and a probe tip sensor 32 are mounted in the probe tip. The probe tip sensor 32 makes no physical contact with the probe tip heater 30 and in this embodiment, they are diametrically separated, although other arrangements are possible.
[0026] Referring now to FIG. 3 which is a cross-sectional view taken along lines 3 - 3 of FIG. 2, the heater 30 and sensor 32 are shown as are their respective electrical conductors 34 and 36 . These conductors make connections 38 with main body conductors 40 in the probe distal end 22 . In this embodiment, the sensor 32 is primarily mounted to the distal end 24 of the probe 10 while the heater 30 is primarily mounted to the distal end wall 42 . This configuration permits enough room for both devices in the distal end without their touching each other. Other arrangements are possible.
[0027] Referring now to FIG. 4, the same view as in FIG. 3 is presented with the additional element of an installed probe cover 12 . As shown, the heater 30 and sensor 32 positions are at locations on the distal tip 22 wall which is in contact with the probe cover 12 . As mentioned above, the probe cover 12 will be located between the patient and the temperature sensor 32 and will also therefore need to be preheated by the heater 30 .
[0028] Referring to FIG. 5, the block diagram generally shows major electronic components of an electronic thermometer 42 . The temperature sensor 32 provides temperature signals in response to the temperature sensed during measurement. In the case where a thermistor is used as the temperature sensor 32 , these signals are analog voltages or currents representative of the resistance of the thermistor and therefore representative of the sensed temperature. They are converted into digital form for further processing by an analog-to-digital converter 44 . The analog-to-digital converter 44 is connected to a processor 46 that receives the digital temperature signals and processes them to determine the temperature of the subject being measured.
[0029] A timer 48 provides time 'signals to the processor 46 used during the processing of the temperature signals, and a memory 50 stores the temperature and time signal data so that the signal data can be analyzed at a subsequent time. The memory 50 also stores empirically-derived constants used by the processor 46 to control the heater 30 and calculate the temperature. Once the signals have been processed, the processor 46 provides a signal to the display 52 to display the temperature. Activating a switch 54 enables the temperature measurement functions of the thermometer 42 . This switch is preferably located within the probe storage well 17 such that removal of the probe enables the measurement. A power source 56 , such as a battery, is connected to the processor. The processor controls the application of power to the heater 30 , or the heater's drive level, as discussed below.
[0030] Referring now to FIG. 6, a graph of the drive level 60 of the heater is presented. The graph has the axes of drive level and probe temperature. In this embodiment, at 94 degrees F, the drive level is reduced to zero, which means that no energy is applied to the heater when it reaches this temperature. The drive level at lower temperatures is set at 0.4 is this embodiment and is reduced as it reaches a particular temperature as will be discussed below.
[0031] In accordance with aspects of the invention, the amount of power applied to the heating element is a function of the difference between a predefined “target” temperature (94 degrees F.) and the tip temperature. Although the basic design of the feedback control loop is that of a “Proportional, Integral, Derivative” (PID) system, novel approaches were incorporated to modify this design.
[0032] In a PID heater control system, the “P” component computes a drive level proportional to the temperature error (target—actual). If the tip temperature is close to the target (small error), the “P” component will be small. If the tip temperature is far away (large error), the “P” component of the drive level will be large. If the tip is at the target temperature, the error will be zero, and the “P” component of the drive level will be zero. However, under normal conditions, a non-zero drive level must be maintained to keep the tip at or near the target temperature. Therefore, an offset must be added to the “P” component to attempt to maintain a zero error under existing conditions (e.g., in a cool room, a larger offset will be needed). As conditions vary (e.g., room temperature, variability of instrument components, etc.), it is often necessary to make small adjustments to the offset to maintain zero error. If adjustments to the offset are proportional to the error, then the offset, which is the sum of the adjustments, will essentially be proportional to the “Integral” of the error. This is the “I” part of PID.
[0033] The “D” component is proportional to the rate of change of the tip temperature. Its purpose is to improve stability by adjusting the drive level if the tip temperature is rapidly increasing or decreasing. Under certain system configurations, the “D” component will minimize overshoot.
[0034] Returning to the examination of the “P” and “I” components, the “P” component is responsible for rapidly driving the tip temperature to the target temperature when they are substantially different. The “I” component is responsible for making small adjustments to maintain the tip at or near the target temperature during slowly varying conditions. The “I” component could be considered the “adaptive” part of the algorithm that compensates for changing room temperature, battery voltage, component tolerances, etc.
[0035] In a patient thermometer, the goal is to heat the probe tip as quickly as possible. In most cases, tissue contact will be established before the tip reaches the target temperature. The faster the probe can heat, the sooner a predicted temperature can be computed.
[0036] In order to heat the tip quickly, in a controlled manner, without severe overshoot, it is necessary to immediately set the drive offset at or near its correct value. There is not enough time for the slow, adaptive “I” component to drive it toward its correct value. In accordance with the invention, the proper drive offset was empirically determined to be a function of ambient temperature and battery voltage. Thus the initial offset was set according to this derived function and not merely initialized to zero, as with a typical PID controller. In addition, while the probe tip is heating but still far away from target temperature, the “I” part of the algorithm is inhibited from adjusting the drive offset. The drive offset has already been set to its optimum value and should not be altered until the tip temperature is close to the target temperature. Therefore, offset adjustment by the “I” part of the PID algorithm is restricted to those times when the error is within a predetermined range. This prevents the algorithm from manipulating the offset during the time when the error is large and the “P” part of the algorithm is quickly driving the tip temperature toward the target temperature. Once the tip temperature is close to the target, and tissue contact has not been achieved, the “I” part of the algorithm can make small adjustments to the offset to adapt to the current environment.
[0037] Significant delays between changing the heater drive level to sensing an effect at the temperature sensor exist. Loop gains for either the “P” or the “I” components must be kept small to ensure loop stability. Since the goal is to quickly heat the probe tip, standard PID techniques are insufficient. As described above, the drive offset has to be initialized to a precomputed value, and the adaptive, “I”, component momentarily disabled. In addition, the “P” component requires novel customization to achieve rapid heating while preserving loop stability. To maintain stability, the loop gain associated with the “P” component has to be severely limited. However, for errors outside a predetermined range, the loop gain is dramatically increased. The increased gain allows the heater drive to be higher for a large error, and thus heat the tip more quickly. Once the tip approaches target temperature, the error enters the “control zone” 62 where the gain is reduced to ensure loop stability. The amount of gain is predetermined as a function of battery voltage. In addition, the maximum allowed drive level 60 is predetermined as a function of battery voltage. If the drive level 60 were allowed to get too high, the stored energy and the thermal delays would allow the tip temperature to severely overshoot the target temperature.
[0038] In accordance with the embodiment shown in FIG. 6, the drive level 60 is modified once it reaches the control zone 62 . The temperatures at which the drive level changes is controlled by the offset. In the case of FIG. 6, the drive level outside the control zone 62 is set at 0.4. Once inside the control zone, the drive level rapidly reduces in a first segment 64 . In a second segment 66 , the slope is approximately one-fourth that of the first segment allowing for less change of the drive level in regard to the temperature. In a third and final segment 68 , the slope of the drive level once again resumes is four times greater value. In this drive control approach, the drive level is altered in steps rather than varied continuously. However, other approaches may be possible.
[0039] Referring finally to FIG. 7, a heater control flow chart is presented. In accordance with this flow chart, from the start step 70 , the routine next gets the next temperature from the A-to-D converter every 0.1 seconds 72 . Next a decision is made as to whether this is the first temperature of the session 74 . If so, the initial heater drive offset is set as a function of ambient temperature and battery voltage 76 .
[0040] While one form of the invention has been illustrated and described, it will be apparent that further modifications and improvements may additionally be made to the device and method disclosed herein without departing from the scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.
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A system and method for rapidly preheating the probe of a thermometer to a temperature closer to the temperature of a patient to be measured. The system comprises a probe heater, a probe temperature sensor, a power source, and a processor for controlling the delivery of energy from the power source to the heater. The processor adds an offset to the drive level to the heater which is dependent on the ambient temperature and the power source voltage to achieve more rapid heater response. The processor maintains control over the drive level applied to the heater in accordance with the temperature sensor so that at all times a closed loop system is provided.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application for Patent No. 62/048,900 entitled Mouth Contoured Drinking Vessel, filed on Sep. 11, 2014, which is incorporated by reference herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The invention relates to drinking vessels and a method of drinking
[0007] 2. Description of the Related Art
[0008] Drinking vessels have existed for thousands of years and come in various shapes and forms. Most vessels have a uniform upper edge or brim that is smooth and uniform in shape. Generally, a drinker tilts the vessel to her mouth or uses a straw to drink. However, straws are not always appropriate and can cause slurping noises. Uniform brims are susceptible to spillage during drinking Also, uninform brims do not inform the drinker of where is proper or best to the drink from the vessel.
[0009] The prior art provides for pitchers, gravy boards, and measuring cups which help reduce spillage during pouring operations, but the prior art is not intended, designed, or optimized for drinking
SUMMARY OF THE INVENTION
[0010] The present invention overcomes problems with the prior art by making it easier for a drinker to drink, sip and pour from a vessel. It also solves the problem of a drinker not knowing from which part of the brim to drink.
[0011] The invention overcomes the problems with the prior art by depressing the brim in one more sections to form a valley or channel in which the drinker can pour the drink into the drinker's mouth. The valley or channel is optimally contoured to interface with the mouth of the drinker.
[0012] Although the invention is illustrated and described herein as embodied in example drinking vessels the invention is not limited to the details shown because various modifications and structural changes may be made without departing from the invention and the equivalents of the claims. However, the construction and method of operation of the invention 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
[0013] FIG. 1 is a front view of a left handed coffee cup with the novel brim for drinking.
[0014] FIG. 2 is a rear view of the left handed coffee cup drawn in FIG. 1 .
[0015] FIG. 3 is a top down view of the left handed coffee cup drawn in FIGS. 1 and 2 .
[0016] FIG. 4 is a bottom up view of the left handed coffee cup drawn in FIGS. 1 through 3 .
[0017] FIG. 5 is a handle side view of the left handed coffee cup drawn in FIGS. 1-3 .
[0018] FIG. 6 is a handle-less side view of the left handed coffee cup drawn in FIGS. 1-3 .
[0019] FIG. 7 is perspective view of the left handed coffee cup drawn in FIGS. 1-6 .
[0020] FIG. 8 is alternate perspective view of the left handed coffee cup drawn in FIGS. 1-7 .
[0021] FIG. 9 is a front view of a tumbler with the novel brim for drinking.
[0022] FIG. 10 is a rear view of the tumbler drawn in FIG. 9 .
[0023] FIG. 11 is a top down view of the tumbler drawn in FIGS. 9-10 .
[0024] FIG. 12 is a bottom up view of the tumbler drawn in FIGS. 9-11 .
[0025] FIG. 13 is a side view of the tumbler drawn in FIGS. 9-12 .
[0026] FIG. 14 is an alternative side view of the tumbler drawn in FIGS. 9-13 .
[0027] FIG. 15 is a perspective view of the tumbler drawn in FIGS. 9-14
[0028] FIG. 16 is a perspective view of the tumbler drawn in FIGS. 9-15 .
[0029] FIG. 17 is a front view of a martini glass with the novel brim for drinking.
[0030] FIG. 18 a rear view of the martini glass drawn in FIG. 17 .
[0031] FIG. 19 is a top down view of the martini glass drawn in FIGS. 17-18 .
[0032] FIG. 20 is a bottom up view of the martini glass drawn in FIGS. 17-19 .
[0033] FIG. 21 is a side view of the martini glass drawn in FIGS. 17-20 .
[0034] FIG. 22 is alternate side view of the martini glass drawn in FIGS. 17-20 .
[0035] FIG. 23 is a perspective view of the martini glass drawn in FIGS. 17-22 .
[0036] FIG. 24 is an alternative perspective view of the martini glass drawn in FIGS. 17-23 .
DETAILED DESCRIPTION OF THE INVENTION
[0037] Referring to the drawings, FIG. 1 shows a left handed coffee cup 100 incorporating the novel drinking brim 102 on its upper edge. The novel drinking brim 102 is contoured to fit with a drinker's mouth and channel the contents of the coffee cup 100 , or the drink, into the drinker's mouth, minimizing spillage and aiding the drinker to drink from the coffee cup 100 . FIGS. 2-8 illustrate multiple views of the same mug with novel drinking brim 102 . The coffee cup 100 and its novel drinking brim 102 are depicted at various angles in FIGS. 1-8 . However, the novel drinking brim 102 is not visible from the back of the coffee cup 100 as shown in the rear perspective of FIG. 2 .
[0038] Novel drinking brim 102 is positioned at the top edge of the open portion of coffee cup 100 , as illustrated in FIG. 7 . The valley or channel of novel drinking brim 102 is optimally contoured to interface with the mouth of the drinker. This is the edge where a drinker's mouth touches coffee cup 100 to drink the contents of coffee cup 100 . For a vessel with a handle 104 , such as coffee cup 100 , novel drinking brim 102 is strategically at a position on the top edge of coffee cup 100 relative to the handle 104 position.
[0039] Alternatively, exemplary embodiments of the instant invention implemented as a coffee cup include right handed embodiments where the handle is on the right side approximately ninety degrees counter-clockwise from the novel drinking brim 102 . Additional embodiments of the instant invention include the novel drinking brim 102 on both the left and right hand sides of the coffee cup 100 , not depicted, with two handles to accommodate both left and right handed drinkers.
[0040] The instant invention relating to a drinking vessel includes different handle 104 orientations compared to pouring vessels. Examples of pouring vessels include: pitchers, gravy boats, and measuring cups. Unlike the instant invention, vessels designed for pouring generally orient the pouring handle approximately 180 degrees (opposite) from the pouring spout. Moreover, the shape of the pouring vessel spout is designed for pouring, not drinking The shape of a pouring vessel spout is related to flow of the vessel contents into an open container, such as a mixing bowl. The instant invention novel drinking brim 102 is designed to contour a drinker's mouth to provide a smooth transition from the drinking vessel, or coffee cup 100 , into the drinker's mouth. In this context, a drinker's mouth includes a drinker's lips, tongue, oral mucosa, and all other parts a drinker's face that comes in contact with the novel drinking brim 102 . A drinker, in the preferred embodiment of the instant invention, is a human being. However, a drinker is any mammal capable of using a drinking vessel to consume contents through the drinker's mouth.
[0041] To accommodate a drinker's mouth, the novel drinking brim 102 protrudes outward from the outer circumferential plane of coffee cup 100 , as shown in FIGS. 1 , 3 , 4 , 5 , 6 , 7 , and 8 . The top surface of novel drinking brim 102 is contoured downward, best illustrated in FIGS. 5-8 .
[0042] Although described as a coffee cup, the drinking vessel of the instant invention includes any type of cup or vessel that has contents consumable by a drinker. Examples include, but are not limited to: mugs, wine glasses, tumblers, collins glasses, martini glasses, pilsner glasses, and highball glasses. A handle is included in example embodiments of the instant invention.
[0043] As shown in FIGS. 1-8 , the preferred embodiment of novel drinking brim 102 is contoured to a drinker's mouth and slightly depressed. When used properly, the novel drinking brim 102 forms a channel to the drinker's mouth to optimally flow the contents of coffee cup 100 into the drinker's mouth.
[0044] FIGS. 9-16 illustrate an example embodiment of the instant invention using a tumbler drinking vessel. In this embodiment, tumbler 200 does not include a handle for the drinker to use when consuming the contents of tumbler 200 . Instead, the outer surface of tumbler 200 has a continuous cylindrical shape.
[0045] Novel drinking brim 102 is contoured to a drinker's mouth and channels the contents of the tumbler 200 , or the drink, into the drinker's mouth. The contoured shaped of novel drinking brim 102 , that protrudes from tumbler 200 and is slightly depressed, optimizes the flow of the contents of tumbler 200 into the drinker's mouth. Novel drinking brim 102 minimizes spillage and assists the drinker in drinking the contents of the tumbler 200 .
[0046] Tumbler 200 does not include a handle, as compared to coffee cup 100 . As shown in FIGS. 9-16 , novel drinking brim 102 is positioned on the top edge of tumbler 200 . Since a drinker can pick up, or grasp, tumbler 200 , in many different circumferential positions, the position of novel drinking brim 102 along the top edge of tumbler 200 is not critical.
[0047] The shape of novel drinking brim 102 is contoured to the mouth of a drinker. As illustrated in FIGS. 9-16 , novel drinking brim 102 extends radially outward from the top edge of tumbler 200 . The top portion of novel drinking brim 102 is depressed relative to the top edge of tumbler 200 . At the outermost portion of novel drinking brim 102 , the bottom contour of novel drinking brim 102 restricts back to the body of tumbler 200 . Overall, the shape of novel drinking brim 102 has multiple contours to provide the best fit between the novel drinking brim 102 and the mouth of the drinker.
[0048] FIGS. 17-24 illustrate an example embodiment of the instant invention using a martini glass. In this exemplary embodiment, martini glass 300 includes novel drinking brim 102 , bowl 302 , stem 304 , and base 306 . Novel drinking brim 102 is positioned on the top edge of bowl 302 , as shown in FIGS. 21-24 . Novel drinking brim 102 is placed at any orientation along the upper edge of bowl 302 . The angled profile, or shape, of bowl 302 does not impact the contoured profile of novel drinking brim 102 since novel drinking brim 102 is shaped to fit a drinker's mouth.
[0049] The bottom of bowl 302 of martini glass 300 is connected to stem 304 . Stem 304 is further connected to base 306 . A drinker typically holds martini glass 300 by stem 304 when picking up martini glass 300 to take a drink. The contents of martini glass 300 are located in bowl 302 . In an example embodiment, the contents of martini glass 300 are located in bowl 302 , stem 304 , and optionally in base 306 . The drinker consumes the contents of martini glass 300 by placing his mouth onto novel drinking brim 102 .
[0050] In an exemplary embodiment, martini glass 300 includes more than one novel drinking brim 102 . Any drinking vessel can include multiple novel drinking brims 102 . Although sized may vary, a standard martini glass holds 4.5 fluid ounces. Oversized martini glasses, which can often include 12 fluid ounces, are popular at restaurant and bar locations. Multiple people order an oversized martini glass to jointly share in the consumption of the contents of the oversized martini glass. An example embodiment of an oversized martini glass includes two or more novel drinking brims 102 on the same side of the bowl 302 . This allows two or more drinkers to consume the contents of the oversized martini glass at the same time.
[0051] In an alternative embodiment the a drinking vessel may be shared by two or more persons through novel drinking brims on alternative sides of the vessel, such that the vessel is passed back and forth between persons sharing the glass, where each person has there own novel drinking brim.
[0052] In an embodiment utilizing more than one novel drinking brim the additional drinking brims may be further identified and/or distinguished by marking, with color, symbol, decoration or otherwise. The identifying channel markers enable persons sharing a drink to identify, maintain and/or choose a specific spot on the brim. In some embodiments the extent of channel depressions forming drinking brims may vary in the extent in which they extend outward and/or downward and/or in the width and depth of the valley channel. This enables a single vessel to have multiple countered drinking brims. Each countered drinking brim provides a different drinking experience. The varying contours of drinking brims may be preferably selected by a drinker or used in a game of chance and/or skill.
[0053] Thus, it is seen that the objects of the present invention are efficiently obtained, although modifications and changes to the invention should be readily apparent to those having ordinary skill in the art, which modifications are intended to be within the spirit and scope of the invention as claimed. It also is understood that the foregoing description is illustrative of the present invention and should not be considered as limiting. Therefore, other embodiments of the present invention are possible without departing from the spirit and scope of the present invention.
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A solution that makes it easier to drink from a cup by contouring the brim to interface with the drinker's mouth. Drinking vessels are improved by depressing the brim to channel the drink to the drinker's mouth.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/246,262, filed Sep. 9, 2009, which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a novel method of producing deuterium labeled compounds including Vitamin D and related analogues and the composition of matter of the labeled compounds. The invention also relates to the use of the labeled compounds for reference standards for mass spectroscopic analysis.
BACKGROUND OF THE INVENTION
[0003] Cholecalciferol (Vitamin D3) and ergocalciferol (Vitamin D2) are important vitamins that mediate calcium absorption. Each vitamin serves as a precursor to the 25-hydroxy metabolite and ultimately to the physiologically active 1,25-dihydroxy metabolites. Other biologically important vitamin metabolites include their respective 24,25-dihydroxy metabolites.
[0000]
[0004] Detection and quantification of these and other vitamin D-related metabolites are important to assess various conditions related to vitamin deficiencies. Current methodology, in particular those methods relying upon radioimmunoassay (RIA), are not entirely unambiguous and can fail to discriminate between parent vitamins and their metabolites.
[0005] New analytical detection and quantification techniques involving mass spectroscopy are capable of discriminating between all vitamin D related compounds. Accurate quantification requires that a suitable stable isotope labeled reference standard be available such that the reference standard has a molecular weight enhancement of at least +2.97 amu and contains less than 0.1% unlabeled parent compound.
[0006] A general method for labeling vitamin D related compounds was first reported by Reischl and Zbiral in Helvetica Chimica Acta 62(6) 1763 (1979) and involves the activation of vitamin D compounds by cycloaddition of sulfur dioxide to yield a cyclic sulfone. Hydrogen atoms alpha to the sulfone are rendered acidic and are susceptible to exchange with deuterium under basic conditions and a suitable source of deuterium. Various bases and solvents have been described in the literature including sodium bicarbonate in dimethylformamide (Yamada, et. Al., Tetrahedron Letters, 22(32) 3085 (1981)), potassium t-butoxide in DMF (Ray, et. al., Steroids 57 142 (1992)), and sodium isopropoxide in isopropanol or sodium methoxide in methanol (Iwasaki, et. al., Steroids 64 396 (1999)). Elimination of the sulfur dioxide followed by isomerization of the thus obtained triene yields a vitamin D or vitamin D analog labeled with up to three deuterium atoms at carbons 6 and 19.
[0007] The primary drawback of all these methods is typified by the reported deuteration of 24,25-dihydroxyvitamin D3 by Yamada, et. al. (Steroids 54(2) 145 (1989)) where total deuterium incorporation is only 2. 6 D/molecule which is far too little to be of any real value for use as a labeled standard.
SUMMARY OF THE INVENTION
[0008] One embodiment of the invention involves a process for preparing the vitamin D and vitamin D-related deuterium labeled compounds shown below suitable for use as analytical reference standards for assays involving mass spectroscopy.
[0000]
[0000] where R1=H or OH, R2=H or OH and R3 can be any saturated or unsaturated side chain including those typical of a steroid or vitamin: where R4=H or OH and R5=H or OH.
[0009] Another embodiment of the invention involves the reaction of the 7Z isomer of a vitamin D or vitamin D analog with sulfur dioxide to facilitate the deuterium labeling of said compounds.
[0010] Still another embodiment of the invention involves deuterium labeled compounds including Vitamin D and related analogues that can be produces by the methods described above and the use of the labeled compounds for reference standards for mass spectroscopic analysis.
[0011] Other objects and advantages of the invention will be apparent to those skilled in the art from the following detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] This invention relates to a novel process for the deuterium labeling of vitamin D and vitamin D analogs and novel compounds produced by the process. The final deuterated compounds so produced have been found to have greater than 2.97 deuterium atoms per molecule and to contain less than 0.1% unlabeled vitamin, and thus are suitable to serve as an analytical reference standards for mass spectroscopy. This invention therefore affords significant advantages over any existing methodology.
[0013] This invention is specifically suitable for the production of deuterium labeled vitamin D3, vitamin D2, 25-hydroxyvitamin D3, 25-hydroxyvitamin D2, 1,25-dihydroxyvitamin D3, 1,25-dihydroxyvitamin D2, 24,25-dihydroxyvitamin D3 and 24,25-dihydroxyvitamin D2. Similarly, all such vitamin and steroid related analogs having a characteristic 5, 7, 10(19) triene system can be labeled with deuterium in accordance with the present invention, to the levels described herein.
[0014] In an example of the practice of the invention, the first steps of the process requires activation of the appropriate triene system with sulfur dioxide, exchange of deuterium into the activated positions and subsequent extrusion of the sulfur dioxide. Purification of the partially labeled intermediate thus obtained is followed by a second activation step with sulfur dioxide, a second exchange labeling procedure, and further extrusion of the sulfur dioxide.
[0015] The second sulfur dioxide addition may be done on either the 7E or 7Z isomer of the partially labeled vitamin, preferably on the 7Z isomer. This is the first report of SO 2 activation on such a 7Z isomer and represents a novel use of this activation method on a vitamin or vitamin related compound bearing a double bond at position 7.
[0016] Photoisomerization of the labeled vitamin followed by chromatographic purification gives the deuterated vitamin with deuterium incorporation of at least 2.97 D/molecule and less than 0.1% unlabeled vitamin remaining, making said product suitable as an analytical reference standard for mass spectroscopy.
[0017] The procedure described above in the practice of the process of the present invention will produce the following general structure with deuterium incorporated at the positions shown:
[0000]
[0000] where R1=H or OH, R2=H or OH and R3 can be any saturated or unsaturated side chain including those typical of a steroid or vitamin: where R4=H or OH and R5=H or OH.
[0018] A preferred embodiment of the invention is shown in Scheme 1, below, where R1, R2, and R3 are as shown above.
[0000]
[0000] The process is comprised of the following steps:
Step A
[0019] The preparation of the sulfur dioxide adduct is readily available by condensation of sulfur dioxide onto the vitamin or vitamin analog as described by Reischl and Zbiral in Helvetica Chimica Acta 62(6) 1763 (1979). It is preferred that the reaction be carried out without solvent. The reaction is stirred until such time as the reaction is complete, typically 15 to 60 minutes, as judged by thin layer chromatography. The sulfur dioxide is removed and the product obtained directly carried on.
Step B
[0020] The adduct with sulfur dioxide is dissolved in a solvent having a labile deuterium atom, typically methanol-D or ethanol-D, and is treated under basic conditions to effect the exchange of hydrogen with deuterium. The base may be sodium hydroxide, sodium methoxide or sodium ethoxide. Those skilled in the art will recognize other possible bases to effect the desired labeling reaction.
Step C
[0021] The deuterated sulfur dioxide adduct is heated until all of the sulfur dioxide has been extruded from the molecule as judged by thin layer chromatography. This process typically takes 2 hours.
Step D
[0022] The partially deuterated product obtained in Step C is photoisomerized with UV light and an appropriate sensitizer, such as Eosin Y, until the correct double bond geometry at C7 has been obtained as judged by thin layer chromatography.
Alternative to Step D
[0023] Step D may be omitted and the product obtained from Step C directly subjected to the conditions described in Steps E through H.
Steps E-H
[0024] Steps A to D are repeated in their entirety. Flash chromatographic purification gives the final deuterated compound(s) having a minimum amu enhancement of +2.97 and having <0.1% unlabeled material contaminating the final product.
EXAMPLE 1
Addition of Sulfur Dioxide to Vitamin D3
[0025] 2 g of Vitamin D3 was placed in a 500 mL round bottom flask which was equipped with a dry ice condenser. Sulfur dioxide was condensed into the flask (30-40 mL). The reaction was initially bright yellow and slowly faded. The dry ice was removed and the sulfur dioxide was allowed to evaporate. When the solution became thick near the end of the sulfur dioxide evaporation a vacuum was applied to remove the last traces of sulfur dioxide giving a white glassy product. This was used directly in the next reaction.
EXAMPLE 2
Addition of Sulfur Dioxide to Vitamin D2
[0026] 500 mg of Vitamin D2 was placed in a 100 mL round bottom flask equipped with a dry ice condenser and was cooled to −40° C. Sulfur dioxide was condensed into the flask (10-15 mL). The cooling bath was removed and the yellow solution was stirred for an hour. The dry ice was removed and the sulfur dioxide was allowed to evaporate. When the solution became thick near the end of the sulfur dioxide evaporation a vacuum was applied to remove the last traces of sulfur dioxide giving a white glassy product. This was used directly in the next reaction.
EXAMPLE 3
Addition of Sulfur Dioxide to 25-Hydroxyvitamin D3
[0027] 90 mg of 25-Hydroxyvitamin D3 was placed in a 50 mL round bottom flask equipped with a dry ice condenser and was cooled to −40° C. Sulfur dioxide was condensed into the flask (10-15 mL). The cooling bath was removed and the yellow solution was stirred for an hour. The dry ice was removed and the sulfur dioxide was allowed to evaporate. When the solution became thick near the end of the sulfur dioxide evaporation a vacuum was applied to remove the last traces of sulfur dioxide giving a white glassy product. This was used directly in the next reaction.
EXAMPLE 4
Addition of Sulfur Dioxide to 25-Hydroxyvitamin D2
[0028] The sulfur dioxide adduct of 25-Hydroxyvitamin D2 was obtained in exactly the same manner as 25-Hydroxyvitamin D3 as described in Example 3.
EXAMPLE 5
[0029] Deuteration and Extrusion of Sulfur Dioxide from Vitamin D3
[0030] The vitamin D3 sulfur dioxide adduct was dissolved in methanol-D (99.5% D). To this was added 1.4 mL of D 2 O. Potassium t-butoxide (8.3 g) was added and the pale yellow solution stirred at room temperature. The reaction was then heated to reflux to eliminate the sulfur dioxide. Reaction was monitored by TLC (4:1 benzene/EtOAc) and took approximately 2 hours to go to completion. The reaction was cooled to room temp and concentrated. The residue was treated with D 2 O and the white precipitate collected by filtration, washed with D 2 O and then dried.
EXAMPLE 6
[0031] Deuteration and Extrusion of Sulfur Dioxide from Vitamin D2
[0032] Deuteration and extrusion of sulfur dioxide from the Vitamin D2 sulfur dioxide adduct was achieved in exactly the same manner as described in Example 5.
EXAMPLE 7
[0033] Deuteration and Extrusion of Sulfur Dioxide from 25-Hydroxyvitamin D3
[0034] The 25-Hydroxyvitamin D3 sulfur dioxide adduct was dissolved in 20 mL of methanol-D (99.5%) and treated with 288 mg of potassium t-butoxide and 0.5 mL of D 2 O. The reaction was stirred at room temperature and then heated at reflux for 2 hours to eliminate the sulfur dioxide. The reaction was cooled to room temp and concentrated. The residue was treated with D 2 O and extracted with methylene chloride. The organic extract was dried and concentrated to give the product.
EXAMPLE 8
[0035] Deuteration and Extrusion of Sulfur Dioxide from 25-Hydroxyvitamin D2
[0036] Deuteration and extrusion of sulfur dioxide from the 25-Hydroxyvitamin D2 sulfur dioxide adduct was achieved in exactly the same manner as described in Example 7.
EXAMPLE 9
Photoisomerization of the Partially Deuterated Vitamin D3 Analog
[0037] The partially deuterated vitamin D3 analog from example 5 was dissolved in ethanol and a small amount of Eosin Y added. The solution was exposed to a UV lamp until isomerization was complete as judged by thin layer chromatography (9:1 benzene/EtOAc). Purification was by flash chromatography (9:1 benzene/EtOAc).
EXAMPLE 10
Photoisomerization of the Partially Deuterated Vitamin D2 Analog
[0038] The partially deuterated vitamin D2 analog from example 6 was photoisomerized as described in example 9.
EXAMPLE 11
Photoisomerization of the Partially Deuterated 25-Hydroxyvitamin D3 Analog
[0039] The product from example 7 was dissolved in ethanol and a spatula tip of Eosin Y added. The solution was exposed to a UV lamp until isomerization was complete as judged by thin layer chromatography (4:1 benzene/EtOAc). Purification was carried out by flash chromatography (4:1 benzene/EtOAc).
EXAMPLE 12
Re-Deuteration of Partially Deuterated Vitamin D3
[0040] The partially deuterated vitamin D3 obtained from either example 5 or example 9 was re-subjected to the entire sequence of chemistry described above in examples 1, 5 and 9. Following this procedure, deuterated vitamin D3 was obtained having an isotopic enrichment of ≧2.97 D/molecule. The product had <0.1% unlabelled vitamin D3 remaining making the end product of this reaction sequence suitable for use as a standard for mass spectroscopy.
EXAMPLE 13
Re-Deuteration of Partially Deuterated Vitamin D2
[0041] The partially deuterated vitamin D2 obtained from either example 6 or example 10 was re-subjected to the entire sequence of the mistry described above in examples 2, 6 and 10. Following this procedure, deuterated vitamin D2 was obtained having an isotopic enrichment of ≧2.97 D/molecule. The product had <0.1% unl abelled vitamin D2 remaining making the end product of this reaction sequence suitable for use as a standard for mass spectroscopy.
EXAMPLE 14
Re-Deuteration of Partially Deuterated 25-Hydroxyvitamin D3
[0042] The partially deuterated 25-Hydroxyvitamin D3 obtained from either example 7 or example 11 was re-subjected to the entire sequence of chemistry described above in examples 3, 7 and 11. Following this procedure, deuterated 25-Hydroxyvitamin D3 was obtained having an isotopic enrichment of ≧2.97 D/molecule. The product had <0.1% unlabeled 25-Hydroxyvitamin D3 remaining making the end product of this reaction sequence suitable for use as a standard for mass spectroscopy.
EXAMPLE 15
Re-Deuteration of Partially Deuterated 25-Hydroxyvitamin D2
[0043] The partially deuterated 25-Hydroxyvitamin D2 obtained from example 8 was re-subjected to the entire sequence of chemistry described above in examples 4, 8 and 12. Following this procedure, deuterated 25-Hydroxyvitamin D2 was obtained having an isotopic enrichment of ≧2.97 D/molecule. The product had <0.1% unlabelled 25-Hydroxyvitamin D2 remaining making the end product of this reaction sequence suitable for use as a standard for mass spectroscopy.
[0044] Among other features of the present invention, it will be appreciated that the compounds produced in accordance therewith can be dissolved in various solutions, including without limitation in methanol, isopropanol, and other organic solvents and, in particular, ethanol is preferred as a solvent as it has been found that such solutions of the compounds in ethanol are capable of providing improved stability for the compounds of the invention, by comparison with other solvents.
[0045] Additional embodiments, as well as features, benefits and advantages, of the present invention will be apparent to those skilled in the art, taking into account the foregoing description of preferred embodiments of the invention. It is therefore to be appreciated that the present invention is not to be construed as being in any way limited by the foregoing description of such preferred embodiments, but that various changes and modifications can be made to the invention as specifically described herein, and that all such changes and modifications are intended to be within the scope of the present invention. Any such limitations are only to be construed as being defined by the claims appended hereto.
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The present invention is directed to a method for the synthesis of deuterium labeled Vitamin D and related compounds with a high level of deuterium incorporation, which are particularly suitable for use as standards for mass spectroscopy.
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BACKGROUND OF THE INVENTION
This invention relates to tufting machines and more particularly to a method and apparatus for increasing the density of the pile fabric produced even in fine gauge tufting machines, and further to a method and apparatus which permits not only the density of such fabric to be increased but patterning effects and streak break-up therein.
In the production of tufted fabrics a plurality of spaced yarn carrying needles extend transversely across the machine and are reciprocated cyclically to penetrate and insert pile into a backing material fed longitudinally beneath the needles. During each penetration of the backing material a row of pile is produced transversely across the backing. Successive penetrations result in a longitudinal row of pile produced by each needle. This basic method of tufting limits the aesthetic appearance of tufted fabrics so produced. Thus, the prior art has developed a number of procedures for initiating relative lateral movement between the backing material and the needles in order to laterally displace longitudinal rows of stitching and thereby create various pattern effects, to break up the unattractive alignment of the longitudinal rows of tufts and to reduce the affects of streaking which results from variations in coloration of the yarn.
One such procedure has been to jog or shift the needle bar transversely across the tufting machine relatively to the base material in a step-wise manner in accordance with a pattern. Exemplary of this prior art are U.S. Pat. Nos. 3,026,830; 3,964,408; 3,972,295; 4,010,700; 4,173,192; and 4,392,440.
It is also known to initiate relative movement between the backing material and the needles by jogging or shifting the needle plate, i.e., the plate over which the backing material is fed and which carries a plurality of fingers between which the needles extend during penetration. Examplary of this prior art are U.S. Pat. Nos. 3,301,205; 3,577,943; 3,934,524 and 3,964,407.
Another procedure for initiating relative lateral shifting between the needle and the backing material is by the use of what is known as a "jute shifter" wherein the gauge parts, i.e., needles etc. remain laterally stationary while the backing material alone is shifted usually by spike rollers upstream and/or downstream of the feed direction. However, when synthetic, as opposed to jute backing, was introduced, difficulties resulted since the synthetic backings are more difficult to shift than jute backings. The synthetic backings do not respond positively in every instance or uniformly to the movement of the rollers. Consequently, use of such "jute shifters" are not in favor at this time.
Another reason for initiating relative lateral movement between the needles and the backing material is to increase the density of the fabric by placing the stitches closer than the gauge of the machine, and in fact this was the main objective in a number of the aforesaid patents including U.S. Pat. Nos. 3,577,943 and 3,934,524. Another proposal for increasing the density of the pile fabrics produced by tufting was a proposal illustrated in U.S. Pat. No. 3,596,617 in which the loopers and cutting knives were proposed to be simultaneously shifted together with the needles and which was proposed at a time when relatively fine gauge tufting machines were not developed to a practical extent. However, this mechanism itself was found to be exeptionally complex and too impractical, and thus was never used in production.
When utilizing a sliding needle bar the needle bar drive pattern and the timing of the machine is generally such that the needles are laterally shifted while they are above the needle plate so as not to contact the needle plate fingers. In the prior art, before it was practical to produce a cam having a large peripheral surface, when it was desired to have a larger pattern repeat, i.e., more stitches within each repetition of the pattern, it was necessary to instigate lateral movement of the needle bar while the needles were still in the backing material and thereafter continue the lateral movement of the needle bar while the needles were free of the backing material to compensate for the small dwell time permitted by the prior art cams. Moreover, in the aforesaid U.S. Pat. No. 3,577,943 the backing material was shifted by the needle plate during a portion of the time that the needles were within and moving downwardly through the backing material to produce a dense cut pile fabric.
It has recently been proposed to intentionally shift the needle bar while the needles are within the fabric to move the fabric slightly and thereby increase the density. Obviously, an intentional jogging of the needles while within the base material must occur without the needles engaging the needle plate fingers to prevent breakage of the needles and/or the fingers.
It should be understood that each time the needles shift laterally they must at the time of loop seizure be in cooperative relationship with a corresponding looper. Thus, by jogging back and forth a greater density of tufts occurs at certain portions of the fabric than at others and this can be specifically seen in cut/loop fabrics. Consequently, merely by timing the needle shifting to occur in this manner precludes the use of such constructions in fine gauge tufting machines, e.g., one eighth inch and smaller between the respective gauge parts, and due to variations in density in the fabrics, even some coarser gauge fabrics, such as cut/loop, may be precluded. Thus, the amount of movement of the needles if any shifting within the fabric occurs in this manner is exeptionally limited and such increase in density can only be accomplished in certain coarser gauge machines where there is sufficient space between the needle plate fingers and where patterning will not be detrimentally effected. Thus, although shifting of the needles less than a full gauge has been accomplished in coarse gauges, a practical solution to increasing the density of fine gauge tufting machine products has not heretofore been proposed.
SUMMARY OF THE INVENTION
Consequently, it is a primary object of the present invention to provide a method and apparatus for producing a very dense pile tufted fabric.
It is another object of the present invention to provide in a tufting machine a method and apparatus for producing dense pile fabric by shifting both the needles and the backing material by either a common drive means or by separate drive means.
It is a further object of the present invention to provide in a tufting machine a method and apparatus for producing lateral movement of the backing material by means of providing a shift to the needle plate fingers and the needles, the movement being less than the gauge of the tufting machine gauge parts while maintaining the needles alway substantially centered between the corresponding needle plate fingers for permitting a much wider range of shifting motions than heretofore available.
It is a still further object of the present invention to provide a method and apparatus for operating a tufting machine such taht the needle bar and the needle plate fingers are shifted laterally while maintaining the needles intermediate respective fingers so that less than full gauge shifting can occur even in fine gauge tufting machines.
It is yet a further object of the present invention to provide a method and apparatus for a tufting machine in which the needle bar and the needle plate fingers are shifted laterally together from a common pattern controlled drive while the needles are within the backing material so that the needles may be maintained intermediate respective needle plate fingers and produce less than full gauge shifting over a wide range of shifting movements.
It is still yet a further object of the present invention to provide in a tufting machine a method and apparatus in which the needle bar and the needle plate fingers are shifted laterally for maintaining the needles intermediate the respective fingers so that less than full gauge shifting can occur, the amount of laterally displacement being selectively varied.
It is further yet another object of the present invention to provide in a tufting machine a method and apparatus for increasing the density of the product produced by shifting the needle bar and the needle plate fingers to maintain the needles intermediate respective fingers and to produce pattern effects by moving the needles relatively to the needle plate fingers.
Accordingly, the present invention provides a tufting machine having apparatus, and a method of operating the tufting machine, for producing a high density tufted fabric in a wide range of gauges and patterns. To this end, in one aspect of the invention the needle bar and needle plate fingers are laterally shifted together by a common drive. The drive is controlled by a patterning device, which in the preferred embodiment is a cam, and controls the movement such that the needles are shifted or jogged on the upstroke when they are out of the backing material, and on the downstroke after they enter the backing material. The needles in this embodiment always cooperate with the same loopers, and when shifting within the backing occurs the backing material is jogged or moved from its relaxed position where it was disposed when the needles were outside the backing, however, since the needle plate fingers are jogged together with the needles, the needles are always centered between respective needle plate fingers thereby permitting a much wider range of shifting motions than can be obtained from shifting the needles between stationary needle plate fingers. Thus, shifting within the backing can occur in machines of substantially any gauge. To obtain a denser pile than the normal gauge of the machine requires alternate shifting of the needles in a first direction on one stitch and in a second direction on the subsequent stitch, the stitches which tend to pile up alternately adjacent the pair of needle plate fingers between which a needle operates in the prior art, does not occur when the fingers are shifted together with the needles--the stitches are always centered between the fingers. Consequently, the fabric so produced has uniform density across the entire width of the fabric.
Another aspect of the invention is the provision of means in the common drive which can be adjusted for driving the needle bar and needle plate for moving a different selected distance. For example, assuming that the pattern device whether a cam, a chip in the case of an electromechanical or electrohydraulic drive, etc. is constructed to provide the needle bar and needle plate with a one half gauge shift, the needle bar and needle plate will shift only that amount, and if a different amount of shift, such as one third gauge etc., is desired the pattern device would have to be changed. However, by providing the drive with mechanism that can be adjusted for selective shifts, the same pattern device can be used for providing the various shift increments. Consequently, this aspect of the invention recognizes such a need for reducing the number of pattern devices required. Moreover, the pattern device could be used with different gauge machines without necessitating an inventory of different pattern devices, e.g., cams, a single cam design thereby may be utilized with machines of a different gauge and the amount of shift adjusted by the adjustable mechanism.
A further aspect of the invention is the provision for a separate drive for the needle bar and needle plate so that they can be driven selectively together less than the full gauge while maintaining the needles centered between the needle plate fingers, or the needles may be shifted a full gauge or multiples thereof relative to the fingers thereby stepping over the fingers to cooperate with another looper to produce a pattern on the fabric. In the preferred form of this aspect of the invention the needle bar is driven by a first cam drive while the needle plate is driven by a second cam drive, the cams being such that they may drive both the needle bar and the needle plate simultaneously equal amounts, and the needle bar can also have pattern information for driving the needle bar relative to the needle plate for other selected stitches.
A further related aspect of the present invention is the provision of utilizing a jute shifter in combination with a shifting needle bar, the jute shifter providing the increase pile density while the needle bar provides the patterning and streak breaking affects. In such a case the backing material may be shifted independently of the needles while the needles are outside the backing which would preclude needle breakages due to the reaction forces of the backing, and the needles can be shifted while substantially outside the backing. This would provide wide range patterning designs in a dense pile fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a framentary front elevational view of a tufting machine incorporating apparatus constructed in accordance with the principles of the first aspect of the present invention illustrating a common drive for shifting both the needle bar and the needle plate fingers together as a unit;
FIG. 2 is an enlarged cross-sectional view taken substantially along line 2--2 of FIG. 1;
FIG. 3 is an enlarged cross-sectional view taken substantially along line 3--3 of FIG. 1;
FIG. 4 is an enlarged cross-sectional view taken substantially along line 4--4 of FIG. 1;
FIG. 5 is a view of a portion of FIG. 4 greatly enlarged and with parts thereof broken away;
FIGS. 6a through 6d depict in a diagrammatic form the disposition of the needles, loopers and needle plate fingers at different positions of the cycle in carrying out the method of the invention;
FIG. 7 is a front elevational view illustrating in diagrammatic form a shift distance selection mechanism;
FIG. 8 is a view similar to FIG. 1 illustrating a second embodiment of the invention; and
FIG. 9 is a diagrammatic perspective view of another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 1 generally illustrates a portion of a tufting machine 1 having a frame comprising a bed 12 and a head 14 disposed above the base. The bed includes a needle plate support plate 16 disposed on a bed plate 17 over which the backing material (not illustrated) is adapted to be fed by conventional means.
Mounted in the head for vertical reciprocation within one of a plurality of bushing assemblies 18 is a respective push rod 20 to the lower end of which a clamping foot 22 is carried. The clamping foot 22 includes a pair of linear bearings within which a pair of slide rods 24 are slidably disposed. The rods 24 are secured to a plurality of bracket members 26 which in turn are secured to a needle bar 28 which carries a plurality of needles 30. The needle bar and thus the needles are slidable laterally relative to the support feet 22 and are reciprocably driven vertically by the action of the push rods. Upon reciprocation of the push rods the needles cyclically penetrate the backing material to project loops of yarn therethrough as the push rods are reciprocated by conventional means. The needles cooperate with loopers (illustrated only in FIG. 6) mounted beneath the needle plate support plate in the bed for seizing the loops of yarn presented by the needles and for releasing the loops to form loop pile and for holding the loops until cut by a knife cooperating with the loopers or hooks as is notoriously well known in the tufting art to produce cut pile.
To drive the needle bar selectively with controlled lateral movement a bracket 32 is clamped to the slide rods 24, the bracket 32 carrying a pair of spaced rollers 34 rotatable about a respective substantially horizontal axis. Each pair of rollers 34 straddles and is guided by a hardened block 36 which is clamped to a pair of drive rods 38, 40. At one end of the head 14 of the tufting machine the rods 38 and 40 are clamped to a needle bar drive bracket 42. The bracket 42 is supported by bearings guided for lateral sliding movement on a pair of short support or stud shaft 44 carried by lugs 46 depending from the head 14. The bracket 42 is secured to a drive rod 48 which is journalled in and extends through the end housing 50 of the tufting machine head 14 toward a pattern control shifting apparatus generally indicated at 52.
Although any pattern controlled shifting apparatus including mechanical, electromechanical, hydromechanical, pneumaticmechanical, etc. may be utilized in accordance with the present invention, it is preferred to utilize the shifting apparatus 52 which forms the subject matter of and is described fully in copending U.S. patent application Ser. No. 480,244 filed Mar. 30, 1983, and assigned to the common assignee of the present invention. For a complete description of that apparatus reference may be had to the aforesaid patent application, but in general this shifting apparatus includes a pattern cam 54 mounted on a shaft 56 driven in timed relationship to the reciprocation of the needle bar 28. The periphery of the cam 54 acts againt a pair of followers 58 which are each supported on a respective block 60 clamped to slide rods 62 which are slidably carried in bearing blocks 64. The rods 62 are also clamped to a block 66 to which the drive rod 48 is fastened. Consequently, as the cam 54 rotates it drives the followers 58 together with the blocks 60 and thus the rod 62, and since the block 66 is connected to both the slide rod 62 and the needle bar drive rod 48, this latter drive rod is driven laterally as controlled by the cam 54. The movement of the needle drive rod 48 is transmitted to the bracket 42 which in turn drives the rods 38 and 40. The rods 38 and 40 drive the block 36 which not only permits the rollers 34 to roll vertically against the surface thereof as the push rods reciprocate, but also laterally drives the rollers 34. Since the rollers 34 are carried by the bracket 32 which is clamped to the slide rods 24, lateral movement of the rods 38 and 40 is transmitted to the needle bar 28 by the brackets 26 fastened to the rods 34 and to the needle bar. Consequently, the cam 54 drives the needle bar laterally according to the pattern information thereon.
In accordance with the present invention in addition to the needle bar driven bracket 42 the drive rod 48 also carries a needle plate finger drive bracket 68 which is secured thereto and extends downwardly from adjacent the needle bar drive bracket 42. The needle bar drive bracket carries a plate 70 at its lower end which is secured to the needle plate support plate 16. A plurality of abutting needle plates 74 having spaced needle plate fingers 76 are secured to the upper surface of the needle plate support plate 16 adjacent a laterally extending edge beneath the needles, and a plurality of lugs 72 are secured to the needle plate support plate 16 at spaced locations adjacent the edge remote from the fingers 76. A shaft 78 is journalled in bearings in the lugs 72 and is secured to a plurality of spaced clamping brackets 80 disposed in open slots 82 formed in the needle plate support plate 16, the brackets 80 having a portion 84 extending toward the closed end of each slot 82 and are fixed to the bed plate 17. Thus the needle plate support plate 16 together with the needle plates 74 and the fingers 76 carried thereon may be moved relatively to the bed plate 17 as the needle plate drive bracket 68 is moved by the drive rod 48. Consequently, the fingers 76 move together laterally with the needles 30 and the needles will always remain centered between a respective pair of fingers 76.
To support the needle plate support plate 16 on the fixed bed plate rail 17 and yet permit it to move relative thereto while precluding upward pivoting of the needle plate support plate about the shaft 78, a laterally elongated slot 86 is formed in the needle plate support plate at spaced locations for receiving a cylindrical bushing 88. The bushing 88 extends through the slot 86 so that the bottom of the bushing abuts the bed plate 17, the bushing being of a length such that the top of the bushing extends above the surface of the needle plate support plate 16. A washer 90 having a low friction bearing tape 92 such as that sold under the trademark RULON attached to the bottom thereof is positioned about the periphery of the bushing where it extends above the needle plate support plate and a screw 94 extends through the washer and bushing and is threaded into the bed plate 17, the head of the screw 94 acting against the washer and the bushing to force the washer and bushing downwardly against the bed plate 17. The low friction bearing tape permits the needle plate support plate to slide relatively to the washer with little friction. Additional low friction bearing tape 96 is fastened to either the top of the bed plate 17 or the lower surface of the needle plate support plate 16 so that the needle plate support plate may slide with little friction on the bed plate. With this construction the washer 90 acts against the top surface of the needle plate support plate and prevents the needle plate support plate from lifting and pivoting about the shaft 78, yet the needle plate support plate is permitted to slide readily relatively to the bed plate. The slot 86 is elongated laterally a distance at least equal to the maximum amount of shift of the needle plate fingers, which distance is less than the gauge of the tufting machine, i.e., less than the space between two needle plate fingers 76.
The operation of a tufting machine incorporating apparatus constructed in accordance with the principles of the invention will now be described with reference to FIGS. 6a through 6d, and described with regard to the operative cycle of the needle 30. In FIG. 6a a needle 30 has shed its loop and is ascending. Since the loop shedding and seizing operation is the same as that of a conventional tufting machine the yarn and loops thereof are, for reasons of clarity of presentation, not illustrated. However, it can be seen that the needle is elevated above and in line with its normal disposition at loop seizure with the corresponding looper 100 and substantially centered between the needle plate fingers 76. Once the needle has ascended above the fingers 76, the needle 30 is shifted off-gauge by means of the needle shifting apparatus to the position illustrated in FIG. 6b. This lateral shift occurs while the needle is above the backing material illustrated at 102, and when the needle again penetrates the backing material on the downstroke, as illustrated in FIG. 6c, the needle 30 is still off-gauge from the looper 100 but begins to shift to the on-gauge position. The needle thereafter continues to shift back on-gauge prior to cooperation with the looper for loop seizing and shedding, such position being illustrated in FIG. 6d. Since the needle and the fingers shift between the positions illustrated in FIGS. 6c and 6d, the backing material is jogged less than a full gauge of the machine prior to loop seizure by the looper. In the prior art the shifting of the needle occurred without a corresponding shift of the fingers 76 which were fixed. Thus, since the fingers are spaced apart by an amount equal to the gauge of the machine, the amount of needle movement is limited to prevent contact with the needle plate fingers, and this process could only be used with coarse gauge machines. However, with the present invention, the shifting apparatus moves the fingers 76 together with the needles and as illustrated in FIGS. 6a-6d the needles are always in the same position relative to the fingers, i.e., substantially centered therebetween. Consequently, a jogging of the base material may be performed even in fine gauge tufting machines. In other words, the restrictions imposed by small gauge machines in the jogging of the base material is now overcome by the present invention, and the density of the pile fabric produced by fine gauge tufting machines may be increased.
Furthermore, with the present invention it is possible to select the degree or amount of shift made by the needles and fingers to a selective amount less than a full gauge. Normally only one half shift is desired. However, in some situations more or less of a shift may be desirable yet still be less than the full gauge using the same pattern device, e.g., cams etc. Moreover, it is desirable to reduce the number of pattern devices so that the same pattern device may be used for machines of different gauges. To this end another aspect of the present invention is the provision of a shift variation device 120 illustrated in FIG. 7. Such device may be inserted into the shifting apparatus between the shifting apparatus 52 and the drive shaft 48. Thus, the shift variation device may comprise a first lever 122 having one end pivoted at 124 to a fixed portion of the tufting machine or to the shifting apparatus and has an elongated slot 126 formed in another end 128 which is constructed for receiving the slot. The slot 124 has an arcuate shape and receives a slide block 130 which is pivoted to one end of an arm 132. The lever 122 is pivotably connected at 134 to a drive rod 148 while the other end of the arm 132 is pivotably connected to a drive rod 149, the rods 148 and 149 effectively being similar to the drive rod 48 illustrated in FIG. 1 split for insertion of the device 120. The arc of the slot 126 is a radial arc of the arm 132 about the pivot 136 so that by securing the slide block 130 at selective locations within the slot, the amount of shift imparted from the rod 148 to the rod 149 may be varied. The block 130 may be fastened to a shift variation selector 138 which can be controlled from a convenient location. Thus, when utilizing a single cam 54 the amount which the needle bar and needle plate support plate is shifted may be varied selectively utilizing the same pattern cam.
In another aspect of the invention the needle bar and the needle plate fingers may be shifted by separate shifting apparatus so that the needles and fingers may be shifted simultaneously together for less than a full gauge shift for density increasing purposes while maintaining the needles centered between the fingers and yet the needles may be shifted periodically at least a full gauge for placing a pattern in the fabric product. Thus, as illustrated in FIG. 8 a first shifting apparatus 152 having a first pattern cam 154 may be used to drive a first drive rod 148 operably connected to the needle bar 28 to slidably drive the needle bar and the needles 30 in a manner as heretofore described, and a second shifter 156 having a second cam 158 may drive a second drive rod 160 operably connected to the needle plate support plate 16 to shift the needle plate support plate and the needle fingers. The cams 154 and 158 are cut such that both move their respective followers and the needle bar and fingers respectively simultaneously the same amount less than full gauge such that the needles are always centered between the fingers. However, periodically as desired by the pattern, the cam 154 has increased lobes thereon for shifting the needle bar a full gauge or multiple thereof while the cam 158 provides no shift at all and its followers are at a dwell condition. Consequently, each needle steps over a respective finger as determined by the pattern at certain stitches, while during the remainder of the pattern the needles and fingers shift less than full gauge together so that a high density fabric having a pattern thereon is provided. Alternatively, the cam 154 may have a pattern which provides a needle shift of a full gauge or multiple thereof plus or minus a fraction of the gauge while the cam 158 would then have a pattern providing a shift of the fingers in the amount of that fraction of the gauge.
Additionally a related aspect of the present invention is illustrated in FIG. 9 wherein the needle bar 28 is shifted by shifting apparatus such as described above, and the backing material 200 is jogged by a jute shifter illustrated generally at 202. The jute shifter may comprise one or more spiked rollers 204, upstream, downstream or at both locations and driven by shifting apparatus illustrated generally at 206 for laterally moving arms 208, 210 which support the rollers 204. Preferably the backing material is shifted in opposition to the needle bar so that as the needles move to the right the backing material moves to the left and vice versa. In that case the needles would be shifted a full gauge or multiple thereof, while the backing material would be shifted in a jogging manner less than a full gauge. In this manner a high density fabric can be produced by apparatus having a simplified construction. However, if found desirable the needle bar may be shifted together with the fingers and in addition the jute shifter may be used. If should be understood that in FIG. 9 the backing material is supported by needle plate fingers which, for purposes of clarity of presentation, have been omitted from the figure.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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Tufting apparatus and method for producing a high density tufted fabric in a wide range of gauges and patterns. In one embodiment the needles and backing material support fingers are laterally shifted together by a common drive controlled by a cam having pattern information thereon. The needles and fingers are shifted in a first direction while the needles are outside the backing material and are thereafter shifted back toward the original position after the needles have penetrated and are within the backing material. In another embodiment the needles are shifted in accordance with a first cam operated pattern control, and the support fingers are shifted by means of a second cam actuated pattern control. Provision may be made in the common drive for adjusting the amount of lateral shift provided by a single cam and/or utilization of the same cam with machines having different gauge part spacings. An additional feature is the provision of shifting the needles in a first direction and jogging the backing material in an opposite direction to provide a high density fabric having various patterns.
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BACKGROUND OF THE INVENTION
This invention relates to spool type, electro-pneumatic control valves and more particularly to apparatus to aid in the proper assembly of these valves.
The spool type valve for which this apparatus was directly developed is shown in FIG. 1 and is the subject of patent application Ser. No. 892,303, which is incorporated herein by reference, as though set-out in full. All compound spool type valves have a generally similar arrangement of parts if they are driven electro-mechanically by face type armatures with core assemblies and coils.
Since this valve is a pneumatic valve and is generally applied in missile applications, the leakage at no flow is extremely important and the spool must be properly centered on the sleeve ports when the valve is in the off position. Also, the spool has a total displacement from the neutral or off position of 0.003 to 0.005 inches and since the response time is very critical, exact air gaps between the face type armatures and the core assemblies are critical.
It is an object of this invention to provide a device which locates the spool in relationship to the valve sleeve ports to minimize gas leakage in the off position. It is a further object of this invention to provide means for adjusting the armature on the spool to insure an optimum air gap between the armature and the core assembly, while assuring that the armature face is aligned perpendicular to the spool centerline and parallel to the core surface.
SUMMARY OF THE INVENTION
In summary, the apparatus of this invention accomplishes the above objects by providing a fixture for supporting the valve which is arranged for connecting a gas source to the valve through a suitable gas flow measuring device while interconnecting the first and second cylinder ports of the valve. The apparatus is further equipped with means to displace the spool in the valve body while measuring the gas flow and means to lock the spool in any position. Further, a device is provided which supports the armature on the spool so as to accurately provide the proper air gap between the armature and the core assembly of the solenoid when the valve is assembled. This latter device, of course, must be readily removable as it is a tool to aid the accuracy of assembly.
BRIEF DESCRIPTION OF THE DRAWING
With reference to the drawings, wherein like reference numbers designate like portions of the invention:
FIG. 1 is an assembly of the valve for which the apparatus was specifically developed;
FIG. 2 is a view of the apparatus of the invention with the outside line of the valve being assembled shown in reference lines;
FIG. 3 is a view of the device for setting the armature air gap; and
FIG. 4 is two views of the armature.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A compound pneumatic valve 15, of the type for which the apparatus of this invention applies, is shown in FIG. 1, having a valve body 16 which supports a sliding spool 18 in a bore 19 of sleeve 17. Spool 18 has a pair of lands 20 oriented such that when the spool is in the center or closed position the two lands align with or cover the first and second load or cylinder ports 21 and 22. Both ports are shown with an annular relief 24 and first cylinder passage 25 and second cylinder passage 26 which are shown with annular o-ring grooves 28 for bolt on connection to the actuator. The external connections, of course, are a matter of design choice and in some cases it may be preferable to have threaded fittings. The pressure port is shown at 29 also including an annular relief 24 and the passage and external connection are not shown as they are rotated in the plane of the paper. However, pressure enters through the annular relief 24 to the port 29 into the chamber isolated by the bore 19 and the two lands 20. An external vent connection is shown at 30 and contains a dust device 33 which prevents dust from entering the vent connection and in turn connects to the vent bore 31.
Actually ports 21 and 22 are four flow slots equally spaced in the bore 19 of the sleeve 17. Since the spool stroke is only 0.003 to 0.005 inches or about 5% of the width of the slots 21 and 22, the asymmetrical slot allows inlet flow throttling across the smaller right side of the slot and vent flow across the larger left side of the slot. Typically, four such slots are located in the sleeve 17 opposite each of the two spool lands 20.
Connected to both distal ends of the valve spool 18 are face type solenoid armatures 32. The armature 32 consists of a stem portion 34 and a face portion 35 perpendicular to the stem and containing lightening holes 36 to minimize the mass of the armature. The armature 32 is fastened to the spool 18 by a suitable bonding agent, e.g., Locktite™ 609, available from Locktite Corporation, Newington, Conn. 06111. It is recommended that machine operations be selected which provide circumferential or circular striations to both mating surfaces of the spool and armature. The assembly is made so that the distal ends 38 of the spool 18 protrude beyond the face 35 of the armature 32.
The core assembly 39 consists of a helical wire coil 40 clad or jacketed with a magnetic core material which is in two parts, inner jacket 41 and outer jacket 42 with a gap at 44. One end of the core assembly 39 fits into the valve body 16 and is retained by a end cap 46 which is rectangular in cross section and bolts into the valve body to retain the core assembly by corner bolts, not shown. The armature 32 is oriented, in assembly, to the core assembly 39 so that air gaps occur at two places 45 and 45a. This arrangement increases the initial pull of the core assembly by establishing a path for the magnetic flux across the core and through the armature via the air gaps 45 and 45a. End cap 46 contains a threaded bore 48 on the longitudinal center line which contains an adjustable flow spool centering stop 49.
The flow spool centering stop 49 consists of a housing 50 which is threaded on the outside to match the threaded bore 48 in the end cap 46. Housing 50 has a through bore with a reduced diameter at one end so as to provide a shoulder 51 and an internal thread at the opposing end. Inside the housing 50 is a tappet 52 which engages shoulder 51 and a spring 55. Finally, a threaded plug 54 with a slot 53 and a shouldered end termination 56, which centers the spring, provides a preload adjustment on the spring 55 and forms a caged spring assembly. The flow spool centering stop 49 is adjustable via slot 57 so as to position the tappet 52 against the distal end 38 of the flow spool stem 18 and further provides an independent adjustment for the preload acting against the tappet 52 by adjusting plug 54. Thus, the flow spool centering stops function to lock the flow spool in the centered position in the absence of valve commands in any type of acceleration environment, provide the spool centering or restoring force in conjunction with the Bernoulli force, to rapidly return the spool to the center position during solenoid drop-out and permit easy final valve adjustment without the need for precise tolerances.
Now, a source of high pressure gas is connected to the pressure port 29 (external connection not shown, but discussed) while first cylinder passage 25 and second cylinder passage 26 are connected to opposing cylinders of a balanced piston actuator. The left solenoid, as pictured, is energized, flow spool 18 moves to the left compressing the spring 55 in the flow centering stop 49. Spool 18 displacement allows the high pressure gas to flow to cylinder 1 while at the same time the gas from the second cylinder flows out second cylinder port 22 and through the vent 31 to the external vent 30. The exhaust gases, of course, cool the core assembly 39. When the solenoid is de-energized, the left and right adjustable flow spool centering stops 49 again center the flow spool, cover the flow ports 21 and 22 to shut off the flow of the gas. Since the total spool 18 displacement in either direction is 0.003 to 0.005 inches, the initial preloaded centering force provided by the spring 55 remains essentially constant.
Since the stroke of the spool 18 from the neutral or off position to full movement in one direction is only 0.003 to 0.005 inches, setting the air gap 45 between the armature 32 and the core assembly 39 is critical. It must be maintained within a few ten-thousandths of an inch while at the same time limiting the runout between the armature 32 and the core surface to a few ten-thousandths of an inch. These critical dimensions are maintained by counter-boring the diameter C in FIG. 2 on the same setup used to produce the spool sleeve bore 65 so as to maintain the shoulder surface A in the valve body (FIG. 2) on which the core assembly surface 47 bottoms perpendicular to spool motion.
The adjustment apparatus, shown in FIG. 2, is used to lock the spool in its centered position, based on flow measurements. That is, after attaching the valve body 16 to the fixture base, the spool 18 is inserted in the bore 19 after the spool lands 20 have been trimmed to exactly match the ports 21 and 22 in the valve body (FIG. 1). The armatures 32 are slipped on the ends 38 of the spool 18 along with the magnetic adapters 60. A low pressure gas source is then hooked up through a flow meter to the pressure port 29 of the valve body 16 and the spool 18 is positioned by the micrometer adjusters 61 by turning the thumbscrews 62 until the inlet gas flow is a minimum with a shunt connected between ports 63 and 64 which are in turn connected to cylinder passageways 25 and 26, respectively, (FIG. 1). This represents the neutral or off position of the valve, and the valve spool is locked in this position by the micrometer adjusters 61. Magnetic adapter plate 60 is then bolted to the valve body 16 with the fasteners 66 and, since it is magnetic, it holds the armature 32 against the surface B of the adapter 60. Since the dimension X (FIG. 3) is closely held to the proper tolerance on the adapter, it automatically presets the air gap as the adapter 60 surface D represents the core assembly 39. When the armatures 32 are indexed to the spool 18, a drop of Locktite 609 or equivalent is placed at the intersection of distal end 38 of the spool 18 and the inside diameter of the armature 32 and allowed to "wick" into the joint. The assembly in the jig is then heated to 150° F. for two hours to cure the bonding agent. The armatures are now indexed to the flow spool with the solenoid stroke accurately set to the X dimension as shown on the adapter 60.
The apparatus of this invention has been specifically developed for use with the compound valve shown. However, all compound spool type control valves using face type armatures are generally similar and the apparatus would be beneficial. It is to be understood that the shown embodiment is merely illustrative of and not restrictive on, the broad invention. It is not intended to limit the invention to these specific arrangements, constructions or structures described, for various modifications thereof may be accomplished by persons having ordinary skill in the art.
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An apparatus for positioning the spool in the valve body and setting the armature air gap with respect to the core assembly of a compound, spool type valve driven electro-mechanically by a pair of face type opposing solenoids.
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CROSS-REFERENCE TO FOREIGN PRIORITY APPLICATION
[0001] The present application claims the benefit under 35 U.S.C. §119(b) of European Patent Application No. EP 15197107.4 filed Nov. 30, 2015, entitled “Cooking System.”
FIELD OF THE INVENTION
[0002] The present disclosure relates to a cooking system including a kitchen utensil and a household electrical appliance, particularly a cooking hob, wherein the utensil has sensors that are arranged at the handle of the utensil.
BACKGROUND OF THE INVENTION
[0003] A utensil having sensors in the handle is disclosed by DE102011080246. In that utensil, infrared sensors are arranged for determining the position of the utensil on the hob by a plurality of fixed infrared beacons provided on the cooking hob.
[0004] Other “intelligent” kitchen utensils are known in the art. Such known utensils include lance-shaped thermometers that may be inserted into foodstuff, such as meat and fish, both for pan cooking and for convection ovens. Such lance thermometers come either in the form of simple electromechanical devices or electronic ones, and in some cases they are equipped with wireless communication means with the appliance in order to perform an automatic regulation of the energy sources with the object of reaching target temperatures.
[0005] Temperature probes of the type described in EP1239703B1 combine temperature information with other physical parameters related to food state, such as conductivity, humidity, and vibration.
[0006] One drawback of such temperature probes is that they are not able to determine the actual action being performed with the utensil itself, thus resulting in the inability to relate the sensed quantities to the use scenario being performed by the user (i.e., the use context). For instance, the information returned by a temperature sensor has a different meaning if captured with the utensil being inserted stationary inside a casserole versus the case when the utensil is being used to stir a risotto. Even if not manipulated (i.e., zero acceleration), the information read by the sensor is interpreted differently if the probe is dipped vertically inside a pot compared to inserted horizontally inside a roast. In other words, the knowledge of the position, displacement, and acceleration is fundamental for the correct interpretation of the sensor readings.
[0007] DE3119496 and U.S. Pat. No. 6,753,027B1 try to obviate those limitations by adopting multiple temperature measuring points along the part of the probe which is to be inserted into the food. Although the plurality of temperature sensors mitigates the problem of detecting the very core temperature of the food, they all have the drawback of being unable to detect the actual position of the probe with respect to the food, resulting in largely varying results caused by the degree of expertise of the user or cook in correctly placing the probe. To partially obviate to that limitation, WO2012149997A1 proposes a method to assess probe tip orientation with respect to food surface, based on the relationship among the different temperatures monitored along the different measuring points positioned on the probe itself. However this temperature-based determination of the probe inclination might be highly disturbed by food anisotropy (i.e., non-uniformity) and spatial gradient in the heat application sources.
[0008] The activity of cooking food items with cooking hobs entails a high degree of attention from the cook to manually regulate the burner's power output in accordance to the recipe requirements. Such regulation generally occurs based on a cook's sensorial perception (visual, olfactory, texture), which is often weakly related with actual food state. Although professional and experienced cooks have developed great skill in inferring the actual cooking state from the aforementioned sensorial inputs, average cooks often struggle with the correct interpretation of such sensorial inputs, thus resulting in poorly prepared meals.
SUMMARY OF THE INVENTION
[0009] An object of the present disclosure is to provide a user with a cooking system using a cooking utensil which is able to assist the cook in the process of determining the actual state of the food being cooked by relying on multiple inputs simultaneously and, on the basis of the monitored physical states, adapting the cooking hob output to achieve and hold the desired food state.
[0010] More specifically, it is an object of the present disclosure, to provide a cooking system in which the kitchen utensil used therein is not merely able to sense known physical parameters, such as temperature or humidity, or the position of the utensil and therefore of the cooking utensil, but also to determine the tool's use pattern over time. Such object is reached by virtue of the features listed in the appended claims.
[0011] According to one of the features of the claims, the kitchen utensil associated with the household electrical appliance is provided with at least a multi-axis accelerometer and/or gyroscope, with the aim of assessing the context of use of the utensil itself. The kitchen utensil according to the present disclosure can determine and control the food's cooking state based on multiple physical quantities related to food state, such as temperature and food conductivity, and combining such information with probe spatial position and acceleration along multiple axes, in order to understand which action is being performed with the utensil, with the purpose of interpreting and conditionally processing the sensed physical quantities accordingly. Kitchen utensils according to the present disclosure broaden the function and the utility of the intelligent kitchen utensils known up to now, helping the cook in significantly improving the result of the performed cooking processes.
[0012] According to a further feature of the disclosure, the shape of the kitchen utensil according to the invention is such that it can be used both as a lance (to detect the core temperature of bulky pieces of foods) or as tongs (to measure surface temperature of thin food). In one preferred embodiment, the kitchen utensil comes in the form of tongs of the kind normally used by cooks to flip food in the pan, equipped with two or more temperature sensors distributed along the tong arms, up to the vicinity of its tips. In a further preferred embodiment, one of the arms of the tongs could be shaped in the form of a lance to enable insertion into bulky foods.
[0013] Moreover, according to another embodiment, two or more electrically conductive contacts might be placed in the vicinity of the tongs tips, to monitor food juiciness or water/salt content through the measurement of the impedance across any pairs of those contacts.
[0014] In another preferred embodiment, the data processing of the signals obtained by the conductivity sensors signals are conditioned to the handling condition identified through acceleration, inclination, and/or strain information. For instance, the conductivity measurement is used to determine food conductivity only whenever the tool inclination is within a given range, corresponding to the typical orientation being assumed when a cook grabs the food with a tongs and is otherwise discarded in any other orientation angles.
[0015] In another example of conditional processing, the conductivity strips would be used to determine the starch concentration in the water contained in a pot where potatoes or pasta are boiled. In this particular configuration, the kitchen utensil would be positioned in a vertical position. Should the orientation of the probe deviate from that particular vertical position by +/−10° or more, and/or its acceleration along any axis exceeds 0.1 m/s 2 , the kitchen utensil be deemed to be manipulated by the user and then no longer being steadily immersed into the water bath. In such case, the monitoring of the conductivity must be suspended until the correct stationary, vertical orientation is achieved again.
[0016] In all the aforementioned embodiments, in order to provide information on the spatial orientation of the utensil as well as its trajectory in the space, a multi-axial accelerometer/gyroscope/inclinometer is provided within the tool, particularly within the handle thereof. Such device is coupled with a transmitter that sends to the electronic control unit of the household cooking appliance signals about rotational (inclination) and translational (position) movements of the tool in the space. The mathematical processing of those signals allows the determination of the action being performed by the cook with the utensil itself (such as stirring, food flipping, food grabbing, or stationary positioning of the utensil tips inside the pan, for instance, during deep frying or stewing).
[0017] Once the action performed on the food by the cook is determined through the accelerometer/gyroscope, the temperature/conductivity information may be processed with a much higher level of correlation with the food actual state. For instance, during the initial heat-up phase of stir frying, the kitchen utensil would be laid horizontally and steadily (acceleration <0.01 m/s 2 ), with the tongs tip dipped into the oil film. In that case, the cooking process would be controlled through a closed loop control of the oil temperature, just relying on the temperature sensor on the very tip of the probe, ignoring the other sensors.
[0018] Whenever the cook would use the kitchen utensil to stir the food, its inclination and acceleration would deviate from the conditions previously indicated. In such conditions, should the closed loop temperature control be maintained with the same logic, it would result in a sudden increase of cooking hob power, caused by the momentarily exposure of the temperature sensors to the ambient air temperature instead of the hot oil. On the other hand, a tool according to the present disclosure would detect the momentary tool manipulation through the acceleration and/or inclination signals and then inhibit the power increase through a differentiated action, such as a holding the feedback temperature to the last value observed before the manipulation was detected or, alternatively, by holding the delivered power until the proper tool inclination and/or acceleration is achieved again.
[0019] Furthermore, the discrimination between stir frying and deep frying could be performed by detecting the utensil acceleration combined with the difference between the temperature recorded by the sensor on the very tip (which is surely fully immersed) and the other sensors, which would be immersed only in case of deep frying.
[0020] In the case of meat searing, the food generally needs to be flipped one or more times, depending on food category. At the moment of food flipping, the tongs arm that used to be in between the meat and the pot will turn 180° and face the air and vice versa. In order for the temperature controller to keep working correctly, the feed must always be from the bottom temperature rather than the sensor in the air. To ensure this, the food flipping is detected by the accelerometer/gyroscope through a sudden change of roll coordinate (≧150°) (as per spatial coordinate convention shown in FIG. 1 ). Based on such information, the control would switch between the two sensors used for temperature feedback. In addition, during food flipping, it is normal that the temperatures recorded by the sensors overcome some fairly large spikes, due to momentary change of contact with the food. Thanks to the aforementioned detection of food flipping, it would be possible to reject those temperature spikes and possibly inhibit the closed loop control of the temperature until a stationary state is reached again.
[0021] In another preferred embodiment, the kitchen utensil is equipped with a strain sensor or an electrical contact to allow the determination of the time when the utensil in the form of a tongs is used to grasp the food. Based on the information given by that sensor, the temperature readings could be immediately associated with the surface temperature of the food, whereas the same temperature readings are ignored by the temperature controller whenever said strain and/or position and/or acceleration are indicating that the utensil is not actually in contact with the food, but rather just being manipulated outside the cooking area and/or far away from the foodstuff.
[0022] In another case where meat is seared or grilled, the kitchen utensil would not be inserted into the food, but rather used as a tongs, periodically used to grab and flip the food. Once again, based on accelerometer information, the very moment when the food is grabbed could be inferred and then a spot measurement of the temperatures would be triggered to detect surface temperature of the food. Moreover, impedance measurements could be triggered to detect surface browning through the ratio between surface impedance (measured across adjacent contact on the same arm of the tongs) and bulk impedance (measured across contacts sitting on different arms of the tongs). The trigger condition for those impedance and/or temperature measurements would be given by the simultaneous permanence of the kitchen utensil spatial coordinates within predetermined ranges for more than a predetermined time.
[0023] In the particular case of a tongs form of the kitchen utensil according to the present disclosure, an additional force sensor could be employed in order to detect the act of clamping the food and/or an additional angle sensor (preferably located in the tongs' hinge) could be used to detect food thickness.
[0024] It is evident that all the described measurements (temperature, impedance, humidity) would be hardly correlated with food state unless information on the utensil use (i.e., information from the accelerometer and/or gyroscope) is available.
[0025] The kitchen utensil according to the invention could be advantageously used both to assist pan-cooking, as described, and to assist pot cooking by laying the utensil vertically across the pot's rim, thus having one end of the tongs immersed in the cooking liquid and the other end exposed to the ambient. Because of the gyroscope information, the utensil could easily self-determine that it is used in this particular mode, by detecting a substantially vertical orientation and a substantially stationary operation (zero acceleration along the vertical axis). When used in such mode, the cooking liquid inside the pot could be regulated at a given temperature by controlling heating element power output by using known closed loop regulation. The measurement of the conductivity across any couple of immersed electrical contacts may give an indication of the ionic content of the cooking liquid, which is directly associable with salt and starch concentration, which vary, such as during the boiling of pasta or rice. Moreover, in case multiple electrical contacts are placed along the length of the utensil, a determination of the liquid level could be performed by detecting which pairs of contacts are actually shorted by the liquid. The impedance measurement could be aimed at the determination of the resistive part of the impedance or, more advantageously, to the complex impedance, thus allowing the discrimination between galvanically conductive foodstuff (ionic solution) and poorly conductive ones (pure water or fat tissue).
[0026] The kitchen utensil according to the present disclosure is configured to communicate with the control unit of the cooking hob by means of either an electrical harness or, more advantageously, through known radio frequency or optical wireless communication techniques.
[0027] Other known kind sensors could be advantageously added to the kitchen utensil according to the invention, with the aim of determining more precisely the state of the food. A non-exhaustive list of such sensors includes: chemical sensors (pH, electronic tongues), optical sensors (colorimeter, reflectometers), and strain sensors (strain gauges) to detect tongs compression state and food consistency/softness.
[0028] In another preferred embodiment of the present disclosure, the kitchen utensil interacts with a graphical “man-machine” interface adapted to show the individual steps of recipes, informing the cook about the effective actions to be performed and progressing through the recipe steps automatically. In other words, the user interface would present behavioral changes conditioned to the kitchen utensil use case, thus resulting in another form of conditional processing.
[0029] For instance, when the man-machine interface instructs the cook to turn the food, the kitchen utensil would detect the actual gesture and, once performed by the user, would automatically progress into the next step of the recipe. Alternatively, when the man-machine interface instructs the cook to add broth to a risotto, the kitchen utensil would detect the actual pouring of liquid through a combination of conductivity and temperature, both parameters being altered by the addition of that ingredient.
[0030] In another embodiment of the present disclosure, the kitchen utensil comprises a handle, into which an electronic board is inserted. One or more sensors carrying bars are connected to and protrude out of the handle and are designed to contain the temperature and conductivity sensors. In order to ensure economical manufacture and long life, all the electronic parts, including the accelerometer, gyroscope, and battery, are located in the handle, which is designed with a clinch feature to prevent it from slipping into a cooking pan or pot.
[0031] In another preferred embodiment, the battery is rechargeable through a contactless magnetic charger of known type. Independent of the type of battery used (rechargeable or non-rechargeable), the battery is designed to ensure, in conjunction with a low power electronic board, a life time of several years without need of battery replacement. These provisions allow the device to be fully sealed from the external environment so that it can be washed either by hand or in a dishwasher.
[0032] In another preferred embodiment of the present invention, the kitchen utensil is split into a handle, which carries the electronic module, electrically and mechanically connectable, in a releasable form, to a set of different tips, having the known forms of spoons, forks, tongs, or knives and carrying one or more of the aforementioned sensors (like temperature, conductivity, humidity, pH, etc.).
[0033] These and other aspects, objects, and features of the present disclosure will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a perspective view of a kitchen utensil according to the present disclosure in the form of tongs, where spatial coordinates for rotational (inclination) and translational (position) are indicated;
[0035] FIG. 2 is a block diagram of the cooking system according to the present disclosure in which the kitchen utensil of FIG. 1 is used;
[0036] FIG. 3 is a perspective view of the utensil of the present disclosure of FIG. 1 used in connection with a pot and with one arm immersed to control water temperature;
[0037] FIG. 4 is a perspective view of another version of a kitchen utensil according to the present disclosure, in the form of a fork, which is configured to detect starch concentration through conductivity;
[0038] FIG. 5 is a perspective view of the utensil of FIG. 1 used in connection with a pan;
[0039] FIG. 6 is a front view of a user interface with recipe progression indication based on detected gesture performed on the kitchen utensil of the present disclosure of FIG. 1 ;
[0040] FIG. 7 is a perspective view of another type of a fork-shaped kitchen utensil according to the present disclosure, in which the electronic unit is located in a removable handle;
[0041] FIG. 8 is a partial exploded view of the kitchen utensil of FIG. 7 where a removable electronic unit is located in a sliding handle and sensors are placed in the utensil tip;
[0042] FIGS. 9 a -9 d are cross-sectioned longitudinal views of another version of a kitchen utensil according to the present disclosure;
[0043] FIG. 10 shows a further version of kitchen utensils according to the present disclosure where a sensorized tip is detachably mounted on an electronic board;
[0044] FIG. 11 shows accelerometer and gyroscope signals during a flipping movement of the cooking utensil;
[0045] FIG. 12 shows accelerometer and gyroscope signals during a stirring movement of the cooking utensil; and
[0046] FIG. 13 shows accelerometer and gyroscope signals during a whisking movement of the cooking utensil.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0047] As referenced in the figures, the same reference numerals may be used herein to refer to the same parameters and components or their similar modifications and alternatives. For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the present disclosure as oriented in FIG. 1 . However, it is to be understood that the present disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0048] With reference to the drawings, a kitchen utensil 10 shaped as a pair of tongs presents a sensor 12 capable of detecting acceleration and spatial position of the kitchen utensil 10 , with the term “spatial position” being the yaw, pitch, and roll angles (referred to as a fixed reference position). The sensor 12 comprises an accelerometer 12 a and a gyroscope 12 b , which are both power supplied by a battery 14 ( FIG. 2 ) and which are connected to a microcomputer 16 and a wireless data transmitter 18 .
[0049] With reference to FIG. 2 , the cooking system S according to the present disclosure comprises, on one hand, the kitchen utensil 10 and, on the other hand, a cooking hob 20 , which comprises a wireless data receiver 22 and a control unit 24 configured to drive heating elements for heating cooking vessels placed on a cooking plate 26 .
[0050] In addition to the accelerometer 12 a and the gyroscope 12 b , the kitchen utensil 10 comprises other sensors, for instance a strain gauge 12 c placed preferably in a zone A, where the two pair of tongs are connected, as well as impedances 12 d and temperature sensors 12 e , which are each placed in end zones B of the tongs, and which are designed to come into contact with food during the cooking process. Also these sensors 12 c , 12 d , and 12 e are connected to the microcomputer 16 as well.
[0051] The control unit 24 of the cooking hob 20 receives signals from the kitchen utensil 10 , and, particularly, signals from accelerometer 12 a and gyroscope 12 b , so that the control unit 24 can elaborate such data and assess by analyzing the trend of these values versus time how the kitchen utensil 10 is either moved by the cook or how such kitchen utensil 10 is placed in a stationary configuration (vertical, horizontal, inclined). By elaborating such information, the control unit 24 can correctly interpret the other values of further sensors 12 c , 12 d , and 12 e , for instance, by disregarding such values when they do not fit with the current spatial configuration of the kitchen utensil 10 . Moreover, the control unit 24 drives the heating elements of the cooking hob 20 according to the way in which the cook manipulates and places the kitchen utensil 10 . Data received from the accelerometer 12 a and/or the gyroscope 12 b , or any other inclination sensor, are preferably processed by the control unit 24 through known statistical and spectrum analysis techniques (as shown in FIG. 12 ).
[0052] According to the present invention, in steady state condition, the spatial orientation of the cooking utensil 10 can be easily obtained from only the accelerometer signals according to the following relationships:
[0000]
Pitch
=
α
=
atan2
(
A
x
A
y
2
+
A
z
2
)
;
Roll
=
β
=
atan
2
(
A
y
A
x
2
+
A
z
2
)
;
Yaw
=
γ
=
atan2
(
A
z
A
x
2
+
A
y
2
)
[0000] wherein:
[0053] Pitch (α) is the angle between the X-axis of the Micro Electro Mechanical System (MEMS in the following) device, which is the mechanical construction comprising the accelerometer and the gyroscope sensors, and horizontal plane;
[0054] Roll (β) is the angle between MEMS Y-axis and the horizontal plane, and
[0055] Yaw (γ) is the angle between MEMS Z-axis and the horizontal plane.
[0056] Ax, Ay, and Az are the accelerometer signals, which in steady state condition represent components of the earth gravity vector on the three axes of the kitchen utensil 10 .
[0057] The Applicant has discovered that accelerometer and/or gyroscope sensors can be used to identify and recognize any kind of movement of the kitchen utensil 10 . Moreover, the Applicant has surprisingly discovered that signals sampled from the sensors during certain movements of the kitchen utensil 10 in some specific cooking preparations are substantially independent on the cook involved in the same preparations.
[0058] On the other hand, the Applicant has also measured that for some specific cooking preparations, the data pattern from the sensor(s) is substantially stable among repeated recipes. This allows identifying a specific footprint associated with each cooking preparation. Repeatability of the results also makes an assessment of a cook's behavior much easier.
[0059] As a non-limitative example, accelerometer and gyroscope signals are used to identify any kind of movement of the kitchen utensil 10 , as described in FIGS. 11, 12, and 13 , in connection with stirring, whisking, and flipping actions performed by the cook with the kitchen utensil 10 during food preparation.
[0060] As can be seen from FIG. 11 , a flipping gesture is characterized by a wide half wave signal on the X-axis gyroscope signal, during which the Z-axis accelerometer signal changes sign due to gravity. Furthermore, the integral of the X-axis gyroscope signal over the gesture duration must be equal to π radians, because the total rotation performed by the utensil is equal to 180°.
[0061] Thus, a possible method for detecting a flipping action can be: if the Z-axis accelerometer signal decreases in absolute value while other accelerometer signals are approximately at zero, the system starts to integrate the X-axis gyroscope signal until it becomes approximately equal to π radians, which identify the flipping gesture. In the case that the calculated integral is less or greater than π, it is possible to conclude that the gesture was not a complete flip.
[0062] In case of stirring and whisking gestures, the recognition of such gestures can be obtained by processing the accelerometer and gyroscope signals with a known Fast Fourier Transform (FFT) algorithm.
[0063] In both cases, accelerometer and gyroscope signals result in sinusoidal signals on a certain axis. The processing of these signals with an FFT algorithm reveals that the fundamental frequency of the signal exactly corresponds to the number of turns per second of the kitchen utensil 10 .
[0064] The two gestures can be discriminated not only by the frequency of rotation (higher in case of whisking with respect to stirring), but also by monitoring the rotation axis. In the case of stirring, the FFT analysis shows significant signal components of the accelerometer only on Y-axis and Z-axis, and significant signal components on all three axes of the gyroscope. In the case of whisking, due to different disposition of the kitchen utensil 10 , significant signal components can be detected only on X-axis and Y-axis of accelerometer and on Y-axis and Z-axis of the gyroscope.
[0065] Furthermore, as shown in FIG. 3 upon the detection of the vertical position of the kitchen utensil 10 from data received from the gyroscope 12 b , the control unit 24 can then attribute the values of the temperature sensor 12 e placed on one tip B of the tongs to the actual temperature of the content of the pan P.
[0066] In a similar way, the kitchen utensil 10 shown in FIG. 4 provides to the control unit data from at least an impedance sensor 12 d in order to assess starch or salt concentration in the cooking vessel Q. Also, the almost horizontal configuration of the kitchen utensil 10 shown in FIG. 5 can be detected by means of the gyroscope 12 b and signals from other sensors are interpreted accordingly.
[0067] According to FIG. 6 , the cooking hob 20 is also provided with a user interface 30 , which can inform the cook, in an interactive way and on the basis of data received from the acceleration and spatial position sensors 12 a , 12 b , as to the proper act to be performed in the cooking process (for instance, in a grilling process, the user interface 30 can inform the cook of the need to flip the food).
[0068] With reference to FIGS. 7 and 8 , a kitchen utensil 110 in the form of a fork is shown, which is made of two parts 110 a and 110 b , which can be assembled together. The part 110 a carries the temperature and impedance sensors 12 e and 12 d and having longitudinal rails 112 which cooperate with corresponding longitudinal grooves 114 provided in the second part 110 b , which is also the handle of the kitchen utensil 110 . Such handle 110 b has a cover 116 for the battery 14 and electrical contacts 118 for electrical connection of sensors 12 d and 12 e . The fork part 110 a of the kitchen utensil 110 is also provided with a notch 120 for supporting the kitchen utensil 110 on the sidewall of a pot P or similar cooking vessel. The solution shown in FIGS. 6 and 7 has the advantage of requiring only one “handle” 110 b with the electronics that can be coupled with different parts configured to be in contact with the food and having different shapes.
[0069] FIGS. 9 a to 9 d show a similar kitchen utensil 210 where, in correspondence with the handle thereof, the kitchen utensil 120 is provided with a concave seat 212 for placing a cartridge 214 containing the electronic unit carrying the accelerometer 12 a , the gyroscope 12 b , the battery 14 , the microcomputer 16 , and the radio transmitter 18 . A cartridge 214 is provided with an unlock sliding button 216 which is operated by the cook in order to unlock the cartridge 214 from the seat 212 (sequence indicated in FIGS. 9 b to 9 c ). The cartridge 214 is also provided with a flat spring 218 , which urges the cartridge 214 out of its seat 212 once the cook activates the sliding button 216 . For electrically connecting the electronic unit to the sensors on the tip of the kitchen utensil 210 , the seat 212 is provided with electrical contacts 220 configured to cooperate with corresponding contacts of the cartridge 214 in order to assure electrical connection from sensors provided on the tip of the kitchen utensil 210 to the electronic unit by means of wires 220 , which are preferably insulated with Kapton.
[0070] The embodiment shown in FIG. 10 refers to a kitchen utensil 310 having a soft touch body 312 in different forms (a pair of tongs and a spoon are shown in FIG. 10 ) into which an “intelligent” part 314 is inserted. Such part 314 contains a printed circuit board 316 , a battery 14 , and the accelerometer 12 a and gyroscope 12 b as well. The fact that the body 312 is made of soft polymeric material has the advantage of assuring insulation of the sensors 12 d and 12 e placed on the tip of the tongs or spoon. Moreover, between the part 314 and the soft touch body 312 , a light source 318 in the form of a ring is interposed which can inform the cook when the kitchen utensil 310 is transmitting data to the control unit 24 of the cooking hob 20 .
[0071] Even if the cooking system according to the invention has been disclosed with reference to an electric or electronic cooking hob 20 (for instance, an induction cooking hob), nevertheless it can also be also in connection with a gas cooking hob where the heating power is adjusted electronically by means of valves.
[0072] It will be understood by one having ordinary skill in the art that construction of the present disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.
[0073] For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.
[0074] For purposes of this disclosure, the terms “operably coupled” and “operably connected” generally mean that one component functions with respect to another component, even if there are other components located between the first and second component, and the term “operable” defines a functional relationship between components.
[0075] It is also important to note that the construction and arrangement of the elements of the present disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that, unless otherwise described, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes, and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating positions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
[0076] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
[0077] It is also to be understood that variations and modifications can be made on the aforementioned structures and methods 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.
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A cooking system includes a kitchen utensil and a cooking hob, wherein the kitchen utensil is provided with one or more sensors arranged on the kitchen utensil. The sensors include acceleration sensors, gyroscopic sensors, and inclination sensors. The cooking appliance is provided with a control unit configured to receive data from the sensors and to elaborate information on how the kitchen utensil is being used, and to control the cooking appliance accordingly.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional application that claims the priority benefit of a co-pending non-provisional patent application entitled “Dynamic Stabilization Device Including Overhanging Stabilizing Member,” which was filed on Jun. 23, 2005 and assigned Ser. No. 11/159,471. The foregoing non-provisional patent application claimed priority benefit to a provisional patent application entitled “Dynamic Spine Stabilizer,” filed on Jun. 23, 2004 and assigned Ser. No. 60/581,716. The entire contents of the foregoing provisional patent application are incorporated by reference herein.
BACKGROUND OF THE DISCLOSURE
[0002] 1. Technical Field
[0003] The present disclosure is directed to a dynamic stabilization device and system for spinal implantation and, more particularly, to a dynamic stabilization device and system that is adapted to be positioned/mounted relative to first and second laterally-spaced pedicle screws and that includes at least one dynamic stabilization member that is positioned beyond the region defined between the pedicle screws, e.g., in an “overhanging” orientation.
[0004] 2. Background Art
[0005] Low back pain is one of the most expensive diseases afflicting industrialized societies. With the exception of the common cold, it accounts for more doctor visits than any other ailment. The spectrum of low back pain is wide, ranging from periods of intense disabling pain which resolve, to varying degrees of chronic pain. The conservative treatments available for lower back pain include: cold packs, physical therapy, narcotics, steroids and chiropractic maneuvers. Once a patient has exhausted all conservative therapy, the surgical options range from micro discectomy, a relatively minor procedure to relieve pressure on the nerve root and spinal cord, to fusion, which takes away spinal motion at the level of pain.
[0006] Each year, over 200,000 patients undergo lumbar fusion surgery in the United States. While fusion is effective about seventy percent of the time, there are consequences even to these successful procedures, including a reduced range of motion and an increased load transfer to adjacent levels of the spine, which accelerates degeneration at those levels. Further, a significant number of back-pain patients, estimated to exceed seven million in the U.S., simply endure chronic low-back pain, rather than risk procedures that may not be appropriate or effective in alleviating their symptoms.
[0007] New treatment modalities, collectively called motion preservation devices, are currently being developed to address these limitations. Some promising therapies are in the form of nucleus, disc or facet replacements. Other motion preservation devices provide dynamic internal stabilization of the injured and/or degenerated spine, without removing any spinal tissues. A major goal of this concept is the stabilization of the spine to prevent pain while preserving near normal spinal function. The primary difference in the two types of motion preservation devices is that replacement devices are utilized with the goal of replacing degenerated anatomical structures which facilitates motion while dynamic internal stabilization devices are utilized with the goal of stabilizing and controlling abnormal spinal motion.
[0008] Over ten years ago a hypothesis of low back pain was presented in which the spinal system was conceptualized as consisting of the spinal column (vertebrae, discs and ligaments), the muscles surrounding the spinal column, and a neuromuscular control unit which helps stabilize the spine during various activities of daily living. Panjabi M M. “The stabilizing system of the spine. Part I. Function, dysfunction, adaptation, and enhancement.” J Spinal Disord 5 (4): 383-389, 1992a. A corollary of this hypothesis was that strong spinal muscles are needed when a spine is injured or degenerated. This was especially true while standing in neutral posture. Panjabi M M. “The stabilizing system of the spine. Part II. Neutral zone and instability hypothesis.” J Spinal Disord 5 (4):390-397, 1992b. In other words, a low-back patient needs to have sufficient well-coordinated muscle forces, strengthening and training the muscles where necessary, so they provide maximum protection while standing in neutral posture.
[0009] Dynamic stabilization (non-fusion) devices need certain functionality in order to assist the compromised (injured or degenerated with diminished mechanical integrity) spine of a back patient. Specifically, the devices must provide mechanical assistance to the compromised spine, especially in the neutral zone where it is needed most. The “neutral zone” refers to a region of low spinal stiffness or the toe-region of the Moment-Rotation curve of the spinal segment (see FIG. 1 ). Panjabi M M, Goel V K, Takata K. 1981 Volvo Award in Biomechanics. “Physiological Strains in Lumbar Spinal Ligaments, an in vitro Biomechanical Study.” Spine 7 (3):192-203, 1982. The neutral zone is commonly defined as the central part of the range of motion around the neutral posture where the soft tissues of the spine and the facet joints provide least resistance to spinal motion. This concept is nicely visualized on a load-displacement or moment-rotation curve of an intact and injured spine as shown in FIG. 1 . Notice that the curves are non-linear; that is, the spine mechanical properties change with the amount of angulations and/or rotation. If we consider curves on the positive and negative sides to represent spinal behavior in flexion and extension respectively, then the slope of the curve at each point represents spinal stiffness. As seen in FIG. 1 , the neutral zone is the low stiffness region of the range of motion.
[0010] Experiments have shown that after an injury of the spinal column or due to degeneration, neutral zones, as well as ranges of motion, increase (see FIG. 1 ). However, the neutral zone increases to a greater extent than does the range of motion, when described as a percentage of the corresponding intact values. This implies that the neutral zone is a better measure of spinal injury and instability than the range of motion. Clinical studies have also found that the range of motion increase does not correlate well with low back pain. Therefore, the unstable spine needs to be stabilized especially in the neutral zone. Dynamic internal stabilization devices must be flexible so as to move with the spine, thus allowing the disc, the facet joints, and the ligaments normal physiological motion and loads necessary for maintaining their nutritional well-being. The devices must also accommodate the different physical characteristics of individual patients and anatomies to achieve a desired posture for each individual patient.
[0011] With the foregoing in mind, those skilled in the art will understand that a need exists for a spinal stabilization device which overcomes the shortcoming of prior art devices. The present invention provides such an apparatus and method for spinal stabilization.
SUMMARY OF THE DISCLOSURE
[0012] The present disclosure provides advantageous apparatus and methods for stabilizing adjacent spinal vertebrae in spinal axial rotation and spinal lateral bending. The disclosed stabilization devices and systems are adapted to be disposed between laterally-spaced pedicle screws attached to the same spinal vertebra. The disclosed spinal stabilization devices/systems are advantageously adapted to include at least first and second stabilizing elements which function, according to exemplary embodiments, in concert for stabilization in spinal flexion and spinal extension. Thus, according to exemplary embodiments of the present disclosure, the spinal stabilization devices/systems provide stabilizing functionality with laterally-spaced pedicle screws, but in a manner that is not confined within the region defined between such laterally-spaced pedicle screws. Such spinal stabilization designs offer several clinical advantages, including a reduced spatial requirement between the laterally-spaced pedicle screws since a portion of the stabilization functionality is achieved through structures positioned beyond such laterally-spaced region, e.g., in an overhanging orientation relative to one of the laterally-spaced pedicle screws.
[0013] According to an exemplary embodiment of the present disclosure, a dynamic spine stabilization device/system is provided that is adapted to span adjacent spinal vertebrae. Attachment members are provided to mount/position the dynamic spine stabilization device/system with respect to laterally-spaced pedicle screws that are mounted into the adjacent spinal vertebrae. The attachment members of the spine stabilization device/system are generally coupled/mounted with respect to the laterally-spaced pedicle screws and are adapted to couple to the disclosed spinal stabilization device/system. Of note, the spinal stabilization device/system includes a dynamic element that is positioned between the first and second pedicle screws, and at least one additional dynamic element that is positioned beyond or external to the region defined by the laterally-spaced pedicle screws.
[0014] According to an exemplary embodiment of the present disclosure, first and second dynamic elements are associated with the disclosed dynamic stabilization device/system. A first dynamic element is positioned on a first side of an attachment member and a second dynamic element is positioned on the opposite side of such attachment member. Relative motion between the pedicle screws, which is based upon and responsive to spinal motion (i.e., in flexion or extension), is stabilized through the combined contributions of the first and second dynamic elements. Each dynamic element includes one or more components that contribute to the dynamic response thereof, e.g., one or more springs. According to exemplary embodiments, a pair of springs are associated with each of the dynamic elements, e.g., in a nested configuration. In a further exemplary embodiment, each of the dynamic elements includes a single spring, and the single springs are adapted to operate in concert to provide an advantageous stabilizing response to spinal motion.
[0015] According to other exemplary embodiments of the present disclosure, a dynamic stabilization device/system is provided in which an elongate rod/pin extends from both sides of an attachment member. The dynamic stabilization device/system may be equipped with one or more stops associated with the elongate rod/pin. First and second resilient members may be disposed on the pin (e.g., springs), the first resilient member being located in the region defined between the first attachment member and the second attachment member, and the second resilient member being located between either the first or the second attachment member and the stop. According to further exemplary embodiments of the present disclosure, a compressive preload may be established with respect to a first resilient member, a second resilient member, or both, to provide a desired stabilizing force profile, as described in greater detail herein.
[0016] Exemplary methods of use of the disclosed dynamic stabilization devices and systems are also provided in accordance with the present disclosure. The disclosed dynamic stabilization devices, systems and methods of use have a variety of applications and implementations, as will be readily apparent from the disclosure provided herein. Additional advantageous features and functionalities associated with the present disclosure will be apparent from the detailed description which follows, particularly when read in conjunction with the figures appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] To assist those of ordinary skill in the art in making and using the disclosed spinal stabilization device/system, reference is made to the accompanying figures, wherein:
[0018] FIG. 1 is Moment-Rotation curve for a spinal segment (intact and injured), showing low spinal stiffness within the neutral zone.
[0019] FIG. 2 is a schematic representation of a spinal segment in conjunction with a Moment-Rotation curve for a spinal segment, showing low spinal stiffness within the neutral zone.
[0020] FIG. 3 a is a schematic of a spinal stabilization device in conjunction with a Force-Displacement curve, demonstrating the increased resistance provided within the central zone according to spinal stabilization systems wherein a dynamic element is positioned between laterally-spaced pedicle screws.
[0021] FIG. 3 b is a Force-Displacement curve demonstrating the change in profile achieved through spring replacement.
[0022] FIG. 3 c is a dorsal view of the spine with a pair of dynamic stabilization devices secured thereto.
[0023] FIG. 3 d is a side view showing the exemplary dynamic stabilization device in tension.
[0024] FIG. 3 e is a side view showing the exemplary dynamic stabilization device in compression.
[0025] FIG. 4 is a schematic of a dynamic spine stabilization device that is adapted to position dynamic elements between laterally-spaced pedicle screws.
[0026] FIG. 5 is a schematic of an alternate dynamic spine stabilization device that is adapted to position dynamic elements between laterally-spaced pedicle screws.
[0027] FIG. 6 is a Moment-Rotation curve demonstrating the manner in which dynamic stabilization devices using the principles of the present disclosure assist in spinal stabilization.
[0028] FIG. 7 a is a free body diagram of a dynamic stabilization device in which dynamic elements are positioned between laterally-spaced pedicle screws.
[0029] FIG. 7 b is a diagram representing the central zone of a spine and the forces associated therewith for dynamic stabilization according to the present disclosure.
[0030] FIG. 8 is a perspective view of an exemplary dynamic stabilization device in accordance with the present disclosure.
[0031] FIG. 9 is an exploded view of the dynamic stabilization device shown in FIG. 8 .
[0032] FIG. 10 is a detailed perspective view of the distal end of a first pedicle screw for use in exemplary implementations of the present disclosure; according to exemplary embodiments of the present disclosure, the second pedicle screw is identical.
[0033] FIG. 11 is a detailed perspective view of a first pedicle screw secured to an exemplary attachment member according to the present disclosure.
[0034] FIG. 12 is a perspective view of the exemplary dynamic stabilization device shown in FIG. 8 as seen from the opposite side.
[0035] FIG. 13 is a perspective view of a dynamic stabilization device of the type depicted in FIG. 8 with a transverse torsion bar stabilizing member.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0036] Exemplary embodiments of the disclosed dynamic stabilization system/device are presented herein. It should be understood, however, that the disclosed embodiments are merely exemplary of the present invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as the basis for teaching one skilled in the art how to make and/or use the devices and systems of the present disclosure.
[0037] With reference to FIGS. 2 , 3 a - e and 4 , a method and apparatus are disclosed for spinal stabilization. In accordance with a preferred embodiment of the present disclosure, the spinal stabilization method is achieved by securing an internal dynamic spine stabilization device 10 between adjacent vertebrae 12 , 14 and providing mechanical assistance in the form of elastic resistance to the region of the spine to which the dynamic spine stabilization device 10 is attached. The elastic resistance is applied as a function of displacement such that greater mechanical assistance is provided while the spine is in its neutral zone and lesser mechanical assistance is provided while the spine bends beyond its neutral zone. Although the term elastic resistance is used throughout the body of the present specification, other forms of resistance may be employed without departing from the spirit or scope of the present disclosure.
[0038] As those skilled in the art will certainly appreciate, and as mentioned above, the “neutral zone” is understood to refer to a region of low spinal stiffness or the toe-region of the Moment-Rotation curve of the spinal segment (see FIG. 2 ). That is, the neutral zone may be considered to refer to a region of laxity around the neutral resting position of a spinal segment where there is minimal resistance to intervertebral motion. The range of the neutral zone is considered to be of major significance in determining spinal stability. Panjabi, M M. “The stabilizing system of the spine. Part II. Neutral zone and instability hypothesis.” J Spinal Disorders 1992; 5(4):390-397.
[0039] In fact, the inventor has previously described the load displacement curve associated with spinal stability through the use of a “ball in a bowl” analogy. According to this analogy, the shape of the bowl indicates spinal stability. A deeper bowl represents a more stable spine, while a more shallow bowl represents a less stable spine. The inventor previously hypothesized that for someone without spinal injury there is a normal neutral zone (that part of the range of motion where there is minimal resistance to intervertebral motion) with a normal range of motion, and in turn, no spinal pain. In this instance, the bowl is not too deep nor too shallow. However, when an injury occurs to an anatomical structure, the neutral zone of the spinal column increases and the ball moves freely over a larger distance. By this analogy, the bowl would be more shallow and the ball less stable, and consequently, pain results from this enlarged neutral zone.
[0040] In general, pedicle screws 16 , 18 attach the dynamic spine stabilization device 10 to the vertebrae 12 , 14 of the spine using well-tolerated and familiar surgical procedures known to those skilled in the art. In accordance with a preferred embodiment, and as those skilled in the art will certainly appreciate, a pair of opposed stabilization devices are commonly used to balance the loads applied to the spine (see FIG. 3 c ). The dynamic spine stabilization device 10 assists the compromised (injured and/or degenerated) spine of a back pain patient, and helps her/him perform daily activities. The dynamic spine stabilization device 10 does so by providing controlled resistance to spinal motion particularly around neutral posture in the region of neutral zone. As the spine bends forward (flexion) the stabilization device 10 is tensioned (see FIG. 3 d ) and when the spine bends backward (extension) the stabilization device 10 is compressed (see FIG. 3 e ).
[0041] The resistance to displacement provided by the dynamic spine stabilization device 10 is non-linear, being greatest in its central zone so as to correspond to the individual's neutral zone; that is, the central zone of the stabilization device 10 provides a high level of mechanical assistance in supporting the spine. As the individual moves beyond the neutral zone, the increase in resistance decreases to a more moderate level. As a result, the individual encounters greater resistance to movement (or greater incremental resistance) while moving within the neutral zone.
[0042] The central zone of the dynamic spine stabilization device 10 , that is, the range of motion in which the spine stabilization device 10 provides the greatest resistance to movement, may be adjustable at the time of surgery to suit the neutral zone of each individual patient. In such exemplary embodiments, the resistance to movement provided by the dynamic spine stabilization device 10 is adjustable pre-operatively and intra-operatively. This helps to tailor the mechanical properties of the dynamic spine stabilization device 10 to suit the compromised spine of the individual patient. The length of the dynamic spine stabilization device 10 may also be adjustable intra-operatively to suit individual patient anatomy and to achieve desired spinal posture. The dynamic spine stabilization device 10 can be re-adjusted post-operatively with a surgical procedure to adjust its central zone to accommodate a patient's altered needs.
[0043] According to exemplary embodiments of the present disclosure, ball joints 20 , 22 link the dynamic spine stabilization device 10 with the pedicle screws 16 , 18 . The junction of the dynamic spine stabilization device 10 and pedicle screws 16 , 18 is free and rotationally unconstrained. Therefore, first of all, the spine is allowed all physiological motions of bending and twisting and second, the dynamic spine stabilization device 10 and the pedicle screws 16 , 18 are protected from harmful bending and torsional forces, or moments. While ball joints are disclosed in accordance with a preferred/exemplary embodiment of the present disclosure, other linking structures may be utilized without departing from the spirit or scope of the present disclosure.
[0044] As there are ball joints 20 , 22 at each end of the stabilization device 10 , no bending moments can be transferred from the spine to the stabilization device 10 . Further, it is important to recognize the only forces that act on the stabilization device 10 are those due to the forces of the springs 30 , 32 within it. These forces are solely dependent upon the tension and compression of the stabilizer 10 as determined by the spinal motion. In summary, the stabilization device 10 sees only the spring forces. Irrespective of the large loads on the spine, such as when a person carries or lifts a heavy load, the loads coming to the stabilization device 10 are only the forces developed within the stabilization device 10 , which are the result of spinal motion and not the result of the spinal load. The stabilization device 10 is, therefore, uniquely able to assist the spine without enduring the high loads of the spine, allowing a wide range of design options.
[0045] The loading of the pedicle screws 16 , 18 in the present stabilization device 10 is also quite different from that in prior art pedicle screw fixation devices. The only load the stabilizer pedicle screws 16 , 18 see is the force from the stabilization device 10 . This translates into pure axial force at the ball joint-screw interface. This mechanism greatly reduces the bending moment placed onto the pedicle screws 16 , 18 as compared to prior art pedicle screw fusion systems. Due to the ball joints 20 , 22 , the bending moment within the pedicle screws 16 , 18 is essentially zero at the ball joints 20 , 22 and it increases toward the tip of the pedicle screws 16 , 18 . The area of pedicle screw-bone interface which often is the failure site in a typical prior art pedicle screw fixation device, is the least stressed site, and is therefore not likely to fail. In sum, the pedicle screws 16 , 18 , when used in conjunction with the present invention, carry significantly less load and are placed under significantly less stress than typical pedicle screws.
[0046] In FIG. 2 , the Moment-Rotation curve for a healthy spine is shown in configurations with stabilization device 10 . This curve shows the low resistance to movement encountered in the neutral zone of a healthy spine. However, when the spine is injured, this curve changes and the spine becomes unstable, as evidenced by the expansion of the neutral zone (see FIG. 1 ).
[0047] In accordance with a preferred embodiment of the present invention, people suffering from spinal injuries are best treated through the application of increased mechanical assistance in the neutral zone. As the spine moves beyond the neutral zone, the necessary mechanical assistance decreases and becomes more moderate. In particular, and with reference to FIG. 3 a , the support profile contemplated in accordance with the present invention is disclosed.
[0048] Three different profiles are shown in FIG. 3 a . The disclosed profiles are merely exemplary and demonstrate the possible support requirements within the neutral zone. Profile 1 is exemplary of an individual requiring great assistance in the neutral zone and the central zone of the stabilizer is therefore increased providing a high level of resistance over a great displacement; Profile 2 is exemplary of an individual where less assistance is required in the neutral zone and the central zone of the stabilizer is therefore more moderate providing increased resistance over a more limited range of displacement; and Profile 3 is exemplary of situations where only slightly greater assistance is required in the neutral zone and the central zone of the stabilizer may therefore be decreased to provide increased resistance over even a smaller range of displacement.
[0049] As those skilled in the art will certainly appreciate, the mechanical assistance required and the range of the neutral zone will vary from individual to individual. However, the basic tenet of the present invention remains; that is, greater mechanical assistance for those individuals suffering from spinal instability is required within the individual's neutral zone. This assistance is provided in the form of greater resistance to movement provided within the neutral zone of the individual and the central zone of the dynamic spine stabilizer 10 .
[0050] The dynamic spine stabilization device 10 provides mechanical assistance in accordance with the disclosed support profile. Further, the stabilization device 10 may advantageously provide for adjustability via a concentric spring design.
[0051] More specifically, the dynamic spine stabilization device 10 provides assistance to the compromised spine in the form of increased resistance to movement (provided by springs in accordance with a preferred embodiment) as the spine moves from the neutral posture, in any physiological direction. As mentioned above, the Force-Displacement relationship provided by the dynamic spine stabilization device 10 is non-linear, with greater incremental resistance around the neutral zone of the spine and central zone of the stabilization device 10 , and decreasing incremental resistance beyond the central zone of the dynamic spine stabilization device 10 as the individual moves beyond the neutral zone (see FIG. 3 a ).
[0052] The relationship of stabilization device 10 to forces applied during tension and compression is further shown with reference to FIG. 3 a . As discussed above, the behavior of the stabilization device 10 is non-linear. The Load-Displacement curve has three zones: tension, central and compression. If K 1 and K 2 define the stiffness values in the tension and compression zones respectively, the present stabilizer is designed such that the high stiffness in the central zone is “K 1 +K 2 ”. Depending upon the preload of the stabilization device 10 as will be discussed below in greater detail, the width of the central zone and, therefore, the region of high stiffness can be adjusted.
[0053] With reference to FIG. 4 , a dynamic spine stabilization device 10 in accordance with one aspect of the present disclosure is schematically depicted. The dynamic spine stabilization device 10 includes a support assembly in the form of a housing 20 composed of a first housing member 22 and a second housing member 24 . The first housing member 22 and the second housing member 24 are telescopically connected via external threads formed upon the open end 26 of the first housing member 22 and internal threads formed upon the open end 28 of the second housing member 24 . In this way, the housing 20 is completed by screwing the first housing member 22 into the second housing member 24 . As such, and as will be discussed below in greater detail, the relative distance between the first housing member 22 and the second housing member 24 can be readily adjusted for the purpose of adjusting the compression of the first spring 30 and second spring 32 contained within the housing 20 . Although springs are employed in accordance with a preferred embodiment of the present disclosure, other elastic members may be employed without departing from the spirit or scope of the present disclosure. A piston assembly 34 links the first spring 30 and the second spring 32 to first and second ball joints 36 , 38 . The first and second ball joints 36 , 38 are in turn shaped and designed for selective attachment to pedicle screws 16 , 18 extending from the respective vertebrae 12 , 14 .
[0054] The first ball joint 36 is secured to the closed end 38 of the first housing member 20 via a threaded engagement member 40 shaped and dimensioned for coupling, with threads formed within an aperture 42 formed in the closed end 38 of the first housing member 22 . In this way, the first ball joint 36 substantially closes off the closed end 38 of the first housing member 22 . The length of the dynamic spine stabilization device 10 may be readily adjusted by rotating the first ball joint 36 to adjust the extent of overlap between the first housing member 22 and the engagement member 40 of the first ball joint 36 . As those skilled in the art will certainly appreciate, a threaded engagement between the first housing member 22 and the engagement member 40 of the first ball joint 36 is disclosed in accordance with a preferred embodiment, although other coupling structures may be employed without departing from the spirit or scope of the present disclosure.
[0055] The closed end 44 of the second housing member 24 is provided with a cap 46 having an aperture 48 formed therein. As will be discussed below in greater detail, the aperture 48 is shaped and dimensioned for the passage of a piston rod 50 from the piston assembly 34 therethrough.
[0056] The piston assembly 34 includes a piston rod 50 ; first and second springs 30 , 32 ; and retaining rods 52 . The piston rod 50 includes a stop nut 54 and an enlarged head 56 at its first end 58 . The enlarged head 56 is rigidly connected to the piston rod 50 and includes guide holes 60 through which the retaining rods 52 extend during operation of dynamic spine stabilization device 10 . As such, the enlarged head 56 is guided along the retaining rods 52 while the second ball joint 38 is moved toward and away from the first ball joint 36 . As will be discussed below in greater detail, the enlarged head 56 interacts with the first spring 30 to create resistance as the dynamic spine stabilization device 10 is extended and the spine is moved in flexion.
[0057] A stop nut 54 is fit over the piston rod 50 for free movement relative thereto. However, movement of the stop nut 54 toward the first ball joint 36 is prevented by the retaining rods 52 that support the stop nut 54 and prevent the stop nut 54 from moving toward the first ball joint 36 . As will be discussed below in greater detail, the stop nut 54 interacts with the second spring 32 to create resistance as the dynamic spine stabilizer 10 is compressed and the spine is moved in extension.
[0058] The second end 62 of the piston rod 50 extends from the aperture 48 at the closed end 44 of the second housing member 24 , and is attached to an engagement member 64 of the second ball joint 38 . The second end 62 of the piston rod 50 is coupled to the engagement member 64 of the second ball joint 38 via a threaded engagement. As those skilled in the art will certainly appreciate, a threaded engagement between the second end 62 of the piston rod 50 and the engagement member 64 of the second ball joint 38 is disclosed in accordance with a preferred embodiment, although other coupling structures may be employed without departing from the spirit of the present invention.
[0059] As briefly mentioned above, the first and second springs 30 , 32 are held within the housing 20 . In particular, the first spring 30 extends between the enlarged head 56 of the piston rod 50 and the cap 46 of the second housing member 24 . The second spring 32 extends between the distal end of the engagement member 64 of the second ball joint 38 and the stop nut 54 of the piston rod 50 . The preloaded force applied by the first and second springs 30 , 32 holds the piston rod in a static position within the housing 20 , such that the piston rod is able to move during either extension or flexion of the spine.
[0060] In use, when the vertebrae 12 , 14 are moved in flexion and the first ball joint 36 is drawn away from the second ball joint 38 , the piston rod 50 is pulled within the housing 24 against the force being applied by the first spring 30 . In particular, the enlarged head 56 of the piston rod 50 is moved toward the closed end 44 of the second housing member 24 . This movement causes compression of the first spring 30 , creating resistance to the movement of the spine. With regard to the second spring 32 , the second spring 32 moves with the piston rod 50 away from second ball joint 38 . As the vertebrae move in flexion within the neutral zone, the height of the second spring 32 is increased, reducing the distractive force, and in effect increasing the resistance of the device to movement. Through this mechanism, as the spine moves in flexion from the initial position both spring 30 and spring 32 resist the distraction of the device directly, either by increasing the load within the spring (i.e. first spring 30 ) or by decreasing the load assisting the motion (i.e. second spring 32 ).
[0061] However, when the spine is in extension, and the second ball joint 38 is moved toward the first ball joint 36 , the engagement member 64 of the second ball joint 38 moves toward the stop nut 54 , which is held is place by the retaining rods 52 as the piston rod 50 moves toward the first ball joint 36 . This movement causes compression of the second spring 32 held between the engagement member 64 of the second ball joint 38 and the stop nut 54 , to create resistance to the movement of the dynamic spine stabilization device 10 . With regard to the first spring 30 , the first spring 30 is supported between the cap 46 and the enlarged head 56 , and as the vertebrae move in extension within the neutral zone, the height of the second spring 30 is increased, reducing the compressive force, and in effect increasing the resistance of the device to movement. Through this mechanism, as the spine moves in extension from the initial position both spring 32 and spring 30 resist the compression of the device directly, either by increasing the load within the spring (i.e. second spring 32 ) or by decreasing the load assisting the motion (i.e. first spring 30 ).
[0062] Based upon the use of two concentrically positioned elastic springs 30 , 32 as disclosed in accordance with the present disclosure, an assistance (force) profile as shown in FIG. 2 is provided by the present dynamic spine stabilizer 10 . That is, the first and second springs 30 , 32 work in conjunction to provide a large elastic force when the dynamic spine stabilization device 10 is displaced within the central zone. However, once displacement between the first ball joint 36 and the second ball joint 38 extends beyond the central zone of the stabilization device 10 and the neutral zone of the individual's spinal movement, the incremental resistance to motion is substantially reduced as the individual no longer requires the substantial assistance needed within the neutral zone. This is accomplished by setting the central zone of the device disclosed herein. The central zone of the force displacement curve is the area of the curve which represents when both springs are acting in the device as described above. When the motion of the spine is outside the neutral zone and the correlating device elongation or compression is outside the set central zone, the spring which is elongating reaches its free length. Free length, as anybody skilled in the art will appreciate, is the length of a spring when no force is applied. In this mechanism the resistance to movement of the device outside the central zone (where both springs are acting to resist motion) is only reliant on the resistance of one spring: either spring 30 in flexion or spring 32 in extension.
[0063] As briefly discussed above, dynamic spine stabilization device 10 may be adjusted by rotation of the first housing member 22 relative to the second housing member 24 . This movement changes the distance between the first housing member 22 and the second housing member 24 in a manner which ultimately changes the preload placed across the first and second springs 30 , 32 . This change in preload alters the resistance profile of the present dynamic spine stabilization device 10 from that shown in Profile 2 of FIG. 3 a to an increase in preload (see Profile 1 of FIG. 3 a ) which enlarges the effective range in which the first and second springs 30 , 32 act in unison. This increased width of the central zone of the stabilization device 10 correlates to higher stiffness over a larger range of motion of the spine. This effect can be reversed as evident in Profile 3 of FIG. 3 a .
[0064] The dynamic spine stabilization device 10 is attached to pedicle screws 16 , 18 extending from the vertebral section requiring support. During surgical attachment of the dynamic spine stabilization device 10 , the magnitude of the stabilizer's central zone can be adjusted for each individual patient, as judged by the surgeon and/or quantified by an instability measurement device. This optional adjustable feature of dynamic spine stabilization device 10 is exemplified in the three explanatory profiles that have been generated in accordance with the present disclosure (see FIG. 2 ; note the width of the device central zones).
[0065] Pre-operatively, the first and second elastic springs 30 , 32 of the dynamic spine stabilization device 10 can be replaced by a different set to accommodate a wider range of spinal instabilities. As expressed in FIG. 3 b , Profile 2 b demonstrates the force displacement curve generated with a stiffer set of springs when compared with the curve shown in Profile 2 a of FIG. 3 b .
[0066] Intra-operatively, the length of the dynamic spine stabilization device 10 is adjustable by turning the engagement member 40 of the first ball joint 36 to lengthen the stabilization device 10 in order to accommodate different patient anatomies and desired spinal posture. Pre-operatively, the piston rod 50 may be replaced to accommodate an even wider range of anatomic variation.
[0067] The dynamic spine stabilization device 10 has been tested alone for its load-displacement relationship. When applying tension, the dynamic spine stabilization device 10 demonstrated increasing resistance up to a pre-defined displacement, followed by a reduced rate of increasing resistance until the device reached its fully elongated position. When subjected to compression, the dynamic spine stabilization device 10 demonstrated increasing resistance up to a pre-defined displacement, followed by a reduced rate of increasing resistance until the device reached its fully compressed position. Therefore, the dynamic spine stabilization device 10 exhibits a load-displacement curve that is non-linear with the greatest resistance to displacement offered around the neutral posture. This behavior helps to normalize the load-displacement curve of a compromised spine.
[0068] In another embodiment of an aspect of the disclosed design and with reference to FIG. 5 , the stabilization device 110 may be constructed with an in-line spring arrangement. In accordance with this embodiment, the housing 120 is composed of first and second housing members 122 , 124 which are coupled with threads allowing for adjustability. A first ball joint 136 extends from the first housing member 122 . The second housing member 124 is provided with an aperture 148 through which the second end 162 of piston rod 150 extends. The second end 162 of the piston rod 150 is attached to the second ball joint 138 . The second ball joint 138 is screwed onto the piston rod 150 .
[0069] The piston rod 150 includes an enlarged head 156 at its first end 158 . The first and second springs 130 , 132 are respectively secured between the enlarged head 156 and the closed ends 138 , 144 of the first and second housing members 122 , 124 . In this way, the stabilization device 110 provides resistance to both expansion and compression using the same mechanical principles described for the previous embodiment.
[0070] Adjustment of the resistance profile in accordance with this alternate embodiment is achieved by rotating the first housing member 122 relative to the second housing member 124 . Rotation in this way alters the central zone of high resistance provided by the stabilization device 110 . As previously described one or both springs may also be exchanged to change the slope of the force-displacement curve in two or three zones respectively.
[0071] To explain how the stabilization device 10 , 110 assists a compromised spine (increased neutral zone), reference is made to the moment-rotation curves ( FIG. 6 ). Four curves are shown: 1 . Intact, 2 . Injured, 3 . Stabilizer and, 4 . Injured+Stabilizer. These are, respectively, the Moment-Rotation curves of the intact spine, injured spine, stabilizer alone, and stabilizer plus injured spine Notice that this curve is close to the intact curve. Thus, the stabilization device, which provides greater resistance to movement around the neutral posture, is ideally suited to compensate for the instability of the spine.
[0072] With reference to FIGS. 8 to 13 , a stabilization device 210 according to the present disclosure is schematically depicted. This embodiment positions the first and second springs 230 , 232 on opposite sides of a pedicle screw 218 . As with the earlier embodiments, the stabilization device 210 includes a housing 220 having a first attachment member 260 with a first ball joint 262 extending from a first end 264 of the housing 220 and a second attachment member 266 with second ball joint 268 extending through a central portion of the stabilizer 220 . Each of the ball joints 262 , 268 is composed of a socket 270 a , 270 b with a ball 272 a , 272 b secured therein.
[0073] More particularly, each of the pedicle screws 216 , 218 includes a proximal end 274 and a distal end 276 (as the first and second pedicle screws 216 , 218 are identical, similar numerals will be used in describing them). The proximal end 274 includes traditional threading 278 adapted for secure attachment along the spinal column of an individual. The distal end 276 of the pedicle screw 216 , 218 is provided with a collet 278 adapted for engagement within a receiving aperture 280 a , 280 b formed within the ball 272 a , 272 b of the first and second attachment members 260 , 266 of the stabilization device 210 .
[0074] The collet 278 at the distal end 276 of the pedicle screw 216 , 218 is formed with the ability to expand and contract under the control of the medical practitioner installing the present stabilizer 210 . The collet 278 is composed of a plurality of flexible segments 282 with a central aperture 284 therebetween. As will be explained below in greater detail, the flexible segments 282 are adapted for movement between an expanded state used to lock the collet 278 within the receiving aperture 280 a , 280 b of the ball 272 a , 272 b and an unexpanded state wherein the collet 278 may be selectively inserted or removed from the receiving aperture 280 a , 280 b of the ball 272 a , 272 b.
[0075] The receiving apertures 280 a , 280 b of the respective balls 272 a , 272 b are shaped and dimensioned for receiving the collet 278 of the pedicle screw 216 , 218 while it is in its unexpanded state. Retention of the collet 278 is further enhanced by the provision of a lip 286 at the distal end 276 of the collet 278 . The lip 286 is shaped and dimensioned to grip the receiving aperture 280 a , 280 b for retaining the collet 278 therein.
[0076] Expansion of the collet 278 of pedicle screw 216 , 218 is achieved by the insertion of a set screw 288 within the central aperture 284 formed between the various segments 282 of the pedicle screw collet 278 , As the set screw 288 is positioned within the central aperture 284 , the segments 282 are forced outwardly. This increases the effective diameter of the collet 278 and ultimately brings the outer surface of the collet 278 into contact with the receiving aperture 280 a , 280 b , securely locking the collet 278 , that is, the distal end 276 of the pedicle screw 216 , 218 within the receiving aperture 280 a , 280 b of the ball 272 a , 272 b.
[0077] Access for the insertion of the set screw 288 within the central aperture 284 of the collet 278 is provided by extending the receiving aperture 280 a , 280 b the entire way through the ball 272 a , 272 b . In this way, the collet 278 is placed within the receiving aperture 280 a , 280 b of the ball 272 a , 272 b while in its unexpanded state, the set screw 288 is inserted within the central aperture 284 between the various segments 282 to cause the segments 282 to expand outwardly and lock the collet 278 within the receiving aperture 280 a , 280 b . In accordance with a preferred embodiment, the set screw 288 is secured within the central aperture 284 via mating threads formed along the inner surface along of the central aperture and the outer surface of the set screw 288 .
[0078] Although the present ball joint/pedicle screw structure has been disclosed with reference to a particle stabilizer structure, those skilled in the art will appreciate that the ball joint/pedicle screw structure may be employed with various stabilizer structures without departing from the spirit of the present invention. In fact, it is contemplated the disclosed connection structure may be employed in a variety of environments without departing from the spirit of the present invention.
[0079] With reference to the stabilization device 210 , an alignment pin 250 extends from the first attachment member 260 through a bearing aperture 290 within the second attachment member 266 . The alignment pin 250 includes an abutment member 256 at its free end 258 . First and second springs 230 , 232 are concentrically positioned about the alignment pin 250 . The first spring 230 is positioned to extend between the first attachment member 260 and the second attachment member 266 , while the second spring 232 is positioned to extend between the second attachment member 266 and the abutment member 256 at the free end 258 of the alignment pin 250 . The arrangement of the alignment pin 250 , first and second attachment members 260 , 266 and first and second springs 230 , 232 allows for resistive translation of the alignment pin 250 relative to the vertebrae. In practice, the alignment pin 250 , springs 230 , 232 and attachment members 260 , 266 are arranged to create a compressive preload across the system.
[0080] This design allows for an axial configuration which generates the desired Force-Displacement curves as shown with reference to FIG. 3 , while allowing for a much shorter distance between the first and second attachment members. The stabilization device disclosed above may also be used in the stabilization of multiple level systems. It is contemplated that stabilization on multiple levels may be achieved through the implementation of multiple alignment pins coupled via multiple spring sets and pedicle screws.
[0081] The alignment pin 250 also provides tensile force for achieving the preload utilized in conjunction with the springs 230 , 232 . In accordance with an exemplary embodiment, the alignment pin 250 is flexible and provides flexible guidance for the springs 230 , 232 without debris causing bearing surfaces, provides tensile for the preload, provides a low friction, straight bearing surface as it moves through the second attachment member 266 and functions at times as a straight member and at other times as a flexible guide for springs 230 , 232 .
[0082] As mentioned above, the alignment pin 250 is cable of functioning as both a straight guide member and as a flexible guide member. The determination as to whether the alignment pin 250 functions as a straight guide member or a flexible guide member for the springs 230 , 232 is generally based upon location of the alignment pin 250 relative to the remaining stabilization device 210 components as the spine moves. This functionality is especially important during flexion. In accordance with an exemplary embodiment, the alignment pin 250 has a uniform cross sectional shape capable of performing as both a straight guide member and a flexed guide member.
[0083] In accordance with yet a further embodiment, and with reference to FIG. 13 , the stabilization device 210 may be used in conjunction with a torsion bar 292 connecting the stabilization device 210 to adjacent stabilizers as shown in FIG. 3 c . In accordance with an exemplary embodiment, the torsion bar 292 is connected to the attachment members 260 , 266 of adjacent stabilization devices with conventional connection structures. The use of the torsion bar 292 increases stability in axial rotation or lateral bending. The torsion bar 292 generally has a uniform cross section for purposes where uniform torsion is required. However, and in accordance with exemplary embodiments of the present disclosure, it is contemplated that the torsion bar 292 may have an asymmetric cross section so as to provide for flexibility of stiffness in two planes. In such instances, the asymmetric cross sectional torsion bar 292 will affect the system stiffness in lateral bending and axial rotation independently. Further, the torsion bar 292 may be utilized to tune the systems stabilization in all three planes.
[0084] In addition to the dynamic spine stabilization device described above, other complementary devices are contemplated. For example, a link-device may be provided for joining the left- and right-stabilizer units to help provide additional stability in axial rotation and lateral bending. This link-device would be a supplement to the dynamic spine stabilization device and would be applied as needed on an individual patient basis. In addition, a spinal stability measurement device may be utilized. The measurement device would be used to quantify the stability of each spinal level at the time of surgery. This device would attach intra-operatively to a pair of adjacent spinal components at compromised and uncompromised spinal levels to measure the stability of each level. The stability measurements of the adjacent uninjured levels relative to the injured level(s) can be used to determine the appropriate adjustment of the device. Additionally, the stability measurements of the injured spinal level(s) can be used to adjust the device by referring to a tabulated database of normal uninjured spinal stabilities. The device will be simple and robust, so that the surgeon is provided with the information in the simplest possible manner under operative conditions.
[0085] The choice of spring(s) to be used in accordance with the present disclosure to achieve the desired force profile curve is governed by the basic physical laws governing the force produced by springs. In particular, the force profile described above and shown in FIG. 3 a is achieved through the unique design of the present stabilizer.
[0086] First, the stabilization device functions both in compression and tension, even through the two springs within the stabilizer are both of compression type. Second, the higher stiffness (K 1 +K 2 ) provided by the stabilization device in the central zone is due to the presence of a preload. Both springs are made to work together, when the preload is present. As the stabilization device is either tensioned or compressed, the force increases in one spring and decreases in the other. When the decreasing force reaches the zero value, the spring corresponding to this force no longer functions, thus decreasing the stabilization device function, an engineering analysis, including the diagrams shown in FIGS. 7 a and 7 b , is presented below (the analysis specifically relates to the embodiment disclosed in FIG. 5 , although those skilled in the art will appreciate the way in which it applies to all embodiments disclosed in accordance with the present invention).
[0087] F 0 is the preload within the stabilization device, introduced by shortening the body length of the housing as discussed above.
[0088] K 1 and K 2 are stiffness coefficients of the compression springs, active during stabilization device tensioning and compression, respectively.
[0089] F and D are respectively the force and displacement of the disc of the stabilization device with respect to the body of the stabilizer.
[0090] The sum of forces on the disc must equal zero. Therefore,
[0000] F+ ( F 0 −D×K 2 )−( F 0 +D×K 1 )=0, and
[0000] F=D× ( K 1 +K 2 ).
[0091] With regard to the central zone (CZ) width (see FIG. 3 a ):
On Tension side CZ T is:
[0000] CZ T =F 0 /K 2 . On Compression side CZc is:
[0000] CZ c =F 0 /K 1 .
[0094] As those skilled in the art will certainly appreciate, the concepts underlying the present disclosure may be applied to other medical procedures. As such, these concepts may be utilized beyond spinal treatments without departing from the spirit or scope of the present invention.
[0095] While exemplary embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention.
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Spine stabilization devices, systems and methods are provided in which a single resilient member or spring is disposed on an elongate element that spans two attachment members attached to different spinal vertebrae. The elongate element passes through at least one of the two attachment members, permitting relative motion therebetween, and terminates in a stop or abutment. A second resilient member is disposed on the elongate element on an opposite side of the sliding attachment member, e.g., in an overhanging orientation. The two resilient members are capable of applying mutually opposing urging forces, and a compressive preload can be applied to one or both of the resilient members.
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BACKGROUND OF THE INVENTION
The invention relates to a transmission drive unit. The applicant's subsequent publication DE 10 2009 000 760 A1 discloses a transmission drive unit which has an output element which is produced from metal, in particular from sintered metal, and is at least partially insert molded by an adaptor element designed as a worm wheel. The adaptor element is accommodated within a transmission housing. The adaptor element is mounted rotatably on an axle stub of the housing base, wherein both the axle stub and the adaptor element are composed of plastic. The previously known transmission drive unit which is designed in particular as a sliding roof drive can be produced relatively inexpensively by the adaptor element being injection molded on. The wear resistance of the known transmission drive unit is worthy of improvement in particular under high loads. Furthermore, force is introduced by the adaptor element to the output element over a relatively small axial length, and therefore the driving torque which can be transmitted is restricted.
SUMMARY OF THE INVENTION
Proceeding from the prior art described, the invention is based on the object of developing a transmission drive unit in such a manner that it permits good bearing properties and the possibility of transmitting relatively high torques while being able to be produced economically. This object is achieved with a transmission drive unit according to the invention. The invention is based on the concept of using the output element at the same time as a bearing element in order to improve the bearing properties. Since the output element is composed of metal, there is therefore the possibility of designing a metal/plastics bearing which is distinguished by improved wear resistance in comparison to a plastics/plastics bearing.
Particularly high torques can be transmitted if the output element is designed so as to be extended into a plane of symmetry of the adaptor element. As a result, the torque is introduced by the adaptor element in the plane of the output element.
A cost-effective radial mounting of the output element can be brought about if the output element has at least one region into which a journal serving for the mounting projects.
In an alternative refinement of the invention, the transmission drive unit can be produced particularly cost-effectively, wherein at the same time relatively high torques can likewise be transmitted. In this case, the invention is based on the concept of enabling the output element to be produced particularly simply and inexpensively by means of an output element which can be connected to the adaptor element and is designed as a deep drawn part.
The manufacturing can be configured in a particularly simple manner in this case if the output element is pressed onto the adaptor element. The pressing-on therefore constitutes a single installation step which can be very simply integrated into the manufacturing process.
As an alternative, provision is made for the adaptor element to be formed by at least partial insert molding of the output element. Such a formation permits a particularly intimate connection between the adaptor element and the output element, thus enabling particularly high torques to be transmitted.
In order to permit the torques to be transmitted, provision is made, in an advantageous refinement of the invention, for the output element to be of cup- or sleeve-shaped design and to have, on the inner surface thereof, at least one molding which interacts with a mating molding molded onto the adaptor element and connects the output element to the adaptor element for conjoint rotation.
In this case, particularly simple installation is made possible in the event of pressing on if the at least one molding and the at least mating molding are arranged obliquely in relation to the longitudinal axis of the output element.
Axial securing between the adaptor element and the output element, which securing is expedient in particular in the event of the output element being pressed onto the adaptor element, is made possible if the output element has, on an inner surface, at least one latching geometry which interacts with a mating geometry formed on the adaptor element and, in the process, axially secures the output element on the adaptor element.
A mounting which is particularly reliable and absorbs relatively high radial forces is brought about if the radial mounting of the unit consisting of the adaptor element and output element has two bearings having different diameters.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the invention emerge from the description below of preferred exemplary embodiments and with reference to the drawings, in which:
FIG. 1 shows a first transmission drive unit according to the invention in a longitudinal section,
FIG. 2 shows an exploded illustration of an adaptor element and an output element, as used in the first transmission drive unit according to FIG. 1 ,
FIG. 3 shows a second transmission drive unit according to the invention in longitudinal section with an adaptor element which is changed in relation to FIG. 1 ,
FIG. 4 shows an exploded illustration of the output element and adaptor element, as used in a transmission drive unit according to FIG. 3 ,
FIG. 5 shows a third transmission drive unit according to the invention in longitudinal section,
FIG. 6 shows a unit consisting of the output element and adaptor element, as used in the third transmission drive unit according to FIG. 5 , in a perspective view,
FIG. 7 shows a fourth transmission drive unit according to the invention in longitudinal section,
FIG. 8 shows an exploded illustration of an adaptor element and a drive element, as used in the transmission drive unit according to FIG. 7 ,
FIG. 9 shows a fifth transmission drive unit with a deep-drawn output element in longitudinal section,
FIG. 10 shows an exploded illustration of an adaptor element and output element, as used in the transmission drive unit according to FIG. 9 .
FIG. 11 shows a perspective view of an output element according to FIG. 10 ,
FIG. 12 shows a sixth transmission drive unit according to the invention, in which the adaptor element is formed by insert molding of a deep-drawn output element, and
FIG. 13 shows a perspective view of an output element, as used in the transmission drive unit according to FIG. 12 .
Identical components and components of identical function are provided with the same reference number in the figures.
DETAILED DESCRIPTION
FIG. 1 illustrates a first transmission drive unit 10 , as provided in particular, but not restrictively, for use in a sliding roof drive of a motor vehicle. The transmission drive unit 10 has an output element which is composed of metal, in particular of sintered metal, and is designed as an output pinion 12 . In this case, the output pinion 12 constitutes the intersection with a sliding roof system which is in engagement with a transmission means (not illustrated) via an oblique external toothing 13 formed on the output pinion 12 . The adjustment of the roof mechanism is realized via the transmission means.
According to FIG. 2 , the output pinion 12 has three sections 14 to 16 . The external toothing 13 is formed on the first section 14 . A second section 15 , which is of substantially sleeve-shaped design, adjoins the first section 14 . The second section 15 is surrounded approximately centrally by an annular third region 16 which has an encircling, web-like edge 17 . Molded ribs 18 arranged in a radiated manner are integrally formed on the lower side or upper side (not illustrated) of the third section 15 . As can be seen in particular from FIG. 1 , the first section 14 has, on the inner wall thereof in the region of the external toothing 13 , a first receiving region 19 which is adjoined in the region of the second section 15 on the inner wall by a second receiving region 20 .
The output pinion 12 described to this extent is insert molded with an adaptor element which is composed of plastic and is designed as a worm wheel 22 , and is connected to said adaptor element by a form-fitting connection. As can be seen in particular with reference to FIG. 1 , the second section 15 of the output pinion 12 preferably occupies the entire height of the worm wheel 22 , wherein the third annular section 16 of the output pinion 12 is located approximately in the plane of symmetry 23 of the worm wheel 22 .
The form-fitting connection between the worm wheel 22 and the output pinion 12 is reinforced in particular by the encircling edge 17 and the molded ribs 18 of the output pinion 12 , and therefore the output pinion 12 is connected to the worm wheel 22 for conjoint rotation. The worm wheel 22 has an inner region 24 , on the lower side of which a bearing collar 25 is molded. The external toothing 27 is connected to the worm wheel 22 via an annular central region 26 . The external toothing 27 of the worm wheel 22 is in engagement with an input element which is designed as a worm shaft 29 and forwards the driving torque of a driving motor (not illustrated) for the sliding roof drive to the worm wheel 22 and the output pinion 12 .
The unit 30 which is described to this extent and consists of the output pinion 12 and the worm wheel 22 injection molded onto the output pinion 12 is arranged, with the exception of a region of the output pinion 12 , within a transmission housing 31 composed of plastic. The transmission housing 31 comprises a housing lower part 32 which centrally has a molded-on bearing journal 33 . The bearing journal 33 has two regions 34 and 35 which serve for the radial mounting of the worm wheel 22 in the transmission housing 31 , for which purpose the first region 34 is in bearing contact with the first receiving region 19 of the output pinion 12 and the second region 35 is in bearing contact with the second receiving region 20 of the output pinion 12 . The worm wheel 22 is axially mounted in the transmission housing 31 via an annularly encircling web 36 which is molded onto the base of the housing lower part 32 and interacts with the bearing collar 25 on the lower side of the worm wheel 22 . A further, annularly encircling web 37 on the upper side of the worm wheel 22 is supported on a housing cover 38 which is connected to the housing lower part 32 , for example, by means of a latching or adhesive connection. In this case, the housing cover 38 has a centrally arranged aperture 39 through which the output pinion 12 protrudes out of the transmission housing 31 .
FIGS. 3 and 4 illustrate a second transmission drive unit 40 according to the invention. The second transmission drive unit 40 differs from the first transmission drive unit 10 substantially merely by the design of the output pinion 12 a and of the worm wheel 22 a. In this case, the output pinion 12 a has, in the region of the second section 15 a, a third section 16 a which has gearwheel-like projections 42 . The projections 42 are located, as can be seen in particular with reference to FIG. 3 , likewise substantially level with the plane of symmetry 23 a of the worm wheel 22 a. The projections 42 serve to form a form-fitting connection between the output pinion 12 a and the worm wheel 22 a in order to increase the torques which can be transmitted. The output pinion 12 a is mounted analogously to the mounting of the output pinion 12 via a metal/plastics pairing between the output pinion 12 a and the bearing journal 33 a of the housing lower part 32 a.
FIGS. 5 and 6 illustrate a third transmission drive unit 50 according to the invention. The third transmission drive unit 50 comprises a sleeve-shaped output pinion 51 with an internal toothing 52 which serves for the form-fitting connection between the output pinion 51 and the worm wheel 53 . Furthermore, a bearing collar 54 is formed in the central region of the output pinion 51 , the outer wall 55 of which bearing collar serves as a first radial mounting of the output pinion 51 and of the unit 57 , which consists of the output pinion 51 and worm wheel 53 , in the transmission housing 58 . The bearing collar 54 here interacts with a passage bore 59 in the housing cover 60 composed of plastic. A second radial mounting of the unit 57 is formed between the bearing journal 61 in the housing lower part 62 and a bore 63 formed in the worm wheel 53 . In addition, a hexagon socket 64 which serves for the auxiliary actuation of the sliding roof drive, if the driving motor thereof should be defective, is also formed centrally in the output pinion 51 . The third transmission drive unit 50 therefore has two radial bearings for the unit 57 , the one bearing of which is designed as a metal/plastics pairing while the other bearing is designed as a plastics/plastics bearing.
FIGS. 7 and 8 illustrate a fourth transmission drive unit 70 which differs from the third transmission drive unit 50 substantially only in that the auxiliary actuation for the sliding roof drive is formed by means of the hexagon socket 71 in the worm wheel 73 instead of in the output pinion 72 . The fourth transmission drive unit 70 also has a first radial mounting of the output pinion 72 in the housing cover 74 while the worm wheel 73 , which is composed of plastic, is mounted radially in the region of a bearing journal 75 of the housing lower part 76 . The form-fitting connection between the output pinion 72 and the worm wheel 73 takes place in particular by means of web-like extensions formed on the inner wall of the output pinion 72 in the region of the first mounting.
FIGS. 9 to 11 illustrate a fifth transmission drive unit 80 according to the invention. In the fifth transmission drive unit 80 , the output pinion 81 thereof consists of a deep-drawn, cup-shaped sheet-metal part 82 which, in the region of the toothing 83 thereof, has radially inwardly projecting, obliquely arranged sections 84 which are formed by edges 86 on the side facing the worm wheel 85 . Furthermore, latching sections 88 formed on the inner wall are seen on a lower, annularly encircling section 87 of the output pinion 81 , which section faces the worm wheel 85 . The latching sections 88 interact with a circumferential groove 89 formed on the worm wheel 85 . The unit formed from the output pinion 81 and worm wheel 86 are manufactured in such a manner that the worm wheel 85 and the output pinion 81 are produced in separate processes. The output pinion 81 is subsequently pressed onto the worm wheel 85 , wherein the latching sections 88 interact with the circumferential groove 89 in the end position of the output pinion 81 such that the output pinion 81 is secured axially on the worm wheel 85 .
FIGS. 12 and 13 illustrate a sixth transmission drive unit 90 according to the invention. The sixth transmission drive unit 90 differs from the fifth transmission drive unit 80 essentially in that the worm wheel 92 of said sixth transmission drive unit is formed by insert molding of the output pinion 93 which is likewise designed as a deep-drawn part. In this case, the output pinion 93 according to FIG. 13 has, on the side facing the worm wheel 92 , an annularly encircling collar 94 which, after said output pinion is insert molded by the plastic of the worm wheel 92 , fixes the output pinion 93 axially in the worm wheel 92 . Obliquely arranged depressions 95 which are formed on the inner wall of the output pinion 93 and, after having been injection molded from plastic, ensure that the output pinion 93 and the worm wheel 92 are secure against twisting, are likewise seen. The worm wheel 92 is mounted radially and axially likewise on two different diameters of a bearing journal 96 .
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The invention relates to a transmission drive unit ( 10; 40; 50; 70 ) having an adapter element made of plastic ( 22; 22 a; 53; 73 ) via which a torque is initiated by an input element ( 29 ) and a drive element ( 12; 12 a; 51; 72 ) made of metal for forwarding the torque, wherein the adapter element ( 22; 22 a; 53; 73 ) and the drive element ( 12; 12 a; 51; 72 ) are directly coupled to one another and rigidly connected, wherein the adapter element ( 22; 22 a; 53; 73 ) is an injection molded part which is formed by at least partial overmolding of the drive element ( 12; 12 a; 51; 72 ) and wherein the drive element ( 12; 12 a; 51; 72 ) serves as a bearing element.
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BACKGROUND OF THE INVENTION
This invention concerns improvements in and relating to guttering.
To support guttering against distortion it is customary to provide straps linking opposite walls of the gutter channel at spaced intervals along the gutter. Such straps have to be fitted in advance of fixing the guttering to a structure. Indeed for metal guttering it is conventional to weld gutter straps in position.
SUMMARY OF THE INVENTION
An object of this invention is to provide a gutter strap which may be fitted on site and to provide guttering suitable for receiving gutter straps on site.
According to this invention it is proposed that gutters have on opposed side walls formations for engagement with ends of gutter straps, which ends include deformable formations for securement thereof to the gutter side wall formations.
The side wall formations of the gutters are preferably channels formed by inverted generally L-shaped flanges along the gutter side walls. The gutter straps preferably have upturned ends that fit into the channels. Outer surfaces of the upturned ends of the gutter strap are preferably arcuate at least in part.
The deformable formations of gutter strap ends are preferably arranged to lock over the L-shaped flange of the gutter side walls when the strap is in position. Preferably extending inwardly from the gutter strap ends is a deformable web having a flange on one side that will overlie a gutter side wall flange when the deformable web is urged towards the upturned end of the strap from which it extends. The deformable web preferably has on its opposite side a second flange to act as a lever for deforming said web to lock or release the strap. Preferably the strap itself has a protrusion near each end on its top surface to provide a fulcrum for a lever tool, such as a screwdriver, to act on the lever flange of the deformable web.
Preferably the gutter straps of the invention will be manufactured from aluminium.
The invention may provide various advantages over the prior art. In particular, gutter straps of the invention may be fitted on site. There is no need to weld them in position beforehand. They can be easily removed and their spacing is easily adjustable.
BRIEF DESCRIPTION OF THE DRAWING
This invention will now be further described, by way of example only, with reference to the accompanying drawing, which is an end view of a gutter with a gutter strap according to the invention being fitted.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the accompanying drawing a gutter 10 is a channel section having a base 12 , a taller side 14 with an inwards overhang 16 and a shorter side 18 , which will be adjacent a structure, such as a conservatory. The overhang 16 serves to support a roof structure, typically glazing bars supporting glazing panels. At the junction of the base 12 and side wall 18 is a shaped longitudinal slot 20 for receiving a fixing component for securing the gutter to the adjacent structure.
Both side walls 14 and 18 have on the opposing faces an inverted L-shaped flange 22 , 24 respectively forming downwardly open channels 26 with their respective side walls. These channels are to receive ends of a gutter strap 30 .
Each end of the gutter strap 30 has an upturn 32 whose outer surface 34 is arcuate. Extending inwardly from each end 32 is a deformable formation 36 having a securing part and a lever part 40 . The securing part has a first deformable web 42 extending from the end 32 and a second web 44 normal to the first web. The lever part 40 extends oppositely to the second web 44 . The strap 30 also has near each end on its intended top surface a fulcrum 46 .
The gutter strap is fitted to a gutter section in the following manner. The ends 32 of the strap are fitted into a respective channel 26 . The arcuate shaping of the ends 32 , facilitates that fitment. Then the formations 36 are bent over using a screwdriver 50 or another convenient tool, the screwdriver being pivoted around a fulcrum 46 to act against the lever part 40 , so that the part 38 fits over the L-shaped flange 22 or 24 to secure the strap in place.
To remove the gutter strap downward pressure is applied to the lever parts 40 of the deformable formations 36 . That action releases the deformable formations 36 from the L-shaped flanges 22 , 24 , so that the strap can be lifted out of the gutter.
The side 18 of the gutter which bears the weight of the roof structure supported on overhang 16 can be distorted by the weight and the bottom corner of the gutter on side 18 forced downwards. The strap 30 serves to brace the gutter across its width to fixed side 18 against such distortion.
The gutter straps are desirably sited at optimum structured positions, which may be in the region of the glazing bars of the supported roof structure.
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Gutters have on opposed side walls formations for engagement with ends of gutter straps, which ends include deformable formations for securement thereof to the gutter side wall formations.
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This application is a divisional Ser. No. 09/428,726 filed Oct. 28, 1999, U.S. Pat. No. 6,287,177.
FIELD OF THE INVENTION
The present invention pertains to a method and apparatus for honing precision edges on a workpiece, such as a cutting tool, using an abrasive brush. The invention particularly relates to a process and apparatus for controlling the position of a cutting tool edge relative to an abrasive honing brush in order to provide precise controlled edge honing.
BACKGROUND OF THE INVENTION
Cutting tools for cutting and shaping materials must be very hard to maintain their edges and withstand the high concentrated forces which are present at the cutting edge of the tool. These tools are frequently fabricated from carbide, ceramic, diamond coated carbide, CBN coated carbide or other tool materials which possess the necessary hardness. The disadvantage of using a hard material is that such materials tend to be brittle, and susceptible to crack formation. When cracks form, the material begins to chip, destroying the utility of the tool.
The predominant method of forming carbide edges on cutting tools uses a powder metallurgy process which involves placing powdered materials into a mold, and mechanically compacting them into specific tool geometric forms. The compacted tool form is then densified through a sintering process. The edges created by this process, however, are rough. Rough edges can adversely affect the performance of the tool, by increasing the tendency of the material to crack or chip. Furthermore, forces applied to the rough edge are not evenly distributed but, rather, are concentrated on high points of the edge. The low points of the edge tend to be sharp creating stress concentrations that increase the likelihood of crack formation. The rough edges on cutting tools can be smoothed by honing the edges before the tool is used in a machining process. Honing involves forming a rounded shape on the cutting edge of the tool. Early shapes were directed towards true radii, where the curvature of the smoothed edge was uniform across both surfaces adjacent to the edge.
More recently, edges having varying taper, i.e., non-uniform tapers about the periphery of the edge and generally called waterfall hones (see, FIG. 3 c ). Also, the correct sizing of the edge hone has been shown to affect tool life. As a result, the higher the precision with which the tool edges can be formed, the greater the resultant tool life.
Many different processes were originally used to smooth the edges of a cutting tool, including vibratory honing, mass media honing, slurry honing, honing inserts with media impregnated rubber wheels, dry blasting, wet blasting, and tumbling. These methods have several disadvantages, including intense labor requirements and poor predictability of edge hone characteristics between different tools exposed to the same honing process.
During the late 1970's, a process of honing using a brush having bristles impregnated with abrasive media was developed. In this process, bristles are forced into contact with the edge of the cutting tool. The forced contact results in the removal of material along the edge. Brush honing the cutting tool edges has typically required high brush rotational speeds, resulting in the abrasive bristles striking the cutting tool edge, rather than being dragged across the edge.
In a conventional honing process, the brush is rotated such that the speed of the tips of the brush range from 3,000 to 12,000 feet per minute. In order for these conventional processes to be commercially feasible, a high speed has been necessary in order to hone a sufficient quantity of cutting tools in a short period of time.
The apparatus used in conventional honing processes require the placement of the cutting tools to be honed on a rotating table. As the table rotates, the part is translated along an arcuate path past a rotating abrasive brush. The rotating table allows a continuous honing process to be used, with cutting tools being loaded at one position, honed at a second position, and removed from the table at a third position. The individual cutting tools were rotated as they are passed through the stationary, rotating brush. The circular formation of the table also presents a compact area within which the honing process can be accomplished.
One drawback to the use of a rotary table to feed the cutting tool to the honing brush is that the arcuate path produces an uneven hone on the work piece.
More particularly, the arcuate path causes the contact between the tool edge and the honing brush to vary depending on the location of the tool on the path. As such, the resulting hone will vary across the edge of the part making precision honing very difficult.
Another deficiency with the prior methods of honing edges on the cutting tools is that the high bristle speeds result in the generation of excessive heat at the bristle tips. This heat causes the nylon bristles to partially melt, leading to nylon being deposited on the workpiece. The deposited nylon must then be removed before the tool can be coated, adding an additional step to the honing process.
Attempts have been made to cool the bristles by using fluid coolants to alleviate or reduce the build up of heat at the bristle tips. The coolant, however, creates a material disposal problem which is not desirable.
Also, conventional processes for honing tool edges do not typically permit variation of the rotational speed of the brush during the honing process. Instead, the speed of the table is normally controlled to vary the amount of material removed from the tool.
The present invention overcomes the disadvantages of the prior art by controlling the contact of the cutting tool edge with the bristles of the abrasive brush so that the cutting tool edge moves through the volume occupied by the bristles. Thus, the material removal action is distributed over a greater portion of the bristle, thereby reducing the build-up of heat in the bristles. The movement of the cutting tool edge into the volume of the bristles further results in a greater material removal rate due to the greater contact between the individual bristles and the cutting tool edge.
SUMMARY OF THE INVENTION
An apparatus is disclosed for honing at least one edge on a workpiece, such as a cutting tool. In one embodiment of the invention, the apparatus includes a base with a variable speed motor mounted on it. An abrasive brush is mounted to the motor and includes a plurality of bristles attached to a hub. The bristles each have a tip end and an interior end, with the interior end being fixed to the hub. The motor is adapted to cause the abrasive brush to rotate about an axis of rotation. The width of the abrasive brush is defined by first and second ends. The combination of the width of the brush and the length of the bristles defines a volume. The honing apparatus also includes a rotational controller means for controlling the rotational speed of the motor.
A mount for holding a workpiece is attached to the base. The mount includes a fixture for holding the workpiece, and a translational movement mechanism for controlling the position of an edge of the workpiece along a path substantially parallel to the axis of rotation of the abrasive brush.
In another embodiment, the motor is a fixed speed motor and the position of the workpiece edge relative to the abrasive brush is controlled by horizontal and vertical movement mechanisms.
A honing process is also disclosed for controlling the formation of a hone on the edge of a workpiece by controlling the movement and positioning of the workpiece through the volume of the rotating bristles. The movement and position of the workpiece is controlled so as to control the angle of impact between the bristles of the abrasive brush and an edge of the workpiece. The process results in the formation of precise tapered edges on the workpiece edge.
The foregoing and other features and advantages of the present invention will become more apparent in light of the following detailed description of the preferred embodiments thereof, as illustrated in the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, the drawings show a form of the invention which is presently preferred. However, it should be understood that this invention is not limited to the precise arrangements and instrumentalities shown in the drawings.
FIG. 1 is a perspective view of an embodiment of a brush honing apparatus according to the present invention.
FIGS. 2 a - 2 c are illustrations of generic cutting tools showing a representative cutting edge.
FIGS. 3 a - 3 c are partial sectional views of the generic cutting tool of FIG. 2 showing variations in the honing of the edges in more detail.
FIG. 4 is a section view of the motor and abrasive brush.
FIG. 5 is a perspective view of an abrasive brush.
FIG. 6 is a side elevation of a motor and a vertical movement mechanism.
FIG. 7 is a perspective view of an alternate embodiment of the apparatus incorporating horizontal and vertical movement mechanisms into the mount.
FIG. 8 is a perspective view of an alternate embodiment of the apparatus incorporating a distance positioning mechanism into the motor and an orientation mechanism into the mount.
FIG. 9 is a side view of an abrasive brush and a cutting tool identifying an alternate orientation of a cutting tool to an abrasive brush.
FIG. 10 is a side view of an abrasive brush identifying reference points on the first end of the abrasive brush.
FIG. 11 is a side view of a cutting tool and abrasive bristle, showing the relation between the bristle and the cutting tool with the cutting tool inside the brush volume along a path through reference point A in FIG. 10 .
FIG. 12 is a side perspective of a cutting tool and abrasive bristle, showing the relation between the bristle and the cutting tool with the cutting tool inside the brush volume along a path through reference point B in FIG. 10 .
FIG. 13 is a side perspective of a cutting tool and abrasive bristle, showing the relation between the bristle and the cutting tool with the cutting tool inside the brush volume along a path through reference point A′ in FIG. 10 .
FIG. 14 is a perspective view of an abrasive brush identifying reference elements of the honing process.
FIGS. 15 a and 15 b are cross-sectional illustrations comparing a workpiece with a constant hone and a workpiece with a variable hone.
DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like reference numerals illustrate corresponding or similar elements throughout the several views, FIG. 1 is an isometric illustration of one embodiment of a honing apparatus 10 according to the present invention. The apparatus 10 is designed to provide precise honing of an edge of a workpiece 22 . The invention can be used on a wide variety of workpieces which require honing, including components subject to wear, such as seal rings, piston plungers, slitter knives, valve seats, counter-balance weights and carbide or ceramic bushings. The invention has particular use in honing edges of cutting tools, such as drills, end mills, milling inserts, threading tools, burrs, router bits grooving tools, form tools and tools designed to cut materials , such as metal and wood.
The apparatus 10 includes an abrasive brush 20 driven by a motor 24 . The motor 24 is mounted to a base 32 . The workpiece 22 is mounted such that its position relative to the abrasive brush 20 can be controlled to vary the shape of the resulting hone.
Referring to FIGS. 2 a - 3 c , the workpiece 22 is shown with its edge 50 in an un-honed condition (FIG. 3 a ), with a radius hone 52 (FIG. 3 b ) and a tapered hone, such as the waterfall hone 54 (FIG. 3 c ). In order to form the various hones, the apparatus 10 is configured to control the position of the workpiece edge relative to the abrasive brush. In the embodiment of the invention shown in FIG. 1, the relative location of the workpiece edge from the abrasive brush is achieved by changing the position of the motor 24 through the use of a horizontal movement mechanism 26 and a vertical movement mechanism 28 as will be discussed in more detail below.
As shown in FIG. 4, the abrasive brush consists generally of a hub 60 to which a plurality of bristles 66 are attached. The bristles 66 have a tip end and an interior or root end 74 , which is attached to the hub 60 . The hub 60 is designed to removably attach to the motor 24 . As shown in FIG. 5, the width of the abrasive brush 20 is defined by a first end 68 and a second end 70 , and the radius of the brush is defined by the distance from the bristle tips 76 to the axis of rotation 44 of the brush. As is apparent from the figures, the width of the brush, in combination with the length of the bristles 66 , defines a volume 72 which is illustrated and preferably in the form of a right cylinder. Although the present embodiment shows the abrasive brush 20 having bristles 66 fully surrounding the hub, the bristles 66 may be located in discrete rows along the hub, with spaces between the rows, as shown in FIG. 6, or other patterns which do not completely fill the volume 72 . The preferred diameter for the abrasive brush is approximately 14 inches.
As described above, during operation, the contact between the bristles of the brush and a workpiece causes the bristles to heat up. In order to reduce the temperature of the bristles 66 , one embodiment of the present invention incorporates an impeller 62 in the hub that has a series of vanes designed to draw air into the hub 60 through an air intake 64 . The impeller 66 forces the air out through the bristles 66 of the abrasive brush 20 , thereby reducing their temperature.
In order to control the rate of material removal, the present invention preferably incorporates a means for controlling the speed of the abrasive brush. Referring to FIG. 4, in one embodiment, the motor 24 that drives the abrasive brush 20 is a variable speed motor. This permits that rate of material removal to be varied depending on the workpiece and/or material being honed. Alternatively, a transmission (not shown) could be interposed between a fixed speed motor 24 and the abrasive brush, allowing variation of the rotational speed of the abrasive brush. A continuously variable transmission (CVT) would be a preferable transmission if a fixed speed motor were to be used.
The abrasive brush 20 is preferably rotated within a speed range which yields a linear speed of 180 to 1800 feet per minute at the tips of the bristles. The linear speed of the bristles tips can be calculated by multiplying the diameter of the abrasive brush times the rotational speed of the abrasive brush times π. As is obvious to one of skill in the art, the motor rotational speed does not need to be equal to the desired rotational speed of the abrasive brush, since gears or pulleys may be used between the motor and the abrasive brush to create non-unitary ratios of the rotational speed of the motor to the rotational speed of the abrasive brush.
The present invention also incorporates a controller 200 to allow an operator of the apparatus or a software program to control the rotational speed of the abrasive brush. The speed can be controlled depending on the desired hone, the location of the workpiece within the brush, and/or the type of material being honed. The controller 200 can be a conventional motor speed controller of a type dependent on whether the motor uses alternating current or direct current. If a CVT is used to vary the speed of the brush, the controller 200 could also be used to control the CVT.
The honing apparatus 10 also includes a mount 35 for positioning and moving the workpiece relative to the abrasive brush 20 . The mount includes a translational movement mechanism or translator 30 for moving the workpiece 22 along a linear path parallel to the axis of rotation 44 of the abrasive brush. It has been determined that linear translation of the workpiece through the abrasive brush produces a consistent and precise hone on the workpiece. The translational movement mechanism 30 is slidably attached to a guide 36 that preferably extends along a linear path parallel to the rotational axis of the abrasive brush 20 . The workpiece is held within a fixture 34 attached to the translational movement mechanism 30 . The translational movement mechanism preferably is driven along the guide 36 by a motor-driven screw drive. It is contemplated, however, that other drive systems can be substituted for the preferred screw-drive without detracting from the invention.
The present invention also preferably incorporates a controller (such as controller 200 discussed above) which includes a process control software program to accurately control movement of the workpiece on the translational movement mechanism with respect to the abrasive brush. For example, the controller 200 can be programmed to control the translational movement mechanism such that the workpiece moves in the forward direction through the abrasive brush, the reverse direction through the abrasive brush 20 , is stopped within the rotating abrasive brush, or oscillates in the forward and reverse directions within the abrasive brush. Those skilled in the art would readily be capable of making such a substitution.
In one embodiment of the invention, the fixture 34 that holds the workpiece 22 is attached to a rotating base 33 . The rotating base 33 is, in turn, attached to a positioning motor 37 , either directly or indirectly, through a transmission or direct drive. The positioning motor 37 positions or rotates the fixture 34 containing the workpiece while the translational movement mechanism 30 moves the workpiece 22 through the rotating abrasive brush 20 . A controller, such as controller 200 , controls the positioning motor 37 to vary the rotation of the fixture 34 in accordance with a predetermined program, such as a numerical control program, which accurately rotates, positions or stops the rotation of the positioning motor 37 . Alternately, the controller permits an operator to provide positioning commands to the motor 37 .
As shown in FIG. 1, a vertical movement mechanism 28 is employed which adjusts the vertical position of the motor 20 relative to the base. In one embodiment, the vertical movement mechanism 28 includes a screw driven actuator that is controlled either manually, as by a handle 46 (FIG. 1 ), or by a control motor 80 (FIG. 6 ). If a control motor 80 is utilized, the motor 24 is preferably engaged to one or more guide rails 84 through linear bearings 86 . A screw 82 turned by the control motor 80 passes through a threaded fitting on the motor 24 , such that rotation of the screw 82 causes the motor 24 to move up or down. It is contemplated that the movement of the motor 24 and abrasive brush 20 may be pre-programmed into a computer or other control device (such as the controller 200 ) to provide automated and repeatable workpiece honing.
The embodiment of the invention shown in FIG. 1 also preferably includes a horizontal movement mechanism 26 for moving the motor 24 and abrasive brush 26 relative to the base 32 . Similar to the vertical movement mechanism 28 , the horizontal movement mechanism 26 preferably uses a screw drive to control the position of the motor 24 relative to the workpiece. The screw drive may be controlled by a handle 46 or a control motor system as discussed above.
It is contemplated that the apparatus 10 may include a device for inverting workpieces 22 after they have been honed. A suitable inverting device 39 is shown in FIG. 1 and includes a parallel gripper 38 which is adapted to pick up workpieces from and place workpieces on the fixture 34 . A vertical actuator 42 is attached to the mount 36 and raises and lowers the gripper 38 . A rotary actuator 40 attaches the gripper 38 to the vertical actuator 42 . The rotary actuator 40 is designed to rotate the gripper 38 up to 180 degrees about a horizontal axis for inverting the workpiece 22 .
In operation, after the workpiece passes through the abrasive bristles 66 , the gripper 38 grabs the workpiece. The gripper 38 is then translated upward and rotated a suitable amount to position another edge in an appropriate position for honing. The gripper 38 is then lowered until the workpiece is again placed in the fixture.
An alternate embodiment of the invention is shown in FIG. 7 . In this embodiment, instead of the motor 24 and abrasive brush 26 being vertically and horizontally adjustable with respect to the workpiece, the workpiece is mounted such that it can be appropriately positioned relative to a fixed abrasive brush 120 . Preferably, one or more control motors are used to position the workpiece 122 horizontally and vertically relative to the abrasive brush 120 . Alternatively, manual handles can also be used, similar to the handles described in the previous embodiment.
More particularly, in this embodiment, a vertical movement mechanism 131 , preferably attached to the mount 135 , moves the fixture 134 vertically relative to the base 132 . A horizontal movement mechanism 128 is also preferably engaged with the mount 135 and is designed to move the fixture 134 horizontally toward and away from the abrasive brush (i.e., substantially parallel to the base 132 ). A translational movement mechanism 126 moves the workpiece 122 , fixture 134 , vertical movement mechanism 131 , and horizontal movement mechanism 128 along guides 136 which preferably define a linear path parallel to the axis of rotation 144 of the abrasive brush 120 . As with the previous embodiment, a rotating base and positioning motor can be incorporated to rotate the fixture and/or workpiece. As shown, an inverting device, including a parallel gripper 138 , a rotary actuator 140 , and a vertical actuator 142 , can be incorporated for inverting the workpiece after honing, as discussed above.
A further embodiment of the invention is shown in FIG. 8 . In this embodiment, a mechanism for controlling the distance between the workpiece edge 50 and the axis of rotation 144 of the abrasive brush 120 is incorporated into the apparatus 10 . Referring to FIG. 9, the position of the workpiece edge 150 relative to the abrasive brush 120 is shown. The orientation of the workpiece edge 50 is defined by the angle δ between a side surface 168 of the workpiece 122 and a radial line 170 extending from the axis of rotation 144 of the abrasive brush 120 through the workpiece edge 150 . Rotation of the workpiece 122 about the workpiece edge 150 causes the point of contact between the bristles 166 and a top surface 166 and the side surface 168 of the workpiece 122 to vary, thereby controlling the resulting shape of the hone.
Referring back to FIG. 8, an orientation actuator 160 is used to control the orientation of the workpiece (e.g., cutting tool) with respect to the abrasive brush 120 . The orientation actuator 160 includes a fixed portion 160 F and a rotary portion 160 R. The fixed portion 160 F is mounted to the base 132 . The rotary portion 160 R is rotatably engaged to the fixed portion 160 F. The guides 136 are attached to the rotary portion 160 R. The fixture 134 , which holds the work piece 122 , is slidably attached to the guides 130 . In order to rotate the workpiece, the orientation actuator 160 is controlled (e.g., via a controller, such as controller 200 in FIG. 1) so as to rotate the rotary portion 160 R. This, in turn, causes the guides 136 and the fixture 134 to rotate about an orientation axis of rotation 162 . Depending on the location of the guides 136 , fixture 134 and workpiece 122 , the orientation axis may lie along the workpiece edge 150 . Rotation of the workpiece 122 about this axis changes the angle δ between the side surface 168 and the radial line 170 . As such, the point on the workpiece edge 122 that contacts the abrasive brush 120 will vary.
In this embodiment of the invention, the vertical position of the abrasive brush 120 is controlled by a distance positioning mechanism 164 which increases or decreases the distance between the axis of rotation 144 of the abrasive brush 120 and the workpiece edge 150 . Alternatively, the fixture 134 can be vertically translated or rotated relative to the abrasive brush 120 in a manner similar to the various embodiments described above. As with the above embodiments, an inverting device can be incorporated into the apparatus to invert the workpiece.
The apparatus described in the various embodiments above is useful for honing precise edges on work pieces. The process for honing those edges will now be described in detail. One feature of the process according to the instant invention is the placement of the workpiece edge to be honed at a specific location within the volume of the bristles of the abrasive brush. This proper positioning, in combination with the operation of the abrasive brush at a preferred rotational speed, permits high precision workpiece edge honing.
FIG. 10 illustrates a cross-sectional schematic of an abrasive brush 20 . As discussed in detail above, the present invention permits the workpiece edge 22 to be precisely located within the volume of the bristles. Various paths through the bristle volume 72 are shown in FIG. 10, each of which produces a different hone on the workpiece. At position A, assuming that the workpiece is oriented such that its top surface is parallel to the x-axis in the figure, a contact angle Φ between individual bristles 66 and the top surface 190 of the workpiece is relatively shallow (see, FIG. 11 ). This shallow contact angle results in more material being removed from the top surface 190 then the side surface 192 , producing a waterfall hone (shown by the dashed lines) on the workpiece edge.
If the workpiece were located at position B, an approximately even amount of material would be removed on the top and side surfaces 190 , 192 by the bristles. This results in a radiused hone.
Referring to FIG. 14, the process according to the present invention involves first placing the workpiece 122 into the fixture 134 . The fixture 134 is then positioned relative to the abrasive brush 120 such that the workpiece edge 150 to be honed is located along a desired path 216 through the volume 172 of the abrasive brush. The location of this path in the volume 172 will depend on the desired hone shape as discussed above. The path 216 of translation through the bristle volume 172 is substantially parallel to the axis of rotation 214 of the abrasive brush. After proper positioning of the workpiece edge 150 , the fixture 134 is translated through the volume 172 .
Once the workpiece edge has passed through the bristle volume 172 , an inverting device can be utilized to reposition the workpiece in the fixture 134 to permit a different edge 50 to be processed. For example, since cutting tools typically have cutting edges on opposed sides of the tool, the parallel gripper 38 is rotated 180 degrees before the workpiece is returned to the fixture 134 . With the new edge positioned relative to the abrasive brush 20 , the fixture is translated back through the bristles of the abrasive brush 20 . If a different hone shape is desired on the new edge, the fixture can be repositioned relative to the abrasive brush prior to translation.
It is contemplated that the position and orientation of the work piece within the volume of bristles and the speed of rotation of the abrasive brush can be altered during translation (i.e., while the work piece is within the volume). This allows for the formation of a complex honed edge on the work piece and allows controlled variation of the hone along the workpiece edge. For example, in forming a threading tool, the hone on the thread forming edge can be intentionally varied from the tip end of the tool to the base of the tool. At the tip end, it may be desirable to have a larger hone to permit the thread forming edge, when in use, to dig through the raw material. Conversely, at the base of the thread forming edge it may be desirable to have a sharper hone to permit more precise finishing of the threads in the material. The present invention allows such precise hone control over the finished workpiece.
Another example of the use of the present invention for providing controller hone variation is shown in FIGS. 15 a and 15 b . FIG. 15 a is a cross-sectional illustration of a grooving tool with a constant hone (designated “D” on all three sides). FIG. 15 b is a cross-sectional illustration of a grooving tool with a controlled variable hone. As shown, the hone on the top (designated “D 1 ”) is greater than the hones on the sides (designated “D 2 ” and “D 3 ”).
The various positioning mechanisms discussed above allow complex workpiece edges to be precisely honed. The use of a controller in the present invention allows the honing process to be programmed and automated to ensure repeatability.
Although the invention has been described and illustrated with respect to the exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without parting from the spirit and scope of the present invention.
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The present invention relates to a honing method and apparatus which provides greater control over the edge shape, as well as reductions in the effort required to hone multiple edges on workpieces. The invention accomplishes these improvements by controlling the speed of the abrasive wheel, as well as the orientation and position of the workpiece prior to and/or while it is in contact with the abrasive brush. This provides for greater control over the hone shape, hone size, and hone distribution along all the cutting edges of the tool.
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SUMMARY OF THE INVENTION
As is known, there are many different stresses imposed on any radiator fan. If the fan is unable to withstand any of these stresses, fatigue cracking of the fan will occur resulting in its eventual failure, and often catastrophic destruction due to its high operating rpm. To make matters worse, frequently these stresses act in concert, making it that much more difficult for the radiator fan to survive them. In order to better appreciate the ingenuity of the fan of the present invention, consideration should be given to the kinds of stresses to which any fan is subjected during its operating life.
The first type of stress on a fan is centrifugal stress which tends to cause radial separation of the blades from the hub due to the "centrifugal weight" of the blades. The centrifugal stress on a fan changes each time the fan's rpm changes; increasing as the rpm increases, and decreasing as the rpm decreases.
The second type of stress is lift stress caused by the aerodynamics of the fan blades as they rotate through the air. Lift stress causes each blade to tend to bend slightly so as to tend to rise above the hub a little more as the fan's rpm increases, with the blades gradually resuming their original orientation as the fan slows to a stop. Naturally, each time the fan's rpm changes the lift stress imposed on the fan changes.
The third type of stress is reactive stress caused by the fan blades thrusting air rearwardly behind them. Reactive stress affects the fan in the same way as does lift stress.
The fourth type of stress is flutter stress and is related to lift stress and reactive stress. Flutter stress is caused by obstructions in the fan's air intake or slipstream. For example, a typical cause of flutter stress are the radiator covers frequently used by truckers in the winter to prevent overcooling of their engines, which covers usually expose only a small portion of the radiator to the air. As will be appreciated, the lift and reactive stresses on each blade greatly increase as the blade passes the opening in the radiator cover and is exposed to the air and are greatly reduced as the blade passes behind the rest of the radiator cover. Flutter stress is particularly hard on a fan because each blade is stressed and unstressed each time it makes one revolution, meaning it can be stressed and unstressed thousands of times a minute, depending on the fan's rpm. Flutter stress can also be caused by obstructions in the fan's slipstream, such as by the truck's generator, hoses, belts, etc.
The fifth type of stress is twist stress which causes each fan blade to twist about its longitudinal axis. Twist stress is caused primarily by centrifugal force which, as is known, tends to make any spinning object assume a disc-like configuration. Thus, the twist stress on the blades of the fan tends to twist the blades so they tend to become coplanar with the hub. As will be appreciated, twist stress causes the fan's blades to twist more and more as the fan is spun faster and faster; and then, of course, the blades will untwist in the opposite direction to assume their original configuration as the fan is spun slower and slower. Each time the fan's rpm changes, the blades will correspondingly twist or untwist a little.
The sixth type of stress is inertial stress and occurs as the fan's rpm is accelerated and deaccelerated. Inertial stress tends to cause each fan blade to fold to assume a position wherein it is adjacent the periphery of the hub. As the fan is accelerated, each blade tends to fold in one direction, and as the fan is deaccelerated, each blade tends to fold in the opposite direction. The faster the acceleration or deacceleration, the greater the inertial stress on the fan; and each time the fan is accelerated or deaccelerated it is subjected to a changing inertial stress.
The seventh type of stress is harmonic or noise stress, wherein the resonant vibrations in the fan caused by noise and by any of the stresses discussed above can set up harmful standing waves in the fan.
It will be appreciated that all of these various types of stresses are inflicted on a radiator fan each time it is run, and, as has been mentioned, at certain times all of these types of stresses are inflicted on the fan simultaneously. Even worse, all of these types of stresses are primarily concentrated in the connections between the blades and the hub, and in the connections between adjacent blades. As is known, the repeated stressing and unstressing of a fan can eventually lead to its fatigue cracking, and even to its eventual failure and destruction, particularly when the stresses are concentrated in the same locations.
Radiator fans are used in a variety of environments. Some environments are relatively undemanding, such as when the fan is used in a fixed base gasoline or diesel engine driven electrical gemerating facility where the fan is run at a constant speed in a fixed location, and where the air flows into and out of the fan are relatively uniform. In such an environment even a weak fan may survive since it is subjected to relatively little flutter stress, inertial stress and harmonic stress; and the stresses to which it is subjected are relatively constant, meaning the fan is not being constantly worked through numerous stress cycles.
On the other hand, some environments are much harder on a radiator fan, and a truck environment is particularly hard on a fan because of several factors. The first factor is the large physical size of a truck fan, typically 28 inches in diameter and having ten inch long blades. The longer the blades are of course, the more the forces acting on the blades tend to be multiplied as they stress the interconnection between adjacent blades.
Second, as has been noted, all of the seven kinds of stresses discussed above increase as the fan's rpm increases and decrease as the fan's rpm decreases. Since the rpm of the truck's engine (and fan) are almost constantly changing, the amount of the stresses which are imposed on the fan are also constantly changing, meaning that the blades on the fan are constantly moving or working small amounts with respect to the hub and with respect to each other as the stresses change. The more cycles of movement, the more likely that a stress failure will occur.
Third, when used on a truck, the fan frequently encounters large amounts of stress and quick changes in the amount of stress, both of which can contribute to the failure of the fan. For example, when a truck accelerates between two gears, the engine (and fan) are driven to a high rpm. Then, when the driver hits the clutch and drops the engine into the next higher gear, the engine and fan rpm will drop several thousand rpm in just a second or two, resulting in large, sudden changes in all seven of the stresses discussed. Even worse, this stress cycle is repeated every time the driver shifts gears.
Further, the stresses to which a truck fan is subjected are greatly aggravated by the current trend towards the increased use of radiator fan clutches in trucks which disengage the fan from the engine when the ram air into the radiator from the truck's motion provides sufficient cooling air to the radiator, and engages the fan with the engine when the ram air alone provides insufficient cooling. Fan clutches are increasingly popular because disengaging the fan when it is not needed saves fuel and also reduces the noise produced by the truck. The need for fuel conservation is apparent, while reduction in the noise produced by the truck will become increasingly important as governmental regulations on noise pollution become increasingly stringent.
It should be noted that most fan clutches impose enormous stresses on the fan as it engages. This is because typically, most fan clutches engage quite suddenly, in order to lengthen the life of the friction materials in the clutch. As a result, when the fan clutch engages, the fan is accelerated from a zero or a very low rpm to a very high, operating rpm is just a fraction of a second. This sudden, repeated change from almost zero stress on the fan to a maximum amount of each of the seven stresses discussed above, can eventually cause stress cracking and failure of the fan.
Conventional metal radiator fans which can withstand these stresses have three main drawbacks. They are heavy, costly, and relatively inefficient. They are heavy because they are usually made from steel. They are costly because expensive, heavy machinery and dies are required to stamp their component parts from sheet metal, which then leaves large amounts of scrap metal to be disposed of. In addition, the component parts must be assembled, as by welding or riveting, which is another costly process. Finally, they are relatively inefficient because assembled metal fans are relatively dirty in an aerodynamic sense due to protuding welds or rivets and due to a lack of smooth contours between adjacent parts.
On the other hand, fiber reinforced plastic fans combine strength with lightness, since both plastic and nonmetallic reinforcing fibers such as fiberglass are much lighter than steel. In addition, manufacturing costs are lowered, since the fan is molded in one piece. Finally, since there are no welds or rivets on a one piece molded fan and since all the contours can be molded as smoothly rounded as desired, the fan's efficiency is superior.
Accordingly, the primary objects of the present invention are to provide a one piece, fiber reinforced plastic truck fan which will successfully withstand all of the stresses discussed above, and which will do so at a lower weight, a lower cost and at a higher air moving efficiency than conventional metal truck fans. Of course, such a fan which can withstand a truck environment will withstand the stresses imposed in less demanding, non-truck environments exceptionally well.
These objects are at least partially achieved by the following features of the present invention, all of which preferably act in cooperation to provide the desired result.
Perhaps the most notable feature of the present invention is the hub extension provided for each blade. Each hub extension is substantially as thick as the hub, extends into its respective blade a substantial distance, and tapers in width as it travels out into the blade. The hub extensions are intended to stiffen and reinforce both the blades and their connections with the hub. Each hub extension's leading and trailing edges preferably merge into the hub at a tangent with respect thereto for increased strength and to help prevent undesireable stress concentrations.
In addition, the fan's strength is increased and stress concentrations are reduced by avoiding sudden changes in the thickness and direction of the fan's parts. This means the fan gradually tapers in thickness from the hub and hub extensions to the blades, and that all curves in the blades and hub extensions are gently rounded.
Another feature of the fan of the present invention is that the leading and trailing edges of adjacent blades are connected directly to each other to provide mutual reinforcement. Preferably, the interconnections between adjacent blades are located radially outwardly from the hub, and are located between the hub extensions so as not to weaken nor disturb the hub or the hub extensions, and to help to prevent undesireable stress concentrations between adjacent blades.
Further, each interconnection between the leading and trailing edges of a pair of adjacent blades is smoothly rounded in the shape of a spiral for strength and to help prevent undesireable stress concentration therebetween.
It is to be understood that the forgoing is but a brief summary, not a detailed catalog, of some of the objects and features of the present invention, and is not to be taken as a limitation on the scope of the present invention. The scope of the invention is to be construed to include all of the features and benefits inherent in the disclosed invention, whether or not specifically mentioned anywhere herein.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of the rear of the fan of the present invention having an enlarged central hole and showing its manner of attachment to a viscous type fan clutch;
FIG. 2 is a perspective view of the front of the fan of the present invention which is identical to that shown in FIG. 1 except for its having a smaller central hole and correspondingly relocated mounting holes;
FIG. 3 is a front elevational view of the front of one portion of the fan shown in FIG. 2, on a 1/2 scale;
FIG. 4 is a rear elevational view of the rear of the fan shown in FIG. 3, on a 1/2 scale;
FIG. 5 is a side elevational view of the fan taken along line 5--5 of FIG. 3, on a 1/2 scale;
FIG. 6 is a side elevational view of the fan taken along sight line 6 of FIG. 3, on a 1/2 scale;
FIG. 7 is a cross sectional view of the fan taken along line 7--7 of FIG. 3, on a 1/2 scale;
FIG. 8 is a cross sectional view of the fan taken along line 8--8 of FIG. 3, on a 1/4 scale;
FIG. 9 is a side elevational view of the end of one blade of the fan taken along line 9--9 of FIG. 3 on a full scale, with the background ommitted for clarity;
FIGS. 10-17 are cross sectional views of one blade of the fan taken along lines 10--10 to 17-17 of FIG. 3, on a full scale, with the background omitted for clarity;
FIG. 18 is an elevational view of one of the fiber reinforcing mats used in the fan, the fan being shown in phantom;
FIG. 19 is an elevational view of another of the fiber reinforcing mats used in the fan, the mat being shown in dotted outline;
FIG. 20 is an elevational view of another of the fiber reinforcing mats used in the fan, portions of the fan being shown in phantom;
FIG. 21 is an elevational view of another of the fiber reinforcing mats used in the fan, six being illustrated, with portions of the fan shown in phantom;
FIG. 22 is an elevational view of a portion of the front of a second emboidiment of the fan of the present invention, on a 1/2 scale;
FIG. 23 is a longitudinal cross section of the fan of FIG. 22 on a 1/4 scale, taken along line 22--22 thereof;
FIG. 24 is a transverse cross section of the fan of FIG. 23, taken along line 24--24 thereof, on a one-half scale;
FIG. 25 is an elevational view of the front of a third embodiment of the fan of the present invention on a 1/2 scale;
FIG. 26 is a longitudinal cross section of the fan of FIG. 25 on a 1/2 scale, taken along line 26--26 thereof;
FIG. 27 is a transverse cross section of the fan of FIG. 27, taken along line 27--27 thereof, on a one-half scale;
FIG. 28 is an elevational view of the front of a fourth embodiment of the present invention, on a 1/2 scale;
FIG. 29 is a longitudinal cross section of the fan of FIG. 28 on a 1/2 scale, taken along line 29--29 thereof; and
FIG. 30 is a transverse cross section of the fan of FIG. 28. taken along line 30--30 thereof, on a one-half scale.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures, a description will first be given of the manner of fabricating the fan of the present invention, and then a detailed consideration of its features will be addressed.
The fan of the present invention can be conveniently molded by any suitable conventional molding technique. However, the technique presently used by applicant is to first precut the fiberglass reinforcing mats used in the fan 10. The fiberglass reinforcing mats shown in FIGS. 18-20 are cut from two ounce per square foot fiberglass mat, such as type M8610 continuous strand mat produced by the Owens-Corning Company of Granville, Ohio. The reinforcing mat shown in FIG. 21, is a 24 ounce per square foot, woven fiberglass mat type, such as that produced by the Owens-Corning Company of Granville, Ohio. It is preferred that fiberglass fibers be used as the reinforcing material in the fan due to their relatively low cost and relatively high strength. Naturally, a variety of other metallic and non-metallic reinforcing fibers could be used such as carbon fibers, aramid fibers or any othr suitable material.
Next, the male and female molds, not illustrated, are coated with any conventional release agent to prevent adhesion to the mold of the resin used in the fan. Then, the fiberglass reinforcing mats are placed in the female mold in the following order. One mat 12 (FIG. 18), two mats 14 (FIG. 19), one mat 16 (FIG. 20), two mats 14 (FIG. 19), one mat 16 (FIG. 20), one mat 18 per blade (FIG. 21), one mat 14 (FIG. 19), and one mat 17 (FIG. 18).
Then the male mold is lowered into the cavity of the female mold to compress and hold the fiberglass mats in place between the two molds. Next, the plastic resin is injected into the middle of the mold cavity through a 1/2 inch tube under a pressure of about twenty psi, and any suitable means are used to hold the mold halves together with a pressure of about fifty psi while the plastic resin is injected and cured. Although applicant is presently using thermosetting resin type 99213 produced by the Reichold Chemical Company of Tacoma, Wash. any suitable plastic could be used. The term plastic is used herein in its broadest sense, and includes, without limitation, thermoplastics and thermoset plastics, whether reinforced or unreinforced.
The fan is then allowed to cure within the mold for about 15 minutes, the mold having been preheated to a temperature of about 120 degrees Fahrenheit. The mold halves are parted and the fan is removed, after which the molded fan is deflashed around the perimeter.
From an inspection of FIGS. 18, 20, and 21 it will be seen that the mats 12, 16 and 18 are larger than the final fan 10, and so it is noted that the male and female molds are designed to produce a fan 10 which is larger than the final fan 10. This is done to ensure good distribution of the mats 12-18 in the final fan so the mats will extend fully to the edges of the final fan 10, for the best reinforcement thereof. After the fan is removed from the mold it is deflashed or trimmed to its final configuration by any suitable means such as with a jig and a band saw, the circular intersections 20 are formed with a one and one-half inch drill in a drill press, and the central hole 22 and six bold holes 24 are similarly drilled out to the desired size. All of the fans shown in FIGS. 1-30 are made in the forgoing way.
It has been found that the one piece fan so produced is about 50 percent stronger than a comparable fan which is assembled from similar materials, such as the fans shown in U.S. Pat. No. Des. 246,725 granted Dec. 20, 1977 to Bonifant. In addition, the one piece fan can be manufactured with about 10 percent less material cost and 25 prcent less labor. Finally, the one piece fan so produced is about 10 percent more efficient due to its smooth lines and lack of sharp edges and rivet heads such as found in said patent.
As seen in FIGS. 1 and 2, any of the fans shown in FIGS. 1-30 will accommodate a variety of sizes of central holes, a small central hole 22 being shown in FIG. 2 and a large inch central hole 26 shown in FIG. 1. Due to the unusual strength of the fan shown in FIGS. 1-30, the 83/4 inch hub shown therein by wy of example will accommodate a central hole up to at least about six inches in diameter.
The fans in FIGS. 1-30 can either be mounted with fasteners directly to an engine (not shown), or can be mounted to an engine's fan clutch 28 with fasteners 30. The fan clutch 28 forms no part of the present invention and operates in the usual fashion to disengage the fan 10 when the fan's cooling air flow through the engine's radiator (not shown) is not needed, and to engage the fan 10 when it is needed to provide cooling air.
The front (air receiving side) of the fan 10 is shown in FIG. 2 while its rear (air expelling side) is shown in FIG. 1. Similar terminology as to the front and rear of the fan 10 applies to all of the fans shown in FIGS. 1-30.
The fan 10 shown in FIGS. 1-21 comprises a hub 32 of uniform thickness shown in dotted outline in FIGS. 3 and 4. Extending outwardly into each blade 34 (six being shown by way of example) of the fan 10 is a hub extension 36 which is coplanar with the hub 32 and is of substantially the same strength or thickness. By way of example, the fan has an overall diameter of about 28 inches, the hub 32 is about 83/4 inches in diameter, the extensions 36 are about 31/4 inches long, and the blades 34, from hub 32 to their tips, are about 91/2 inches long. The hole 22 is about 2 inches in diameter and intersection holes 20 are about 11/2 inches in diameter. The hub 32 and extensions 34 are about 1/2 of an inch thick.
As seen in FIGS. 3 and 4, note how the intersections 20 are located radially outwardly from the hub 32 so that the strength of the hub 32 is not diminished. In addition, as seen in FIGS. 5-7, note how the intersections 20 have a spiral configuration to help prevent stress concentrations, how the leading and trailing edges 38, 40 of the adjacent blades 34 merge into each other in a flowing arcuate line, how said leading and trailing edges 38, 40 are almost as thick as the hub adjacent to the hub intersection 20, and how the leading and trailing edges 38, 40 gradually taper in thickness radially outwardly from the hub. The intersections 20 which have a spiral configuration have a diameter of about 5 to 25 percent of the diameter of the hub 32.
Considering now the hub extensions 30, each hub extension has a length in the range of about 15 to 32 percent of the diameter of the fan 10, and a width at the hub 32 in the range of about 50 percent to 100 percent of the width of the blades 34 at the hub 32. The leading and trailing edges 42, 44 of each extension 36 join the hub 32 at substantially a tangent with respect thereto and merge directly into each other in a flowing, arcuate line to help to prevent undesireable stress concentrations. Each extension 36 forms a smoothly contoured depression 46 in the front of its blade 34 and a smoothly contoured protusion 48 in the rear of its blade 34.
The straight portion of the trailing edge 44 of each extension 36 lies on about the longitudinal centerline of its blade 34 and the leading edge 42 of each extension 36 extends generally diagonally from its intersection with the hub 32 to its intersection with the trailing edge 44 of the extension 36. The leading edge 42 of each extension 36 curves in its radially outermost portion to become generally perpendicular to its trailing edge 44 at its intersection therewith. Substantially greater than 50 percent of the intersection of each extension 36 with the hub 32 lies forwardly (towards the leading edge of the blade 34) of the longitudinal centerline of its blade 34.
As has been mentioned, each extension 36 forms a smoothly contoured depression 46 in the front of its blade 34 and a corresponding smoothly contoured protrusion 48 in the rear of its blade 34. The portions of the depression/protrusion 46, 48 between each extension 36 and the leading edge 38 of its blade 34 are substantially as thick as said extension adjacent to said extension, and gradually taper in thickness toward the leading edge 42 of its blade 34 (see FIGS. 14-17). As seen in FIGS. 1-4, those portions of each depression/protrusion lying radially outwardly from its extension 36 have a generally arcuate configuration and are thickened and straightened as compared to those portions of its blade 34 lying radially outwardly therefrom.
The portion of each blade 34 located between its extensions 36 and the blades trailing edge 40 are substantially as thick as said extension adjacent to said extension, and gradually taper in thickness towards the trailing edge 40 of its blade 34 (see FIGS. 14-17). Those portions of the blade located radially outwardly from the end of its extension 36 and its depression/protrusion 46, 48 are of substantially uniform thickness. However, each blade 34 does gradually taper in thickness in a direction radially outwardly from said hub 32 to the tip of said blade 34, and, in those portions of the blade 34 located radially outwardly from said hub extension 36 and depression/protrusion 46, 48. it tapers in thickness from its longitudinal centerline towards its leading and trailing edges 38, 40, being slightly thicker in its central longitudinal portion for increased stiffness (see FIGS. 8-17).
The pitch of each blade 34 with respect to the plane of the hub 32 gradually increases from about zero degrees at its leading edge 38 to about 60 degrees at its trailing edge 40.
Although the edges 38, 40 of the blades shown in the figures do not project equally above and below the plane of the hub 32, it is preferred that they do so, and this can be achieved by suitable trimming of their trailing edges 40, as with a band saw. It should be noted that the fan illustrated in the figures is designed so the tip portions of its blades, as well as their trailing edges, can be trimmed in order to achieve a fan with the desired air moving capacity for use in a particular vehicle. This is possible since in general the air moving capacity of any given fan design is proportional to the length of its blades and the projected height of its blades.
Turning now to FIGS. 22-24, 25-27 and 28-30, second, third and fourth forms of the present invention are illustrated, respectively. Each of these additional forms are identical to the forms shown in FIGS. 1-21 (except for the differences mentioned below) and similar parts have been given the same reference numerals throughout.
Turning now to the forms shown in FIGS. 22-28, each hub extension 50 is coplanar with the hub 32 at its intersection therewith, but now twists to become pitched substantially the same as its blade 34 a short distance radially outwardly from said hub 32. Otherwise, the extensions 50 are about the same as the extensions 32 of the fan of FIGS. 1-21. Of course, since the extensions 50 are twisted to become coplanar with the blades 34, the depression/protrusion 46, 48 of the fan shown in FIGS. 1-21 is no longer seen.
In the forms shown in FIGS. 25-27 and 28-30, each extension 52, 54, respectively, and its respective blade 34 is generally symmetrical about a common centerline extending radially outwardly from the center of the hub 32.
Referring now to the fan shown in FIGS. 25-27, it is seen that the extensions 52 are coplanar with the hub 32. Since the extensions 52 and their blades 34 are symmetrical about a common centerline, the single depression/protrusion 46, 48 of the fan of FIGS. 1-21 is eliminated, and is replaced by a pair of smaller depression/protrusions 56, 58 and 60, 62.
Each element 56, 58 is located between its extension 52 and its blade 34's leading edge 38 and forms a depression 56 on the front of the blade and a protrusion 58 on the rear of the blade. Similarly, each element 60, 62 is located between its extension 52 and its blade 34's trailing edge 40 and form the depression 60 on the rear of the blade 34 and a protrusion 62 on the front of the blade. Other than the differences discussed above, the extensions 52 are about the same as the extensions 34 of the fan of FIGS. 1-21.
Referring now to the fan shown in FIGS. 28-30, each extension 54 is coplanar with the hub 32 but twists to become pitched substantially the same as its blade 34 a short distance radially outwardly from the hub 32. Other than all of these differences discussed above, the extensions 54 are about the same as the extensions 32 of the fan of FIGS. 1-21. Of course, since the extensions 54 are twisted to become coplanar with the blades 34, the depression/protrusion 46, 48 of the fan of FIGS. 1-21 is no longer seen.
From the forgoing, various further applications, modifications and adaptations of the fan disclosed by the forgoing preferred embodiments of the present invention will be apparent to those skilled in the art to which the present invention is addressed, within the scope of the following claims.
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A one piece, fiber reinforced, plastic radiator cooling fan for a truck. The fan is reinforced by: a hub extension which extends from the hub into each blade a substantial distance; by directly interconnecting the leading and trailing edges of adjacent blades to form a juncture therebetween in the form of a spiral located radially outwardly from the hub; by having the leading and trailing edges of adjacent hub extensions interconnect in a smoothly curved line tangent to the hub; by strengthening locations of high stress in each blade; and by avoiding sudden changes in thickness and in direction of the various portions of the fan.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 08/726,955, filed Oct. 7, 1996, now U.S. Pat. No. 5,902,491.
STATEMENT OF GOVERNMENT INTEREST
This invention was made with Government support under Contract No. DABT63-93-C-0025 ordered by Advanced Research Projects Agency (ARPA). The Government has certain rights in this invention.
TECHNICAL FIELD
The present invention is directed generally to the formation of a layer on a substrate and specifically to removing surface protrusions from such a layer which inherently occur during its formation.
BACKGROUND OF THE INVENTION
Processes for depositing a thin film layer on a substrate are known in the art. An example of one such process is physical vapor deposition (PVD). Inherent in the PVD process is the formation of surface protrusions on the thin film during deposition of the material forming the thin film. These surface protrusions can be many times the size of components to be later deposited on the thin film. As a result, the surface protrusions may project into layers of material formed on the thin film layer. In such cases, the surface protrusions may result in an unwanted short circuit between the thin film layer and a layer formed on top of the thin film layer. For example, in the baseplate of a field emission display (FED), such surface protrusions could result in a short circuit between the thin film layer on which emitters are formed and an extraction grid positioned above the emitters. This is true because a surface protrusion can have a height which is much greater than the height of an insulating layer positioned between the thin film layer and the extraction grid.
Various techniques have been attempted in the prior art in an effort to alleviate the adverse effects of surface protrusions. First, the parameters of the PVD process have been adjusted to try and prevent formation of the surface protrusions. This technique has not been entirely successful in that some surface protrusions are inherently formed during the PVD process. Given that some surface protrusions are formed, chemical-mechanical planarization (CMP) has been utilized to try and remove these protrusions from the thin film layer. When CMP is used directly on the thin film layer, however, the larger surface protrusions sometimes break lose and scratch the surface of the thin film layer. These scratches can result in unacceptably large areas of the thin film being unsuitable for the formation of the desired components.
In view of the problems associated with these processes for removing surface protrusions from a thin film, it is desirable to develop a process which removes the surface protrusions from the thin film without detrimentally affecting the surface of the thin film layer.
SUMMARY OF THE INVENTION
The present invention is a method for removing a surface protrusion projecting from a layer of a first material deposited on a surface of a substrate. In one embodiment, the method comprises the steps of applying a layer of a second material on the layer of first material. A sufficient quantity of the second material is removed to expose the protrusion. The first material exposed through the protrusion is then removed.
The step of removing a sufficient quantity of the second material to expose the protrusion can comprise mechanical planarization of the second material, chemical mechanical planarization of the second material, or can comprise the steps of removing the second material above a predetermined distance from the surface of the substrate so that the thickness of the second material above the first material is greater adjacent the protrusion than above the protrusion and isotropically removing the second material to expose the protrusion.
In accordance with another embodiment of the present invention, a field emission display (FED) is constructed from a process comprising the following steps. First, a thin film layer is deposited on a substrate. The thin film layer may have one or more surface protrusions. The thin film layer is covered with a sacrificial layer having a top surface. Through a leveling material removal process, such as chemical-mechanical planarization, a portion of the top surface of the sacrificial layer is removed until the sacrificial layer has a predetermined thickness D to thereby expose on the top surface all surface protrusions having a height of at least D. The exposed surface protrusions are then etched to remove the surface protrusions from the thin film layer. The sacrificial layer is etched to remove the sacrificial layer from the thin film layer. Emitters are then constructed on the thin film layer, and an extraction grid is formed above the emitters. Finally, a screen is constructed above the extraction grid, the screen having a phosphor-coated surface facing the extraction grid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a substrate with a thin film layer having surface protrusions deposited on the substrate;
FIG. 2 is a cross-sectional view of the substrate and thin film layer of FIG. 1 showing a sacrificial layer deposited on the thin film layer;
FIG. 3 is a cross-sectional view showing the sacrificial layer after it had been planarized to remove the tips of the surface protrusions;
FIG. 4 is a cross-sectional view of the substrate of FIGS. 1-3 showing the removal of the surface protrusions from the thin film layer; and
FIG. 5 is a cross-sectional view of the substrate and thin film layer of FIGS. 1-4 depicting the thin film layer after its surface protrusions have been removed in accordance with the preferred embodiment of the present invention.
FIG. 6 illustrates a FED formed according to the methods of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a substrate 10 having a top surface 12 . The substrate 10 may be glass or other materials known in the art which are suitable for use as a substrate. A thin film layer 14 is deposited on the top surface 12 of the substrate 10 . The thin film layer 14 may be a conductive layer on which are formed elements of a device, such as a field emission display baseplate. In one embodiment, the thin film layer 14 is chromium. Other suitably conductive materials can also be used. The depositing of the thin film layer 14 may be done using any of a number of processes known in the art, such as physical vapor deposition (PVD). Inherent in many of these processes is the unwanted formation of surface protrusions 18 on the top surface 16 of the thin film layer 14 . Only one surface protrusion 18 is shown in FIG. 1, but in reality such protrusions may be scattered randomly over the entire surface 16 of the thin film layer 14 .
FIG. 2 shows the first step of the process of the preferred embodiment of the present invention in which a sacrificial layer 20 is deposited on the top surface 16 of the thin film layer 14 . The sacrificial layer 20 typically consists of a material which is selectively removable from the thin film layer 14 . In one embodiment of the present invention, the sacrificial layer 20 consists of silicon dioxide. The sacrificial layer 20 shown in FIG. 2 is deposited as a conformal layer on the thin film layer 14 . The sacrificial layer 20 need not, however, be a conformal layer. If the sacrificial layer 20 is not a conformal layer, the surface protrusion 18 may extend above the top surface of the sacrificial layer (see FIG. 3 ). The sacrificial layer 20 may be deposited so that it has a predetermined thickness d 1 above the top surface 16 of the thin film layer 14 .
A bump 22 is formed on the top surface 24 of the sacrificial layer 20 wherever there is a surface protrusion 18 on the thin film layer 14 . These bumps 22 are removed from the surface 24 by mechanical planarization or chemical-mechanical planarization (CMP). Although CMP is discussed as the preferred method used to remove the bump 22 , one skilled in the art will realize that other known processes can also be utilized. The CMP process is performed until a sufficient amount of the sacrificial layer 20 has been removed to expose the tip of the surface protrusion 18 . FIG. 3 shows the sacrificial layer 20 having a planarized surface 26 after the CMP process is complete. The tip of the surface protrusion 18 —illustrated by the dotted line—is removed by the CMP process. The removal of the tip of the surface protrusion 18 results in an island 28 of the material comprising the thin film layer 14 being exposed on the planarized surface 26 . Such islands 28 occur wherever there was a surface protrusion 18 on the thin film layer 14 having a height greater than d 2 .
The next step of the present process is the removal of the surface protrusions 18 as shown in FIG. 4 . The surface protrusions 18 are removed from the thin film layer 14 through a process, such as etching, which is known in the art. An etchant is disposed on the planarized surface 26 . The etchant is preferably chosen so that it will selectively remove the material of the protrusions 18 exposed through the island 28 to a greater degree than the material of the sacrificial layer 20 . In this way, the sacrificial layer 20 protects the portions of the thin film layer 14 not having surface protrusions 18 while allowing removal of the surface protrusions. The etching process results in a void 30 , which is the space formerly occupied by the surface protrusion 18 .
In FIG. 5, the sacrificial layer 20 is removed from the top surface 16 of the thin film 14 . This removal of the sacrificial layer 20 may be accomplished using known etching processes. In the etching process, an etchant is preferably used which selectively removes the material of the sacrificial layer 20 to a greater degree than the material of the thin film layer 14 . A CMP process could alternatively be used to remove the sacrificial layer 20 . The CMP process will not harm the top surface 16 of the thin film layer 14 since the large surface protrusions 18 (i.e., having a height of at least d 2 ) have been removed from the thin film layer. Although the sacrificial layer 20 is depicted and described as being removed from the thin film layer 14 , the sacrificial layer need not always be removed. For example, if the sacrificial layer 20 is an insulating layer which is part of the device being fabricated, the sacrificial layer could remain and further layers deposited on the top surface 26 of the sacrificial layer.
It should be noted that after the process of the present invention has been performed on the thin film layer 14 , the thin film layer has a void 30 in the same location where a surface protrusion 18 was previously located. Such voids 30 , however, generally do not adversely affect the utility of the thin film layer 14 . These voids 30 occupy a small percentage of the total surface area of the thin film layer 14 , which means the remaining area can be utilized for the formation of the desired elements on the thin film layer. Furthermore, the voids 30 do not pose the threat of short circuiting, as did the surface protrusions 18 , to layers disposed above the surface 16 of the thin film layer 14 .
An FED device formed by the methods provided herein is illustrated in FIG. 6 . After removal of the protrusion 18 and formation of the void 30 in the thin film layer 14 , an emitter 32 is constructed on the upper surface 16 of the thin film layer 14 . An insulating material 34 is formed atop the film layer 14 and fills the voids 30 therein. AD extraction grid 36 is formed on the insulating material 34 above the emitter 32 . Finally, a transparent screen 38 is constructed above the extraction grid 36 , the transparent screen 38 having an anode 40 and a cathodoluminescent coating 42 facing the extraction grid 36 .
The present invention has particular utility in the area of processing field emission displays and flat panel displays. In addition, the process is well suited for application to large area substrates in the range of twelve inches.
From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.
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A method for removing a surface protrusion projecting from a layer of a first material deposited on a surface of a substrate. In accordance with one embodiment of the invention, a layer of a second material is applied on the layer of first material. A sufficient quantity of the second material is removed to expose the surface protrusion. The first material exposed through the surface protrusion is then removed.
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FIELD OF THE INVENTION
[0001] This invention relates to an improved means for hanging a garment on a hanger while relieving the stress of the hanging weight of a garment on the hanger and preventing the garment from slipping off the hanger.
BACKGROUND OF THE INVENTION
[0002] Hanger loops are usually attached to a garment at the junction of the underarm, sleeve and sideseam of the garment in order to relieve the stress of the hanging weight of a full dress or garment on the fabric by slipping the loop over a hanger. Hanger loops are also applied to garments where the neckline is too wide for a hanger, a single strap garment, a garment where there are thin straps or strapless garment in order to prevent the garment from slipping off the hanger and to relive the stress of the hanging weight of the garment on the fabric.
[0003] The hanger loop forms a continuous loop that begins and ends at the underarm seam. The loop can slide over a hanger and take all the hanging weight of the garment and put it on the loops, alleviating any weight from being carried by the bodice of the dress or garment, but short enough that the dress bodice or garment will just rest on the hanger.
[0004] There are many different types of hangers available on the market, which have various different characteristics, such as size and thickness. Because the length of the hanger loop is often predetermined when the garment is manufactured, the length of the hanger loop is not always sufficient so as to carry the entire weight of the garment when it is placed on a hanger.
[0005] As a result, a hanger loop that is too long or to short for a particular hanger can pull the garment fabric and cause wrinkles or puckering in the garment fabric. Typically, when the hanger loop is too long for the hanger, the fabric of the garment stretches because the entire weight of the garment is not transferred to the loops and bumps or pinched fabric form on the garment at the point where the garment is hung on the hanger. In this instance, the bumps or pinched fabric commonly occur on the shoulder of the garment.
[0006] Although in some cases, hanger loops may be effective for solving the problem of storing or displaying a garment on a hanger, hanger loops also pose problems when the garment is worn. Typically, the hanger loops do not lie flat within the garment when it is worn and often are exposed by slipping out through an opening of the garment. A common practice is for the wearer to permanently remove the hanger loops from the garment, tuck the loops into the garment or underneath a bra strap.
[0007] If the hanger loop is tucked within the garment or underneath a bra's strap, the hanger loop can slip out and become exposed; it can create a crease in the fabric or irritate the wearer's skin. If the hanger loop is permanently removed from the garment, it is then difficult to hang the garment on a hanger without putting stress on the fabric, or having the garment slip off the hanger.
[0008] Often when the hanger loop is removed, the garment is placed on a hanger that has a covering, such as velvet that holds the garment in place using friction, or clips are used to attach the garment to the hanger. These solutions, however, do not relieve the stress that a hanging garment places on the fabric and can leave a deformity such as indentation or puckering in the fabric where the garment is in contact with the hanger or the clip. Additionally, friction hangers and clips do not work well for strapless, single strap, thin strap garments or garments that have a wide opening such as a boat neck garment or an off the shoulder garment.
[0009] One solution to the hanger loops is to provide one loop at the back of the garment, just underneath or at the opening of a blouse or a dress. The single hanger loop, however also poses problems. It can get caught around a wearer's neck, head or face when putting on or removing the garment, and it can slip out of an opening of the garment so that it is exposed. If the single hanger loop is removed, the problem again arises as to how to effectively hang the garment without creating puckering or wrinkles in the fabric, stretching the fabric or having the garment continuously slip off the hanger and end up on the floor.
SUMMARY OF THE INVENTION
[0010] Disclosed herein are one or more inventions, the embodiments of which address the problems caused by hanger loops in garments. The garment hanger includes garment attachment means that are removably clipped or attached to a garment in order to hang the garment on a hanger. When a wearer wishes to wear the garment, the garment attachment means can be unclipped or unattached from the garment, permitting the garment to be worn without hanger loops and eliminating a need to tuck the hanger loops inside of the garment when it is worn or removing them completely. When the wearer wishes to re-hang the garment after use, the garment attachment means can be clipped or re-attached to a portion of the garment permitting the garment to hang on the hanger with the weight of the garment transferred to the straps of the garment hanger and prevent the garment from slipping off the hanger.
[0011] In one embodiment the garment hanger includes a hanger attachment means configured to attach the garment hanger to a hanging device, at least one garment strap extending in a downward direction from the hanger attachment means and a garment attachment means secured to an end portion of each garment strap, the garment attachment means configured to be removably attached to a garment.
[0012] In another embodiment according to principles of the invention, the garment hanger includes an adjustment means to adjust the length of the garment strap.
[0013] In another embodiment according to principles of the invention, the garment hanger includes two straps which extend in a downward direction from the hanger attachment means.
[0014] In another embodiment according to principles of the present invention the hanger attachment means is a loop that is secured to the straps.
[0015] In another embodiment according to principles of the present invention, the garment hanger includes hanger attachment means which are configured to attach the fastener to the hook of a hanging device.
[0016] In another embodiment according to principles of the present invention, the garment hanger includes a hanger attachment means that is configured to attach the garment to a horizontal bar.
[0017] In another embodiment according to principles of the present invention, the garment hanger includes a strap comprising a first end and a second end, the strap removably attached to a hanging device; and a garment attachment means secured to each of the first end and second end of the strap, the garment attachment means configured to be removably attached to a garment.
[0018] In another embodiment of the invention, the garment hanger has a strap that is looped over a hanger.
[0019] Other systems, methods, features, and advantages of the present invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of the present invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings:
[0021] FIG. 1A depicts a front perspective of an embodiment of the invention where the strap is attached at the upper portion of a hanger.
[0022] FIG. 1B depicts a front perspective of an embodiment of the invention.
[0023] FIG. 1C depicts a front perspective of an embodiment of the invention.
[0024] FIG. 2 depicts a front perspective of an embodiment of the invention.
[0025] FIG. 3 depicts an exploded view of the garment attachment means of an embodiment of the invention.
[0026] FIG. 4A depicts an embodiment of the invention where the strap is attached to the cross section of a hanger.
[0027] FIG. 4B depicts an embodiment of the invention where the strap is attached to the cross section of a hanger.
[0028] FIG. 4C depicts an embodiment of the invention where the strap is attached to the cross section of a hanger.
[0029] FIG. 5 depicts an embodiment of the invention from a front perspective.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The presently preferred embodiments according to principles of the present invention will be described in detail hereinafter with reference to the accompanying figures. Although the presently preferred embodiments of the present invention will be described below with various technically preferred limitations, the scope of the present invention is not limited thereto.
[0031] FIG. 1A illustrates a garment hanger ( 2 ) according to principles of the present invention. The garment hanger ( 2 ) can be made of various materials known to those of ordinary skill in the art, such as Cotton, Wool, Bamboo, Polyester, Nylon, Denim, Suede, Leather, Velvet, Hemp, Vinyl, Satin, Linen, Heavy to medium weight elastic, Polypropylene, Rayon,
[0032] Neoprene, Recycled Felt, Moleskin, Corduroy, Twill, Tweed, Poplin, Acrylic, Modal, Velour, combinations thereof or the like. The garment hanger ( 2 ) includes a strap ( 4 ), an adjustment means, ( 6 ) a garment attachment means ( 8 ) and a hanger attachment means ( 10 ). The garment attachment means ( 8 ) are removably attached to a portion of the garment, for example at the bodice of a dress or at the seam of an armhole. The adjustment means ( 6 ) are configured to increase or decrease the length of the strap ( 4 ). The garment hanger ( 2 ) can be removably secured to a hanger ( 12 ) via a hanger attachment means ( 10 ) which can be slipped over the hook ( 14 ) at the top portion of a hanger. The garment hanger ( 2 ) does not have to be secured to a hanger via a hanger attachment means ( 10 ), it can be draped ( 16 ) or looped/wound ( 18 ) around the hook of the hanger as shown in FIGS. 1B and 1C .
[0033] In FIG. 1C , the strap ( 4 ) is adjusted in length by increasing or decreasing the amount of loops ( 18 ) draped or wound around the hook. For example, the strap can be wound, one, two, three or four or more times around the hook in order to shorten the length of the strap ( 4 ). If the strap ( 4 ) needs to be increased in length, one or more of the loops ( 18 ) can be unwound from the hook.
[0034] FIG. 2 depicts the garment hanger ( 2 ) according to an embodiment of the invention. The hanger attachment means forms a loop ( 20 ) that is secured to the straps ( 4 ). Each of the straps has an adjustment means ( 6 ) which adjusts the length of the strap in order to carry the entire weight of the garment and prevent any stretching, pulling, wrinkling or puckering of pull the garment fabric. In this embodiment each strap ( 4 ) is threaded through the adjustment means ( 6 ) which can be pulled up or down to adjust the length of the straps. The length of each strap ( 4 ) can vary. For example, one strap may be required to be slightly longer or shorter than the other strap in order to hang a garment that has an asymmetrical design, such as a one shoulder or one strap dress or blouse. Each strap adjustment means ( 6 ) individually adjusts the corresponding strap to the appropriate length. A garment attachment means ( 8 ) is secured at an end point of each strap ( 4 ).
[0035] FIG. 3 depicts an embodiment of the invention where the strap ( 4 ) is a single strap that is threaded through the adjustment means ( 6 ) with a garment attachment means ( 8 ) secured to the end of the strap ( 4 ). The garment attachment means ( 8 ) can be any type of clip or fastener such as an Alligator clip, Bulldog clip, Lingerie clip, Suspender clip, Hanger clip, spring clip, Binder clip, hook and eye, a clasp, button, snap, magnets or any other type securing means known in the art. Lingerie clips or buttons may be preferable for use in manufactured clothing, while an Alligator or Bulldog clip may be preferable for general consumer use. Magnets can be in the form of a magnetic clip, or as a pair of magnets in any shape. If a pair of magnets are used, each garment attachment means ( 8 ) consists of a pair of magnets such that when the magnets are placed so as to be attracted to each other, can removably attach a portion of the garment. The varying strength of magnets well known in the art can be used to attach to various types of fabrics from light weight silk materials to heavier wools and the like. Other types of magnetic attachment means known in the art can also be used. The interior portion ( 22 ) of the garment attachment means ( 8 ) can contain padding, grip or material to provide additional friction and grip when the clip is attached to a portion of the garment. The padding, grip or material can also serve as additional protection or cushioning for delicate fabrics such as silk.
[0036] FIG. 4 depicts an embodiment of the invention where the garment hanger ( 2 ) is removably attached to the lower bar ( 24 ) of the hanger. In this embodiment, the strap ( 4 ) can be used to hang trousers, pants, skirts or the like from the lower bar ( 24 ). The strap ( 4 ) can have an adjustment means ( 6 ) which can vary the length of the strap in order transfer the weight of the garment to the strap and prevent puckering, wrinkling or dimpling of the garment fabric. The garment hanger ( 4 ) can also be placed at any point along the lower bar ( 24 ) in order to adjust to the appropriate width for the garment.
[0037] The garment hanger can be removably attached to a portion of the hanger, for example at the hook or the hanger bar. In other embodiments of the invention, the garment hanger can be permanently affixed to a portion of the hanger.
[0038] FIG. 5 depicts an embodiment of the invention showing the garment attachment means removably attached to the inseam of a blouse.
[0039] While various embodiments of the present invention have been described, it will be apparent to those of skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. Accordingly, the present invention is not to be restricted except in light of the attached claims and their equivalents.
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A garment hanger including a hanger attachment means configured to attach the garment hanger to a hanging device. At least one strap extending from the hanger attachment means and a garment attachment means secured to an end portion of each strap. The garment attachment means configured to be removably attached to a garment.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an integrated, self-sustaining, sensor-based energy optimization system. More particularly, the present invention relates to an energy optimization system based on detecting environmental and usage conditions at specific locations of a building.
[0003] 2. Description of the Related Art
[0004] Heating, ventilation, and air condition (HVAC) systems in commercial buildings typically have zone-level resolutions. A zone is often a relatively large section of a building containing many rooms. For example, control of air conditioning may be provided at a section level—i.e., the air conditioning system provides the user the ability to monitor and control air flows and temperature to a section of a building at a time, and not for a smaller area, such as a single room. In fact, in most residential units with centralized air conditioning, the entire unit is maintained as a single zone. Even though such an HVAC system is easy to install and maintain, the system is considerably inefficient because many portions of a section of a building may be unoccupied at any given time. However, because of the zone-level control resolution, these unoccupied areas are heated or cooled.
[0005] Smoke detectors are required in all commercial and residential buildings. Existing smoke detectors are either battery-operated or require back-up batteries, which have to be maintained. The maintenance task is carried out sufficiently often that the cost of the maintenance is not insignificant.
SUMMARY
[0006] According to one embodiment of the present invention, an air duct cover provides a sensor platform that includes a rich set of sensors. In addition, the air duct cover may include an energy harvesting capability, thereby increasing efficiency in an HVAC system and providing power to support the sensors on the sensor platform. The air duct cover may also integrate a smoke detection device. As power is provided by the air duct cover, maintenance requirements for the smoke detection device are substantially eliminated.
[0007] In one embodiment of the present invention, the air duct cover may serve as an air quality control device, with dust, smoke, and carbon monoxide (CO) sensors that allow it to detect the amount of dust and particulates flowing through and to serve as a smoke detector.
[0008] In one embodiment, the air duct cover includes fans that act as windmills (i.e., fans that drive an electricity generator) to harvest power from the pressurized air flow in the air duct. The harvested power charges an on-board battery which provides power to the sensors, and for data processing and wireless data transmission.
[0009] According to one embodiment, the air duct cover increases local control capability, such as providing room-specific temperature control, thereby avoiding the drawbacks of building section-level control in the prior art. The sensor platform on the air duct cover detects current occupancy and current temperature in its immediate vicinity (e.g., a room in a commercial or residential building). In addition, the louvers or shutters on the air duct cover may be mechanized by a motor, so as to allow them to open or close a vent to different extents automatically, based on the detected temperature and occupancy. In one embodiment, the air duct cover is a part of a control system with an intelligent algorithm that can predict likely times of occupancy and accordingly prepare the room to the comfort of the occupants when they enter the room.
[0010] A significant advantage of the present invention is its “backward compatibility” with existing centralized facility management system, but enhances the control resolution from “section level” to “room level,” thus significantly improves over existing zone-based systems.
[0011] The present invention is better understood upon consideration of the present invention in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows system 100 , which includes controller 101 and smart air duct cover 102 , according to one embodiment of the present invention.
[0013] FIG. 2 is a block diagram 200 showing one set of control operations in local microprocessor 107 of air duct cover 102 and in controller 101 , in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The inventor of the present invention observes that the living, dining and family rooms in a residence are unlikely to be occupied between certain hours at night, while bedrooms are likely occupied during those hours. However, in existing prior art systems, temperature is often set for the whole residence, so that even unoccupied areas are heated or cooled. Worse still, the thermostat in many residences is provided in a controller which is located in an area that is likely to be unoccupied during those times (e.g., the living room), and as the unoccupied areas usually are significantly different in floor area than the occupied areas (e.g., the bedrooms), the occupied rooms are over-heated or over-cooled. Because the whole residence is treated as a single zone, and because the sensors are often inappropriately placed, such an existing prior art system is not only inefficient, but also incapable of maintaining a comfortable temperature across the house, as to create discomfort in the occupants. Recently, Nest Corporation (https://nest.com/) provide a controller that learns user behavior. However, even such a controller provides only whole-house heating or cooling control, and does not provide room-level resolution for heating or cooling control.
[0015] Accordingly, the present invention provides a controller that tracks the temperature and occupancy of each room and closes the vent automatically when the room reaches the preset desired temperature. The controller also detects an unoccupied room using a passive infra-red (PIR) sensor and automatically controls the room to, for example, +/−5° C. of the preset temperature. Sensors, which are provided in substantially all rooms, communicate to the controller to allow shutting off centralized A/C or heating for a given zone if all the occupied rooms within the zone attain preset temperature thresholds.
[0016] According to one embodiment of the present invention, an air duct cover includes sensors that allow a controller or a facility management system to implement an energy conservation program. In one embodiment, the air duct cover provides temperature and occupancy sensors, so as to achieve room-level temperature control in a centralized HVAC system and to thereby conserve energy use. The air duct cover may also include mechanized, motor-driven louvers for controlling air flow into the room, which may be used as one mechanism for temperature control. With an occupancy detector, the air duct cover provides also room-level lighting control. The air duct cover of the present invention may be used in both commercial and residential buildings.
[0017] FIG. 1 shows system 100 , which includes controller 101 and smart air duct cover 102 , according to one embodiment of the present invention. In one embodiment system 100 may be a stand-alone system used in a single residence or an office suite. Alternatively, system 100 may be integrated into a facility management system, such as that described in co-pending patent application (“Smart Facility Management Application”) by the same inventor, entitled “Smart Facility Management Platform,” filed on the same day as the present application. The disclosure of the Smart Facility Management Application is hereby incorporated herein by reference in its entirety.
[0018] As shown in FIG. 1 , smart air duct cover 102 communicates with controller 101 over wireless communication using a suitable communication protocol, such as MQTT. Control of the local operations of smart air duct cover 102 is provided by microcontroller or processor 107 , which is powered by a rechargeable battery. Smart air duct cover 102 provides a sensor platform to support many different type of sensors, e.g., temperature and humidity sensors 103 , smoke and gas sensors (e.g., a carbon monoxide (CO) sensor) 104 , occupancy sensor 105 (e.g., a passive IR sensor), and dust sensor 106 . Smart air duct cover 102 also provides mechanized louvers driven by motor 109 to open and close the vent under local control or control by controller 101 . As the air flow in the air duct is usually slightly pressurized by a centralized pumping mechanism, smart air duct cover 102 also provides one or more fans 108 , which harvest energy from the air flow inside the air duct. The harvested energy charges the rechargeable battery to power sensors 103 - 106 , motor 109 and microprocessor 107 . As described below, as smart air duct cover 101 senses the local environment and provides local air conditioning or heating actuators, controller 101 may be located in any suitable location in the building, or even remotely.
[0019] Dust sensor 106 detects the amount of dust passing through smart air duct cover 102 , thereby providing an estimate indicative of the air quality in the building. For example, one implementation of dust sensor 106 detects PM2.5 and PM10 particulate matters, so that it is suitable to serve in a warning system for alerting allergy or asthma patients. An increase in dust detected in dust sensor 106 can also indicate an air filter that is due for maintenance. The local controller (e.g., microprocessor 107 ) or controller 101 may provide an alert to the facility maintenance company or to the home-owner to indicate the need for an air filter replacement. One example of a suitable dust sensor for implementing dust sensor 106 is the GP2Y1010AU sensor available from Sharp Corporation, Japan.
[0020] As mentioned above, temperature and humidity sensor 103 and PIR sensor 105 provide readings that may be used for energy optimization in commercial and residential buildings. Suitable temperature and humidity sensors for implementing temperature and humidity sensor 103 include, for example, the AM2303 sensor form Aosong (Guangzhou) Electronics Co., Ltd., Guanzhou, China. Suitable PIR sensors for implementing occupancy sensor 105 include, for example, a wide angle PIR sensor (28032) from Parallax, Inc., Rocklin, Calif.
[0021] Smoke and gas sensors 105 may be provided by a combined gas sensor that can detect liquid petroleum gas (LPG), CO and methane, such as a gas sensor board (27983) available also from Parallax, Inc., Rocklin, Calif. Dust sensor 106 may also serve as a smoke detector by detecting an increase in particulate matters typically found in smoke.
[0022] The inventor discovered that a prototype implementation of air duct cover 102 , which is installed in an air duct and which uses modified computer cooling fans, generated a voltage of 2.5 volts and delivered a 20 mA current, while the air conditioning or the heater is operating. A standard size air duct cover may accommodate two or more 3-inch (diameter) fans in the smallest ducts. The inventor surmises that a series connection of the output voltages of these fans would provide 5 volts of output voltage and a current of 20 mA, or 100 mW of power. As common vents may accommodate up to four such fans, which may be connected as two parallel series-connected pairs, such a configuration would provide 5-volt output voltage and a 40 mA current capability, for a 200 mW power harvested. Such a power output is sufficient to fully charge a 1200-mWh NiCd AA battery in six hours. Larger vents in commercial buildings and airports will potentially allow harvesting more power.
[0023] FIG. 2 is a block diagram 200 showing one set of control operations in local microprocessor 107 of air duct cover 102 and in controller 101 , in accordance with one embodiment of the present invention. As shown in FIG. 2 , steps 201 - 205 may be carried out in microprocessor 107 . According to readings from occupancy sensor 105 , microprocessor 107 determines at step 202 whether or not the room at which air duct cover 102 is installed is occupied. If not, the temperature threshold for the room is adjusted suitably by up to +/− five (5) degrees in the direction of reduced energy usage. If the room is determined to be occupied, no adjustment to the temperature threshold is made. When temperature and humidity sensor 103 indicates at step 204 that the temperature threshold is reached, microprocessor 107 actuates motor 109 at step 205 to close the vent, such as to shut off further heating or cooling of the room due to the air flow through air duct cover 102 .
[0024] At steps 206 - 209 , which may be carried out in controller 101 simultaneously with steps 201 - 205 in microprocessor 107 , controller 101 determines whether or not heating or air conditioning operations in the zone in which air duct cover 102 is part of should be shut off. At step 206 , controller 101 computes a suitable metric. For example, as shown in step 206 , a metric zoneOFFb is calculated. In this embodiment, zoneOFF is the difference between the total of all current temperatures in all rooms in the zones (after temperature threshold adjustments of step 203 , everywhere) and the total of all differences in all rooms in the zone between their respective temperature thresholds and their respective temperatures. Controller 101 then determines at step 207 whether or not the calculated zoneOFF metric is greater than zero. If so, the air conditioning or heating for the zone is switched off at step 209 . Otherwise, at step 208 , the air conditioning or heating is switched on (or left on).
[0025] The above detailed description is provided to illustrate the specific embodiments of the present invention and is not intended to be limiting. Numerous variations and modifications of the present invention are possible. The present invention is set forth by the accompanying claims.
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An air duct cover provides a sensor platform that contains a rich set of sensors. In addition, the air duct cover may include an energy harvesting capability, thereby increasing efficiency in an HVAC system and sustaining the sensors on the sensor platform. The air duct cover may also integrate a smoke detection device. As power is provided by the air duct cover, maintenance requirements for the smoke detection device are substantially eliminated. The air duct cover may also serve as an air quality control device, with dust, smoke, and carbon monoxide (CO) sensors that allow it to detect the amount of dust flowing through and to serve as a smoke detector.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of and claims the benefit of U.S. application Ser. No. 09/330,643, filed Jun. 11, 1999, now U.S. Pat. No. 6,295,782, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
This invention relates generally to concrete support structures and in particular, to stay-in-place forms (i.e., composite shells) for forming concrete support structures.
2. Description of the Related Art
Concrete columns are commonly used as upright supports for superstructures. Bridge supports, freeway overpass supports, building structural supports and parking structure supports are just a few of the many uses for concrete columns. Other concrete support members such as beams, walls, slabs, girders, struts, braces, etc. are employed to impart strength and stability to a large variety of structures. These concrete support structures exist in a wide variety of shapes. Typically, these concrete support structures have circular, square or rectangular cross-sections. However, numerous other cross-sectional shapes have been used including regular polygonal shapes and irregular cross-sections. The size of the concrete support structures also varies greatly depending upon the intended use. Concrete columns with diameters on the order of 2 to 20 feet and lengths of well over 50 feet are commonly used as bridge or overpass supports.
Conventionally, some concrete columns have been constructed by filling a cylindrical form having a network of rebar mounted therein with a concrete composition, allowing the composition to cure, and removing the form.
Also, in the past, elongate paper fiber tubes have been used to form concrete columns. The tubes are made by spirally winding several layers of strong fiber paper. The spirally wound paper is laminated along its seams with a special adhesive. The outside of the tube can be coated with hot wax for protection against adverse weather conditions. Concrete is poured into the tube and allowed to harden so as to form a column. After hardening, the tube is stripped away from the concrete column and scrapped.
Rather than paper tubes, reusable steel or wood forms can also be used. Concrete is poured into these forms and allowed to harden. After hardening, the form is removed from the concrete structure and can be used again.
All of these conventional concrete support structures are subject to deterioration of their long-term durability and integrity. Permeability of the exposed concrete by water can cause the concrete to deteriorate over time. When moisture is trapped in the concrete and freezes, cracks typically form in the concrete structural members. In addition, some of these conventional concrete support structures are located in earthquake prone areas but do not have adequate metal reinforcement or structural design to withstand high degrees of asymmetric loading.
More recently, composites have been used to repair and retrofit columns, beams, walls, tanks, chimneys and other structural elements. However, a need exists to use composites in a prefabricated form to strengthen new constructions, protect internal reinforcing steel, provide fiber reinforcement outside of a concrete layer, to provide better appearance features, and to solve the above problems.
SUMMARY OF INVENTION
A stay-in-place composite form in accordance with the present invention provides increased strength and durability to concrete support structures. The stay-in-place form can be used in prefabricated form or can be fabricated at the construction site, to strengthen new constructions.
The stay-in-place form includes a composite shell made up of fibrous fabric layers impregnated with a resin matrix. The composite shell has an inner wall surface defining an enclosure into which concrete may be poured and allowed to harden to form a concrete core. As the concrete is poured into the enclosure, the fibers in the fabric material elongate due to the weight of the concrete. Then, as the concrete dries, the fibers partially shrink back to compensate for shrinkage of the concrete.
In one embodiment of the present invention, the percentage of elongation of the resin matrix is greater than the percentage of elongation of the fibers. Typically, the percentage of elongation of the fibers and resin matrix prevents a gap from forming between the concrete core and the composite shell when the concrete shrinks.
A liner made of a water-impermeable material is affixed to the inner wall surface of the composite shell to protect the composite shell from alkalinity or other chemical products in the concrete core. This liner is in direct contact with an outer surface of the concrete core and either completely or partially surrounds the concrete core.
In one embodiment of the present invention, the stay-in-place form is manufactured using a rigid collapsible tubular member. The exterior surface of the tubular member is wrapped with the liner and then the fabric layers impregnated with resin are applied to the liner. Once the fabric layers cure, the tube is collapsed and removed from beneath the liner. What remains is a hollow stay-in-place composite form.
In yet another embodiment of the present invention, the stay-in-place form is manufactured using a mandrel. In such embodiment, the liner is applied to an exterior surface of the mandrel and then the fabric layers impregnated with resin are applied to the liner. Once the fabric layers cure, the liner and harden fabric layers are separated from the mandrel. Again, what remains is a hollow stay-in-place composite form.
In still another embodiment of the present invention, the collapsible tube or the mandrel is rotated about an axis while the fabric layer and the resin matrix is applied to the liner. Such rotation maintains the form of the tube and composite shell, and ensures that the resin is uniformly distributed. The rotation of the tube or mandrel continues until the resin impregnated fabric layers are fully cured.
These and other features and advantages of the present invention will become apparent by reference to the following detailed description and accompanying drawings which set forth several illustrative embodiments in which the principles of the invention are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective longitudinal view illustrating the stay-in-place form in accordance with the present invention;
FIG. 2 is a perspective longitudinal view illustrating a fully reinforced support structure using the stay-in-place form of the present invention;
FIG. 3 is a detailed sectional view of an exemplary reinforced composite material in accordance with the present invention;
FIG. 4 is a detailed sectional view of an alternative exemplary reinforced composite material in accordance with the present invention;
FIG. 5 depicts a weave pattern which is the same as the weave pattern shown in FIG. 4 except that the yarns are stitch bonded together;
FIG. 6 is a detailed partial section of the face of an external surface of composite shell covered with multiple fabric layers;
FIG. 7 is a perspective view of a protective liner;
FIG. 8 is a cross-sectional inner view of an alternate embodiment of the stay-in-place-form in accordance with the present invention;
FIG. 9 is a cross-sectional inner view of a second alternate embodiment of the stay-in-place-form in accordance with the present invention;
FIG. 10 is a cross-sectional inner view of a third alternate embodiment of the stay-in-place-form in accordance with the present invention;
FIGS. 11A and 11B are a perspective longitudinal view and a cross-sectional inner view, respectively, illustrating a fourth alternate embodiment of the stay-in-place form in accordance with the present invention;
FIGS. 12A-12J are perspective views illustrating the steps of manufacturing a precast stay-in-place form constructed in accordance with the present invention;
FIG. 13 is a demonstrative representation depicting the impregnation of a fabric layer prior to application to the tubular form in accordance with the present invention; and
FIG. 14 is a perspective view illustrating application of a liner to a mandrel in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Stay-In-Place Form
Referring to FIG. 1 , a perspective view of a stay-in-place form 100 for use as a support structure, such as a column or beam, is shown. Although stay-in-place form 100 is illustrated as an elongate tubular structure in FIG. 1 , it will be appreciated that stay-in-place form 100 may be any desired shape, such as rectangular or octagonal. Stay-in-place form 100 includes an exterior composite shell 101 and a liner 103 secured to the inner surface of composite shell 101 . In this way, stay-in-place form 100 provides a hollow closed form into which a slurry of concrete or cement material 105 is placed. Slurry 105 fills stay-in-place form 100 and hardens to form a concrete core 205 of a fully reinforced support structure 200 , illustrated in FIG. 2 .
Composite shell 101 is formed of a resin-impregnated composite reinforcement layer 107 , as illustrated in FIG. 1 . Composite reinforcement layer 300 is in direct contact with the outer surface of liner 103 and may be made of a single layer of fabric, although typically reinforcement layer 107 is made up of multiple layers of fabric. In the exemplary embodiment illustrated in FIG. 1 , composite reinforcement layer 107 is made of seven fabric layers 109 - 115 . Each of fabric layers 109 - 115 has first and second parallel selvedges. For example, the first and second selvedges for fabric layer 109 are shown at 109 A and 109 B, respectively. The first and second selvedges for fabric layer 110 are shown at 110 A and 110 B, respectively. In an exemplary embodiment, the width of the fabric between the selvedges may be from twelve to one hundred inches wide. Fabric layers 109 - 115 may include a single fabric layer or they may be laminates made up of two or more layers of fabric.
An exemplary fabric is shown in FIG. 3 . The fabric is preferably a plain woven fabric having warp yarns 301 and fill yarns 303 . The warp yarns 301 and fill yarns 303 may be made from the same fibers or they may be different. The fabric may be comprised of, for example, glass, carbon, polyaramid, graphite, polyaramid, boron, Kevlar, silica, quartz, ceramic, polyethylene, aramid, or other fibers. A wide variety of types of weaves and fiber orientations may be used in the fabric. Where a single layer of fabric is used, it will often be desirable to use weft cloth containing both horizontal and vertical fibers. For example, composite reinforcement layer 107 may include vertical, horizontal and off-axis fibers which can minimize or eliminate the need for steel reinforcement in support structure 200 . Where multiple layers of fabric are used, it will often be desirable to alternate the orientation of the fibers to provide maximum strength along multiple axes. Typically, fibers oriented along the longitudinal axis provide stiffness of composite shell 101 whereas fibers oriented along the horizontal axis provide strength in the hoop direction or along the circumference of composite shell 101 . Such strengthening in the hoop direction prevents buckling of the longitudinal fibers and restricts the movement of concrete core 205 of support structure 200 in FIG. 2 .
Referring again to FIG. 3 , the warp yarns 301 are preferably made from glass. The fill yams 303 are preferably a combination of glass fibers 305 and polyaramid fibers 307 . The diameters of the glass and polyaramid fibers preferably range from about 3 microns to about 30 microns. It is preferred that each glass yarn include between about 200 to 8,000 fibers. The fabric is preferably a plain woven fabric, but may also be a 2 to 8 harness satin weave. The number of warp yarns per inch is preferably between about 5 to 20. The preferred number of fill yarns per inch is preferably between about 0.5 and 5.0. The warp yarns extend substantially parallel to the selvedge 309 with the fill yarns extending substantially perpendicular to the selvedge 309 and substantially parallel to the axis of the stay-in-place form 100 . This particular fabric weave configuration provides reinforcement in both longitudinal and axial directions. This configuration is believed to be effective in reinforcing the stay-in-place form 100 against asymmetric loads experienced by the support structure 200 of FIG. 2 , during an earthquake.
A preferred alternate fabric pattern is shown in FIG. 4 . In this fabric pattern, plus bias angle yarns 401 extend at an angle of between about 20 to 70 degrees relative to the selvedge 403 of the fabric. The preferred angle is 45 degrees relative to the selvedge 403 . The plus bias angle yarns 401 are preferably made from yarn material the same as described in connection with the fabric shown in FIG. 3 . Minus bias angle yarns 405 extend at an angle of between about −20 to −70 degrees relative to the selvedge 403 . The minus bias angle yarns 405 are preferably substantially perpendicular to the plus bias angle yarns 401 . The bias yarns 401 and 403 are preferably composed of the same yarn material. The number of yarns per inch for both the plus and minus bias angle is preferably between about 5 and 30 with about 10 yarns per inch being particularly preferred.
It is preferred that the fabric weave patterns be held securely in place relative to each other. This is preferably accomplished by stitch bonding the yarns together as shown in FIG. 5 . An alternate method of holding the yarns in place is by the use of adhesive or leno weaving processes, both of which are well known to those skilled in the art. In FIG. 5 , exemplary yarns used to provide the stitch bonding are shown in phantom at 501 . The process by which the yarns are stitch bonded together is conventional and will not be described in detail. The smaller yarns used to provide the stitch bonding may be made from the same materials as the principal yarns or from any other suitable material commonly used to stitch bond fabric yarns together. The fabric shown in FIG. 3 may be stitch bonded. Also, if desired, unidirectional fabric which is stitch bonded may be used in accordance with the present invention.
In FIG. 6 , a portion of a composite reinforcement layer surrounding a concrete column is shown generally at 601 . The composite reinforcement layer 601 includes an interior fabric layer 603 which is the same as the fabric layer shown in FIG. 5 . In addition, an exterior fabric layer 605 is provided which is the same as the fabric layer shown in FIG. 3 . This dual fabric layer composite reinforcement 601 provides added structural strength when desired.
In another embodiment, the composite reinforcement layer 107 of FIG. 1 may have an inner layer of longitudinal axial fibers and an outer layer of circumferential hoop fibers. For example, the multilayer reinforcement material 107 may include a first reinforcement layer including two fabric layers of glass or carbon fibers in a longitudinal direction and a second high strength composite reinforcement layer including three layers of glass or carbon fibers in the hoop direction. In another embodiment, the high strength composite reinforcement layers have spiral layers. These fabric layers not only provide the structural integrity of the composite shell 101 , but also provide significant reinforcement against externally applied forces.
All of the fabric layers 109 - 115 must be impregnated with a resin in order to function properly in accordance with the present invention. Suitable resins for use in accordance with the present invention include polyester, epoxy, polyamide, bismaleimide, vinylester, urethanes and polyurea. Other impregnating resins may be utilized provided that they have the same degree of strength and toughness provided by the previously listed resins. Epoxy based resin systems are preferred. It is also preferred that the fiber and resin matrix are waterproof.
Referring again to FIG. 1 , when slurry 105 is poured into stay-in-place form, the weight of slurry 105 elongates or stretches the fibers in reinforcement layer 107 causing these fibers to be stressed. Thus, liner 103 , reinforcement layer 107 , and the resin impregnated into reinforcement layer 107 are selected to permit elongation of the fibers when slurry 105 is poured into stay-in-place form 100 . In particular, the resin must be flexible enough to allow for such post-tensioning of the fibers. Having been elongated during the pouring of concrete 105 , the fibers are stressed, which strengthens the fibers and allows for reduced thickness of stay-in-place form 100 . These fibers will then partially shrink back or relax to compensate for concrete shrinkage as concrete slurry 105 dries. As a result, the final percent of elongation of the resin should be greater than percent of elongation of the fibers so that the reinforcement layer 107 does not crack from stress caused by the weight of the concrete. For example, in one embodiment the glass fibers have 2% elongation and the epoxy has 3-4% elongation. The percent of elongation of the resin should be balanced with the percent of elongation of the fibers so that there is some stress on the fibers from the weight of the concrete, but not so much so that there is cracking. With such a balance, the fibers are able to shrink back to compensate for concrete shrinkage once slurry 105 hardens without leaving any gaps between concrete core 205 and liner 103 of support structure 200 , illustrated in FIG. 2 .
Liner 103 is received to the inner wall surface of hollow composite shell 101 . A perspective view of liner 103 is illustrated in FIG. 7 . As shown, liner 103 is flexible so that it will conform to the inner wall surface of composite shell 101 regardless of the shape of the shell 101 . Referring again to FIG. 2 , liner 103 is formed of a water-resistant and impermeable material to protect concrete core 205 from moisture and corrosive materials, as well as to protect the composite shell 101 from the alkalinity in concrete core 205 . Liner 103 can be fabricated from plastic or rubber materials such as polystyrene, vinyl, polyethylene, chlorosulfonated polyethylene, neoprene, EPDM (ethylene-propylene-diene terpolymer), rubber, or other resistive materials.
The thickness of liner 103 should be sufficient to prevent damage when slurry 105 is poured into stay-in-place form 100 . For example, if liner 103 is too thin, the weight of the slurry 105 may tear liner 103 as it is poured into stay-in-place form 100 . In an exemplary embodiment, the thickness of liner 103 is between {fraction (1/64)} and ¼ of an inch.
Stay-in-place form 100 is filled with slurry 105 which hardens within stay-in-place form 100 to form a concrete core 205 of structural member 200 shown in FIG. 2 , such as a column or beam. Stay-in-place form 100 is not removed from concrete core 205 , but rather remains in place to increase the shear strength and longevity of support structure 200 over that of conventional support structures.
One way to increase the structural integrity of concrete structural member 200 , illustrated in FIG. 2 , is to attach reinforcing bars to the inner surface of stay-in-place form 100 . FIG. 8 illustrates an alternate embodiment of the present invention, in which a cross-section of stay-in-place form 800 is shown with reinforcing bars 801 , 809 . Stay-in-place form 800 has the same outer composite shell 101 and liner 103 , but also has reinforcing bars 801 , 809 such as steel or composite reinforcing bars, secured to the inner surface of stay-in-place form 800 to provide further reinforcement.
As shown in FIG. 8 , anchors or stiffener tabs 803 are received by grooves 805 and are distributed about the inner wall surface of stay-in-place form 800 . These anchors 803 extend horizontally from the inner wall surface of composite shell 101 , through liner 103 , and terminate within the enclosure of stay-in-place form 800 . In one embodiment, anchors 803 terminate in clamps 807 that are used to hold vertically extending reinforcing bars 801 . With such configuration, reinforcing bars 801 can be pre-installed at the factory or snapped into clamps 807 at the construction site. In an alternate embodiment, vertically extending reinforcement bars 809 are integrally formed with anchor 805 .
As shown in FIG. 8 , vertically extending reinforcing bars 801 , 809 may extend a partial length of composite shell 101 . Alternatively, referring to the cross-section view of stay-in-place form 900 illustrated in FIG. 9 , vertically extending bars 901 , 903 may extend along a substantial length of composite shell 101 . Also, referring to the cross-section view of stay-in-place form 10 illustrated in FIG. 10 , reinforcing bars 1001 may extend across the enclosure within stay-in-place form. It also will be appreciated that although reinforcing bars are illustrated as vertically and horizontally reinforcement bars in FIGS. 8-10 , reinforcement bars can be situated in other positions, such as diagonally or circumferentially.
Stay-in-place forms 100 and 800 , illustrated in FIGS. 1 and 8 respectively, have been disclosed as complete tubular or columnar enclosures. However, stay-in-place forms may also be partial enclosures. FIG. 11A illustrates a perspective view of a stay-in-place form 1100 that has a horizontally extending hollow rectangular channel shape. Stay-in-place form 800 includes a horizontally extending hollow channel composite shell 1101 and a liner 1103 secured to the inner surface of composite shell 1101 . In this way, stay-in-place form 1100 provides a channel form into which a slurry of concrete or cement material 105 is placed, which upon hardening, creates a fully reinforced support structure. With this configuration, stay-in-place form 1100 only partially surrounds a concrete core and may be used, for example, to construct beams. Since the upper portion of the channel shaped stay-in-place form 1100 is open, the beam can easily connect to another support structure (not shown).
Referring now to FIG. 11B , a cross-sectional view of stay-in-place form 1100 along line A—A is illustrated. As shown in FIG. 11B , stay-in-place form 1100 includes reinforcement bars 1105 that extend across the width of the channel-shaped composite shell 1101 , to provide additional reinforcement. In addition, stay-in-place form 1100 also includes built-in connectors 1107 , which may be made of various materials such as fiber composite, steel, etc., formed into composite shell 1101 to connect the completed beam with another support structure, such as a column, foundation or other beam. Stay-in-place form 1100 may also include anchors at the edges or other areas of composite shell 1101 to further reinforce the completed support structure. In all of these embodiments, reinforcement bars 1105 and anchors 1107 are designed to withstand the stresses of concrete slurry 105 that is to be poured into the enclosure.
Stay-in-place forms 100 , 800 , 900 , 1000 , 1100 can be used as a cast-in-place structural member where the construction of the stay-in-place form is done at or near a construction site. Alternatively, stay-in-place forms 100 , 800 , 900 , 1000 , 1100 can be used as precast members, where construction of the stay-in-place form is done in a factory and is then shipped to the construction site.
Method of Manufacturing Stay-In-Place Form
FIGS. 12A-12J illustrate the sequence of steps employed to fabricate stay-in-place form 100 using a reusable form 1201 such as that illustrated in FIG. 12 A. Care should be taken in selecting the shape of reusable form 1201 , as the shape of reusable form 1201 will determine the shape of resulting stay-in-place form 100 . In the embodiment illustrated in FIG. 12A , reusable form 1201 is a tubular form. In this FIG. 12A a perspective view of tubular form 1201 is shown. In an exemplary embodiment, tubular form 1201 is fabricated from a fiber paper which is formed by spirally winding and laminating the fiber paper together with a special adhesive along seams 1203 . Although, tubular form 1201 is fabricated from fiber paper, it will be appreciated that tubular form 1201 can be fabricated from other types of material so long as tubular form 1201 is rigid and collapsible.
A small slit or groove 1205 is cut into the inner surface of tubular form 1201 , as illustrated in FIG. 12 B. Referring now to FIGS. 12C and 12D , a cross-sectional view of tubular form 1201 is shown along line B—B. As shown in FIG. 12C , a tool 1207 such as a steel blade, is able to grasp the small slit 1205 . This enables a portion of tubular form 1201 to be pulled inward as illustrated in FIG. 12D , thereby reducing the diameter of tubular form 1201 . The importance of this collapsing of tubular form 1201 will be explained later in the specification.
FIG. 12E illustrates a perspective view of tubular form 1201 lying on its side. Water bags 1208 , illustrated with phantom lines, may be placed inside tubular form 1201 to maintain the shape of tubular form 1201 during the fabrication process of stay-in-place form 100 . It will be appreciated that although water bags 1208 are illustrated to maintain the shape of tubular form 1201 , it will be appreciated that other devices, such as mechanically expandable wood or steel, placed at the ends of tubular form 1201 , can be used for the same purpose.
Once water bags 1208 have been inserted into tubular form 1201 , liner 103 is applied to tubular form 1201 . FIG. 12F , illustrates a top plan view of liner 103 being applied to the outer surface of tubular form 1201 . Liner 103 is wrapped tightly around tubular form 1201 such that the lateral edges of liner 103 overlap and are held together with an adhesive material such as tape or glue. In some instances it is desirable to prevent at least one end of liner 103 from slipping relative to tubular form 1201 . In such instances, liner 103 may be adhered to tubular form 1201 , such as by applying tape, glue or some other adhesive material to liner 103 , tubular form 1201 or both.
Once liner 103 has been wrapped around tubular form 1201 , a composite reinforcement layer 107 , as illustrated in FIG. 1 , is applied to the exposed outer surface of liner 103 , as illustrated in FIG. 12 G. As explained above in reference to reinforcement layer 107 , such reinforcement layer may be applied in a variety of different patterns and may be made up of multiple layers of fabric.
In the exemplary embodiment illustrated in FIG. 1 , composite reinforcement layer 107 is made up of fabric layers 109 - 115 . All of the fabric layers 109 - 115 must be impregnated with a resin in order to function properly in accordance with the present invention. Preferably, the resin is impregnated into the fabric prior to application to the exterior surface of liner 103 . However, if desired, the resin may be impregnated into the fabric after the fabric is wrapped around the liner.
As illustrated in FIGS. 12G-12H , fabric layers 109 - 115 are resin impregnated prior to application to liner 103 so that the final fabric layers 109 - 115 are provided within a resin matrix. For example, referring to FIG. 13 , a fabric 1301 is shown being unwound from roll 1303 and dipped in resin 1305 for impregnation prior to application to liner 103 . Once a sufficient length of fabric 1301 has been impregnated with resin 1305 , the impregnated fabric layer is cut from roll 1303 and is applied to the exterior surface of liner 103 , as shown in FIGS. 12G-12H . The length of impregnated fabric is chosen to provide either one wrapping or multiple wrappings of liner 103 . Once in place, the resin impregnated fabric layer is allowed to cure to form the composite reinforcement layer 107 .
In an alternate embodiment, fabric layers 109 - 115 are impregnated with resin after being wrapped around liner 103 . In either embodiment, it is preferable that tubular form 1201 be rotated around an axis B in a direction indicated by arrow A, as shown in FIG. 12G , while the fabric layers are wrapped around liner 103 . Such rotation maintains the form of tubular form 1201 and ensures that the resin is uniformly distributed. Tubular form 1201 may be suspended or rotated on a platform while this rotation takes place. The rotation of tubular form 1201 continues until the resin impregnated fabric layers are fully cured.
Curing of the resins is carried out in accordance with well known procedures which will vary depending upon the particular resin matrix used. The various catalysts, curing agents and additives which are typically employed with such resin systems may be used. The amount of resin which is impregnated into the fabric is preferably sufficient to saturate the fabric.
Once the fabric layers are fully cured, tubular form 1201 is pulled out from liner 103 . One technique for removing tubular form 1201 is to use a release tool 1207 , such as a steel blade, as illustrated in FIGS. 12C-12D . Release tool 1207 is inserted into slit 1205 as illustrated in FIG. 12 C. Pulling on release tool 1207 , causes a portion of tubular form 1201 to be pulled inward and away from liner 103 , thereby reducing the diameter of the form 1201 , as shown in FIGS. 12 D. FIGS. 12I-12J further illustrate the collapsing of tubular form 1201 . FIG. 12I illustrates a cross-sectional view along line B of liner 103 and composite reinforcement layer 107 wrapped around tubular form 1201 as shown in FIG. 12 G. FIG. 12J illustrates a top plan view of tubular form 1201 being collapsed inward and away from liner 103 . Using this technique, tubular form 1201 can be collapsed and pulled out from beneath liner 103 . Once tubular form 1201 is pulled out, the resulting structure is stay-in-place form 100 , illustrated in FIG. 1 .
In an alternate embodiment, stay-in-place form 100 is formed using a mandrel, as illustrated in FIG. 14 A. In such an embodiment, mandrel 1401 serves as a core around which liner 103 is wrapped, as illustrated in FIG. 14 A. Composite reinforcement layer 107 impregnated with the resin is then continuously wrapped around liner 103 until a desired thickness is obtained, as illustrated in FIGS. 12G and 12H . Once the fibers are cured, liner 103 and the hardened shell formed from composite reinforcement layer 107 are slipped off mandrel 1401 . In either embodiment, the resulting structure is stay-in-place form 100 .
Various other modifications and alterations in the structure and method of operation of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments.
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A stay-in-place method of manufacturing a composite form that is used to provide a strong and durable concrete structure. The form includes a composite shell having an inner wall surface defining an enclosure into which concrete may be poured and allowed to harden. The composite shell may be made of one or several layers of fabric having a resin matrix impregnated therein. The concrete hardens to form a concrete core within the enclosure and a liner is affixed to the inner wall surface of the composite shell to protect the composite shell from alkalinity in the concrete core. The liner includes at least one sheet of a water-impermeable material to protect the concrete core from water and other corrosive elements. The fabric layers are selected such that the fibers elongate as the concrete is poured into the enclosure due to a weight of the concrete and partially shrink back to compensate for shrinkage of the concrete as the concrete dries to form the concrete core. Such stay-in-place composite form can be used in prefabricated form to strengthen new constructions.
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RELATED APPLICATIONS
This application is a continuation-in-part of my co-pending application Ser. No. 09/643,306 filed Aug. 21, 2000 which is hereby incorporated by reference herein as if fully set forth in its entirety.
FIELD OF THE INVENTION
This invention relates broadly to the boring of a hole through the wall of a tube from the inside of the tube outwardly at an angle to a longitudinal axis of the tube. More specifically, this invention relates to apparatus for drilling through an oil or gas well casing at an angle to the longitudinal axis of the casing and into the earth strata surrounding the well casing. More particularly, this invention relates to an improved such drilling apparatus and to a means of transporting, deploying and retrieving the drilling apparatus.
BACKGROUND OF THE INVENTION
Oil and gas wells are drilled vertically down into the earth strata with the use of rotary drilling equipment. A tube known as a casing is placed down into the well after it is drilled. The casing is usually of made of mild steel and is in the neighborhood of 4.5 inches to 8 inches in external diameter (4 inches in internal diameter and up) and defines the cross-sectional area of the well for transportation of the oil and gas upwardly to the earth surface. However, these vertically extending wells are only useful for removing oil and gas from the terminating downward end of the well. Thus, not all of the oil and gas in the pockets or formations in the surrounding earth strata, at the location of the well depth, can be removed. Therefore it is necessary to either make additional vertical drillings parallel and close to the first well, which is costly and time consuming, or to provide some means to extend the original well in a radial direction relative to the vertical longitudinal axis of the casing horizontally into the surrounding earth strata.
The most common means for horizontal extension of the well has been to drill angularly through the well casing at a first 45° angle for a short distance and then to turn the drill and drill at a second 45° angle thereby making a full 90° angular or horizontal cut from the vertically extending well. These horizontal drills have proved useful for extending the well horizontally but have proved to be relatively expensive.
Another solution to the problem is disclosed in U.S. Pat. Nos. 5,413,184 and 5,853,056, both of which are hereby incorporated by reference herein as if fully set forth in their entirety. In these patents there is disclosed an apparatus comprising an elbow, a flexible shaft or so-called “flex cable” and a ball cutter attached to the end of the flexible shaft. The elbow is positioned in the well casing, and the ball cutter and flexible shaft are passed through the elbow, turning 90°. A motor rotates the flexible shaft to bore a hole in the well casing and surrounding earth strata with the ball cutter. The flexible shaft and ball cutter are then removed and a flexible tube with a nozzle on the end thereof is passed down the well casing, through the elbow and is directed out of the casing through the hole therein. Water pumped through the flexible tube exits the nozzle at high speed and bores further horizontally into the earth strata.
Prototype testing of the device disclosed in U.S. Pat. Nos. 5,413,184 and 5,853,056 has proven less than satisfactory. In particular, a number of problems plague the device disclosed in U.S. Pat. Nos. 5,413,184 and 5,853,056. For example, the disclosed ball cutter is inefficient at best and ineffective at worst in cutting through the well casing. The inherent spherical geometry of a ball cutter causes it “walk” or “chatter” during rotation as it attempts to bore through the well casing which greatly increases the amount of time required to bore through the casing. Ball cutters are best utilized for deburring, and/or cutting a radius in an existing hole or slot for example. and are simply not suitable for drilling holes.
Another problem is the torsional flexibility of the flexible shaft or flex cable. Rather than transmitting rotational displacement to the ball cutter at 100% efficiency the flex cable tends to “wind up” or exhibit “backlash,” thus reducing the already inefficient cutting efficiency of the ball cutter even more.
Yet another problem is the tendency of the elbow to back away from the hole in the casing during drilling with the ball cutter. Such backing away causes the elbow outlet to become misaligned with the hole in the casing thereby preventing smooth introduction of the nozzle and flexible tube into the hole in the casing.
Still another problem is the large amount of torsional friction generated between the elbow passageway and the flex cable which of course increases the horsepower requirements of the motor required to rotate the flex cable. The addition of balls, separated by springs, to the flex cable, in an effort to alleviate the resistance of the apparatus to being rotated, has not remedied this problem.
A further problem is the closed nature of the apparatus of U.S. Pat. Nos. 5,413,184 and 5,853,056, which prevents its being taken apart, inspected, cleaned and repaired as needed.
The invention of my application Ser. No. 09/643,306 overcomes the deficiencies of the apparatus disclosed in U.S. Pat. Nos. 5,413,184 and 5,853,056. That invention is apparatus for boring a hole from an inside of a tube outwardly perpendicular to a longitudinal axis of the tube. The apparatus comprises a drill shoe having a longitudinal axis and being positionable in the tube, the shoe having an inlet, an outlet perpendicular to the shoe longitudinal axis and a passageway connecting the inlet and outlet, a torsional load transmitting element having no torsional flexibility in relation to its bending flexibility, having a longitudinal axis and being disposed in the passageway, the torsional load transmitting element being movable relative to itself about first and second perpendicular axes both of which are perpendicular to the longitudinal axis of the torsional load transmitting element, a hole saw connected to one end of the torsional load transmitting element and a motor rotatably connected to the other end of the torsional load transmitting element. Rotation of the torsional load transmitting element by the motor rotates the hole saw to bore through the tube from the inside of the tube outwardly perpendicular to the longitudinal axis of the tube.
Further improvements in boring technology are nonetheless desired. For example, the invention of U.S. Pat. Nos. 5,413,184 and 5,853,056 is inefficient and time consuming to operate in that after the cutting tool has bored through the well casing the drilling operation must be interrupted so that the entire drilling apparatus can be retrieved to the earth surface in order to remove the well casing cutting tool and to install the earth strata boring water nozzle. The drilling apparatus must then be lowered back down into the well casing to resume the drilling operation.
SUMMARY OF THE INVENTION
The invention includes apparatus for boring a hole from an inside of a casing outwardly at an angle relative to a longitudinal axis of the casing. The apparatus comprises a drill shoe having a longitudinal axis and being positionable in the casing, the shoe having first and second passageways which converge into a third passageway exiting the shoe, a torsional load transmitting element and a cutting element connected to one end of the torsional load transmitting element, the torsional load transmitting element and cutting element being positioned in the first passageway during non-use and in the third passageway during use, and a fluid conduit and a nozzle connected to one end of the fluid conduit, the fluid conduit and nozzle being positioned in the second passageway during non-use and in the third passageway during use.
The third passageway may exit the shoe at any desired angle of between 0° and 90° relative to the longitudinal axis of the drill shoe. The angle may be, for example, 75° or 90°. The apparatus may include an exit insert installable in the shoe to provide variability in the exit angle.
The torsional load transmitting element has a longitudinal axis, and preferably has no torsional flexibility in relation to its bending flexibility and is movable relative to itself about first and second perpendicular axes both of which are perpendicular to the longitudinal axis of the torsional load transmitting element. The torsional load transmitting element may be freely movable relative to itself about the first and second perpendicular axes. The torsional load transmitting element may be pivotable relative to itself about the first and second perpendicular axes. The torsional load transmitting element may be freely pivotable relative to itself about the first and second perpendicular axes.
The cutting element may be a hole saw. The apparatus may further comprise a drill bit connected to the end of the torsional load transmitting element centrally of the hole saw. The drill shoe may be fabricated in halves. The torsional load transmitting element may comprise a plurality of interconnected universal joints. The shoe may include an angled end surface adapted to cooperate with a matingly angled end surface of a drill shoe depth locator for locating the shoe at a selected depth in the casing such that an angular orientation of the shoe relative to the casing is establishable by positioning the depth locating device at an angular orientation relative to the casing.
A drill shoe depth locator for locating a drill shoe at a selected depth in a casing comprises a housing, at least one locking arm pivotally connected to the housing and an actuator for selectively pivoting the arm. The arm is pivotable to and between a retracted non-locking position in the housing and an extended locking position wherein at least a portion of the arm projects out of the housing and is adapted to contact a wall of the casing.
The actuator for selectively pivoting the arm may comprise a firing mechanism which fires a charge that propels the arm to the extended locking position. The firing mechanism may include a chamber adapted to accept a charge cartridge, a gas path between the chamber and the pivoting arm and a firing pin which is selectively activatable to strike the charge cartridge. The housing may include an angled end surface adapted to cooperate with a matingly angled end surface of the drill shoe such that an angular orientation of the drill shoe relative to the casing is establishable by positioning the depth locator at an angular orientation relative to the casing.
A tool for deploying a drill shoe depth locator in the casing comprises a housing, at least one locking arm pivotally connected to the housing and an actuator for selectively pivoting the arm. The arm is pivotable to and between a retracted non-locking position in the housing and an extended locking position wherein at least a portion of the arm projects out of the housing and is adapted to engage a surface of the drilling apparatus depth locator.
The actuator may comprise a rod movable longitudinally relative to the housing which cooperates with a cam surface on the pivoting arm to thereby move the arm.
A tool for retrieving a drill shoe depth locator from a casing comprises a housing, at least one locking arm pivotally connected to the housing and a resilient member normally biasing the locking arm to an extended locking position yet permitting upon application of sufficient force the locking arm to move to a retracted non-locking position. The arm is pivotable to and between the retracted non-locking position in the housing and an extended locking position wherein at least a portion of the arm projects out of the housing and is adapted to engage a surface of the drill shoe depth locator.
A mobile drilling apparatus comprises a wheeled trailer having a trailer bed, a drill shoe, a mast mounted on the trailer bed for suspending therefrom the drill shoe. a first reel rotatably mounted on the trailer bed for paying out and taking up a cable connected to the drill shoe, the cable supported by the mast, a second reel rotatable mounted on the trailer bed for paying out and taking up a first length of tubing which communicates fluid from a fluid source to a fluid motor in the drill shoe, the tubing supported by the mast, and a third reel rotatably mounted on the trailer bed for paying out and taking up a second length of tubing which communicates fluid from a fluid source to a fluid nozzle in the drill shoe, the tubing supported by the mast.
The mast may be pivotally mounted to the trailer bed for pivoting movement to and between an upright operable position and a lowered inoperable position. The mast may be mounted to a work platform and the work platform may be mounted to the trailer bed for movement transverse to a longitudinal axis of the trailer bed. The apparatus may further comprise a catwalk extending the length of the trailer bed on one side thereof and mounted to the trailer bed for pivoting movement to and between an upright inoperable position and a lowered operable position wherein the catwalk extends the width of the trailer bed. The catwalk may include a set of steps secure thereto such that when the catwalk is in the lowered operable position an operator may climb the steps from a ground surface to the trailer bed.
The apparatus may further comprise a motor rotatably driving each of the first, second and third reels, a brake mounted to each of the first, second and third reels, a sensor mounted to each of the first, second and third reels for sensing an angular velocity of each of the first, second and third reels and a controller which controls the brakes in response to signals received from the sensors. The apparatus may further include a sensor mounted on the mast for sensing a depth traversed by the drill shoe.
These and other advantages of the present invention will become more readily apparent during the following detailed description taken in conjunction with the drawings herein, in which:
BRIEF DESCRIPTION OF THE DRAWINGS OF THE INVENTION
FIG. 1 is a side view of a drill shoe of the invention;
FIG. 2 is an enlarged sectional side view of a portion of the drill shoe of FIG. 1;
FIG. 3 is a side view in partial cross section of the cooperatingly matingly angled end surfaces of the drill shoe and drill shoe depth locator;
FIG. 4 is an enlarged view of the end of the drill shoe with angle locating surface;
FIG. 5 is a side cross-sectional view of a device for locating the drill shoe at a selected depth in the casing, and a tool for deploying the drill shoe depth locator;
FIG. 6 is a view similar to FIG. 5 with the drill shoe depth locator fixed in position in the casing and the deploying tool being withdrawn from the casing;
FIG. 7 is a view similar to FIG. 5 but of a tool for retrieving the drill shoe depth locator engaging the drill shoe depth locator;
FIG. 8 is a view similar to FIG. 7 of the retrieving tool and drill shoe depth locator being withdrawn from the casing;
FIG. 9 is a side view of the mobile drilling apparatus of the invention; and
FIG. 10 is a top view of the mobile drilling apparatus of FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1 a boring apparatus 10 according to the principles of the present invention is illustrated. During use apparatus 10 is positionable inside a well casing 12 in the earth strata 14 (FIG. 3 ). The boring apparatus 10 includes a hollow carbon steel drill shoe 20 . Drill shoe 20 has a longitudinal axis which, when inserted into casing 12 , is generally parallel to a longitudinal axis of the well casing 12 . Drill shoe 20 may preferably be fabricated in halves 20 a, 20 b securable together via bolts 22 . Drill shoe 20 may be connected to a ½ inch diameter 6×25 IWRC wire rope 24 which is utilized to lower drill shoe 20 down into casing 12 .
A fluid motor 26 imparts rotation to a motor coupling 28 which is connected to a drill bit shaft 30 itself connected to a plurality of interconnected universal joints 32 which terminate in a hole saw 34 with central pilot hole drill bit 36 . Above motor 26 is a motor locator 38 ; motor locator 38 and drill shoe 20 include cooperating structure (not shown, see U.S. patent application Ser. No. 09/643,306 for same) rotatably fixing the motor locator 38 and hence motor 26 relative to the shoe 20 thereby preventing relative rotation between motor 26 and shoe 20 during operation of motor 26 .
Shoe 20 further includes a first passageway 40 , a second passageway 42 and a third passageway 44 . The universal joints 32 , hole saw 34 and drill bit 36 reside in first passageway 40 during nonuse and in third passageway 44 during use. Similarly, a flexible fluid conduit 46 with a nozzle 48 connected to its end is positioned in the second passageway 42 during nonuse and in the third passageway 44 during use. Motor 26 may be suspended from and supplied with liquid through a ½ inch diameter 0.049 inch wall thickness 316L stainless steel tubing 50 . Similarly, fluid conduit 46 may be suspended from and supplied with liquid through a ⅝ inch diameter 0.049 inch wall thickness 316L stainless steel tubing 52 .
Third passageway 44 may exit the shoe 20 at any desired angle of between 0° and 90° relative to the longitudinal axis of the shoe 20 , depending on the drilling application. Preferably, the angle is in the general range of about 75° to 90°. To provide convenient variability and versatility in the exit angle of the third passageway 44 one of a number of exit angle inserts 54 may be utilized, each of which inserts would include a different exit angle. For example, two exit inserts 54 may employed, one of which is at 75° (FIG. 4) and the other of which is at 90° (FIG. 3) thereby providing an operator with a ready means of quickly changing the exit angle depending on drilling conditions etc. Exit insert 54 may be removably installable in the shoe 20 via screws 56 .
Referring to FIGS. 1-4, shoe 20 may include an angled end surface 58 formed as part of an angular locator 60 secured to a lower end of shoe 20 with a bolt 62 and locating pin 64 . Angled end surface 58 is adapted to cooperate with a matingly angled end surface 66 of a drill shoe depth locator 68 (discussed in more detail below) for locating the shoe 20 at a selected depth in the casing 12 . An angular orientation of the shoe 20 relative to the casing 12 is establishable by positioning the depth locator 68 at an angular orientation relative to the casing 12 . The matingly angled end surfaces 58 and 66 automatically determine the angular orientation of the shoe 20 to locator 68 and thus shoe 20 to casing 12 . The use thereof will be described below in more detail.
Referring now to FIGS. 3, 5 and 6 , the drill shoe depth locator 68 is illustrated which locates the drill shoe 20 at a selected depth in the casing 12 . The depth locator 68 comprises a housing 70 and may preferably comprise a pair of locking arms 72 pivotally connected to the housing 70 as by pivots 74 . The arms 72 are pivotable to and between a retracted nonlocking position in the housing (FIG. 5) and an extended locking position wherein at least a portion of the arms 72 project out of the housing 70 and is adapted to contact the wall of the casing 12 . An actuator 76 may be included for selectively pivoting the arms 72 . The actuator 76 may comprise a firing mechanism, which fires a charge that propels the arms 72 to the extended locking position, which comprises a chamber 78 adapted to accept a charge cartridge 80 . a gas path 82 between the chamber 78 and each pivoting arm 72 and a firing pin 84 which is selectively activatable to strike the charge cartridge 80 thus releasing combustion gases which force the arms 72 upwardly into a locking position relative to the casing 12 . Gas vent paths 86 bleed excess gas out of housing 70 . Preferably the firing mechanism actuator 76 of the device 68 would be activated as the device 68 is being lowered into the casing 12 ; when the device 68 reaches the desired depth as indicated by, for example, a rotary encoder, the mechanism 76 is fired propelling the arms 72 upwardly into engagement with the casing 12 , the downward momentum of the device 68 further assisting in locking the arms 72 into the wall of the casing 12 . In the alternative, the charge cartridge 80 and firing pin 84 could be eliminated; the locking arms 72 can be forced upwardly into engagement with the casing 12 by simply lowering locator 68 at a sufficient velocity such that water in casing 12 moves forcefully up chamber 80 through paths 82 and into contact with arms 72 forcing them upwardly.
Firing pin 84 is spring loaded via compression spring 85 positioned within firing pin housing 87 . A firing pin blocking plate 89 normally blocks firing pin 84 from upward movement. Firing pin blocking plate 89 is maintained in its blocking position via a release rod 91 . Upon upward movement of release rod 91 aperture 93 in blocking plate 89 centers around firing pin 84 thereby freeing firing pin 84 to move upwardly under force of compression spinrg 85 .
As mentioned briefly above, the depth locator 68 preferably includes an angled end surface 66 which cooperates with the matingly angled end surface 58 of the drill shoe 20 . Once the device 68 is in position in the casing 12 , a plurality of radially extending horizontal borings can be made into the earth strata by adjusting the angular position of the angular locator 60 relative to the shoe 20 , it being contemplated that the shoe 20 and locator 60 would have a plurality of locating pins 64 positioned at, for example 5° to 10 20 increments. Thus, with each 5° or 10° readjustment of locator 60 relative to shoe 20 , the shoe 20 can bore a new radial path radially outwardly from the casing 12 but at a known increment relative to the previous boring. If desired, the shoe 20 and locator 60 can be repeatedly readjusted to drill radially outwardly from the well casing 12 in a full 360° circle.
Referring still to FIGS. 5 and 6, there is illustrated a tool 100 for deploying the drill shoe depth locator 68 in the casing 12 . The tool 100 comprises a housing 102 and a pair of locking arms 104 pivotally connected to the housing 102 as by pivots 106 . The locking arms 104 are pivotal to and between a retracted non-locking position (FIG. 6) generally within the periphery of the housing 102 and an extended locking position (FIG. 5) wherein at least a portion of the arms 104 project out of the housing 102 , and are adapted to engage a surface 110 of the depth locator 68 . An actuator 112 selectively pivots the arms 104 to and between the retracted non-locking position (FIG. 6) and the extended locking position (FIG. 5 ). The actuator preferably comprises a rod 114 which is movable longitudinally relative to the housing 102 and which cooperates with a cam surface 116 on each pivoting arm 104 to thereby move the arms 104 . Thus, to lower the depth locator 68 in the well casing 12 , the tool 100 is engaged with the depth locator 68 in that the rod 114 is in a downward position forcing arms 104 outwardly so as to engage underneath surface 110 of the device 68 . Once the depth locator 68 is at the desired depth in the casing 12 , the rod 114 is pulled upwardly thereby permitting upward force on the tool 100 to force the pivoting arms 104 inwardly and free of surface 110 thus permitting the tool 100 to be withdrawn from the casing 12 .
Referring now to FIGS. 7 and 8 there is illustrated a tool 200 for retrieving the depth locator 68 from the casing 12 . The tool 200 comprises a housing 202 and a pair of locking arms 204 pivotally connected to the housing 202 as by pivots 206 . The locking arms 204 are pivotable to and between a retracted non-locking position (FIG. 7) generally within the periphery of the housing 202 and an extended locking position (FIG. 8) wherein a portion of the arms 204 project out of the housing 202 and are adapted to engage the prior mentioned surface 110 of the depth locator 68 . A resilient member 210 normally biases the locking arms 204 to the extended locking position, yet permits upon application of a sufficient force the locking arms 204 to move to the retracted non-locking position, i.e. during initial insertion of housing 202 and locking arms 204 into depth locator 68 (FIG. 7 ).
Referring to FIGS. 9 and 10 a mobile drilling apparatus 300 is illustrated. The apparatus 300 comprises a wheeled trailer 302 having a trailer bed 304 , the prior described drill shoe 20 , a mast 308 mounted on the trailer bed 304 for suspending therefrom the drill shoe 20 , a first reel 310 rotatably mounted on the trailer bed 304 for paying out and taking up cable 24 connected to the drill shoe 20 , the cable 24 being supported by the mast 308 , a second reel 314 rotatably mounted on the trailer bed 304 for paying out and taking up the first length of tubing 50 which communicates fluid from a fluid source (not shown) to the fluid motor 26 in the drill shoe 20 . the tubing 50 supported by the mast 308 , and a third reel 318 rotatably mounted on the trailer bed 304 for paying out and taking up the second length of tubing 52 which communicates fluid from the fluid source to the fluid nozzle 48 in the drill shoe 20 , the tubing 52 supported by the mast 308 . Reels 310 , 314 and 318 may be five feet in diameter and capable of storing up to ten thousand feet of wire rope or tubing.
The mast 308 is preferably mounted to a work platform 340 . Work platform 340 is preferably mounted to the trailer bed 304 for pivoting movement of the mast 308 to and between an upright operable position and a lowered inoperable position, and is also mounted to the trailer bed 304 for movement transverse to a longitudinal axis of the trailer bed 304 thereby providing transverse alignment of drill shoe 20 to casing 12 . Hydraulic cylinder 342 may be operable between the trailer bed 304 and mast 308 to pivot the mast 308 relative to the bed 304 . Hydraulic cylinder 344 may be operable between the work platform 340 and trailer bed 304 to move the work platform 340 transversely to the longitudinal axis of the trailer bed 304 .
Trailer 302 may additionally comprise a catwalk 350 extending along the trailer 302 on one side thereof and mounted to the trailer bed 304 for pivoting movement to and between an upright inoperable position and a lowered operable position wherein the catwalk 350 extends the width of the trailer bed. A hydraulic cylinder 352 may be operable between the bed 304 and catwalk 350 to pivot the catwalk 350 and between the upright inoperable and lowered operable positions. Catwalk 350 may include a set of steps 354 secured thereto such that when the catwalk 350 is in the lowered position an operator may climb the steps from a ground surface to the trailer bed 304 .
With reference to FIG. 10 the apparatus may further preferably comprise hydraulic motors 400 , 402 and 404 rotatably driving each of the reels 310 , 314 and 318 respectively at up to 8 rpm, hydraulic disk brakes 410 , 412 and 414 mounted to each of the reels 310 , 314 and 318 respectively and sensors 420 , 422 and 424 mounted to each of the reels 310 , 314 and 318 respectively for sensing an angular velocity of each of the reels 310 , 314 and 318 . A controller 450 is operable to control the brakes 410 , 412 and 414 in response to signals received from the sensors 420 , 422 and 424 to insure that the cable 20 and tubing 50 and 52 all pay out and are taken back up at the same rate. Controller 450 also includes manually manipulable controls for the reels and brakes. To monitor the distance drill shoe 20 is being lowered into the casing 12 a sensor 460 may be mounted atop mast 308 to sense a depth traversed by the drill shoe 20 . Sensors 420 , 422 , 424 and 460 may take the form of, for example optical rotary encoders. A diesel engine driven 15,000 psi water pump and hydraulic fluid pump 470 supplies high pressure water to motor 26 and nozzle 48 and hydraulic fluid pressure to motors 400 , 402 , 404 , brakes 410 , 412 , 414 and cylinders 342 , 344 , 352 , respectively.
Those skilled in the art will readily recognize numerous adaptations and modifications which can be made to the present invention which will result in an improved boring apparatus, yet all of which will fall within the spirit and scope of the present invention as defined in the following claims. Accordingly, the invention is to be limited only by the scope of the following claims and their equivalents.
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Apparatus for boring a hole from an inside of a casing outwardly at an angle relative to a longitudinal axis of the casing comprises a drill shoe having a longitudinal axis and being positionable in the casing, the shoe having first and second passageways which converge into a third passageway exiting the shoe, a torsional load transmitting element and a cutting element connecting to one end of the torsional load transmitting element, the torsional load transmitting element and cutting element being positioned in the first passageway during non-use and in the third passageway during use, and a fluid conduit and a nozzle connected to one end of the fluid conduit, the fluid conduit and nozzle being positioned in the second passageway during non-use and in the third passageway during use.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a device for compressive engagement. comprised of two coupling pieces and forcible means for reversibly axially compressively engaging the two coupling pieces in mutual engagement, wherein one of the coupling pieces has a plurality of aligning elements and the other coupling piece has a plurality of cooperating elements, wherein when the axially compressive interengagement is carried out the said aligning elements and cooperating elements cooperate in mutual abutment to achieve accurate positioning of the coupling pieces in the circumferential direction.
2. Description of Related Art
A known arrangement, disclosed in Ger. OS 30 03 756, is useful for holding electrodes for electromilling machines, wherein the coupling piece equipped with the aligning elements is fixed to the machine. The aligning elements comprise three axially projecting conical pins, wherein when the two coupling pieces are pressed together the said pins engage conical depressions in the opposite coupling piece, as cooperating elements with said pins. The combination of alignment of the movable coupling piece to the fixed coupling piece in the z-direction (being the direction of the pressing of the two pieces together) and alignment in the plane normal to the z-direction (viz., alignment in the circumferential direction) achieved by the known device has the disadvantage that a compromise of the accuracy of alignment in one direction has a detrimental effect on alignment in the other, e.g. loss in the accuracy of alignment in the said normal plane due to dimensional deviations in the coupling pieces or due to wear after long service will be accompanied by a loss of accuracy of alignment in the z-direction.
Eur. OS 111,092 (U.S. reissue Pat. No. RE 33,249) discloses a device for compressive engagement wherein an axially elastic catch plate is interposed between the two coupling pieces. The catch plate is attached with a gap to one of the coupling pieces, which piece is either a workpiece or a workpiece holder. The other coupling piece is an integral component of the working head of a machine tool, usually an electromilling machine, and has ridges which engage recesses in the catch plate when the assembly comprising the two coupling pieces and the catch plate is brought into compressive engagement. The workpiece is subjected to forming outside the machine tool, such that after mounting on the machine tool it can serve as a tool, e.g. an electrode for electromilling.
With such an arrangement the problem occurs that cuttings, fines, or other debris from the machining can accumulate between the catch plate and the associated coupling piece, resulting in detrimental loss of the free elastic resilience of the catch plate in the compressive engagement of the two coupling pieces.
Eur. Pat. 255,042 (U.S. Pat. No. 4,855,558) discloses a device for compressive engagement wherein the coupling piece provided with ridges is also integrated into the head of the machine tool (principally an electromilling machine). Axially elastic elements in the form of pairs of lip members are provided on the other coupling piece (which piece serves as the workpiece support), wherein when the workpiece holder is compressively engaged with the machine tool head the ridges penetrate between the edges of respective pairs of lip members. Even though between successive compressive mountings the workpiece undergoes appreciable mechanical machining, the requirement is imposed that each re-mounting achieves a high degree of angular accuracy. With the arrangement according to Eur. Pat. 255,042, this necessitates high fabrication costs for the machining to produce the lip members. However, a large number of workpiece holders is required because a large number of electrodes are needed for the electromilling of a single workpiece.
SUMMARY OF THE INVENTION
Accordingly, the underlying problem of the present invention is to devise a device for compressive engagement, of the general type described supra, wherein the coupling piece serving as an electrode support or workpiece support can be fabricated at substantially lower cost.
This problem is solved according to the invention in that in the course of the compressive interengagement the aligning elements and/or the cooperating elements are subjected to a force in the circumferential direction, such that the cooperating elements and aligning elements are brought into forcible mutual abutment and in that the coupling pieces respectively have cooperating reference surfaces extending transversely to the direction of compressive interengagement, which reference surfaces facilitate accurate axial positioning. With this arrangement, the coupling piece bearing the cooperating elements is much easier to fabricate. Further, the problem of high sensitivity to soiling is avoided, because the coupling piece intended to be used as a workpiece holder or the like does not have any complex recesses susceptible to detrimental accumulation of cuttings, fines, or other debris from the machining of the workpiece.
In a preferred embodiment (or refinement) of the invention, a weakly curved convex spherical surface may be provided on the aligning surface of each aligning element which surface neighbors or abuts, the associated cooperating element or, alternatively, such weakly curved spherical surface may be on the cooperating surface of each cooperating element which surface neighbors or abuts the associated aligning element. This ensures that the forcible abutment of the cooperating element against the aligning element in the circumferential direction which is accomplished on the occasion of the compressive interengagement of the two coupling pieces will have essentially a point locus, thereby further reducing susceptibility of the alignment to inaccuracies due to soiling, particulate matter, and the like.
In a particularly simple embodiment of the invention, at least one pressing element is formed on the coupling piece which bears the aligning elements, which pressing element forcibly engages the other coupling piece when the compressive interengagement of the two coupling pieces is carried out.
In another preferred embodiment (or refinement) of the invention, advantageously elastic pressing elements are provided, wherein on the occasion of the compressive interengagement of the two coupling pieces, each cooperating element is essentially forced against an aligning element by such a pressing element. The pressing elements, which advantageously are provided on the coupling piece which is intended to be fixed to the machine, do not themselves perform an aligning function but serve to press the cooperating elements against the aligning elements and facilitate the release of the interengagement of the coupling pieces after the forcible means of compressive interengagement are relaxed.
Other particularly advantageous embodiments are possible according to the invention. For example, the cooperating elements may be in the form of axially projecting ridges which extend from the periphery of a coupling piece inward, advantageously along a radius, wherein advantageously each such ridge has at least one wedge surface or truncated wedge surface. As a means of facilitating interpenetration during the engagement of the movable coupling piece against the coupling piece fixed to the machine, the movable coupling piece may bear a central prominence having a generally frustoconical shape which can be inserted in a central recess in the coupling piece which is fixed to the machine.
It is recommended that the aligning elements be in the form of free, rigid edges extending inward from the periphery. It is further advantageous if an axially elastic lip member is provided at a short separation in the circumferential direction from each aligning element, wherein said lip members are configured and disposed such that during the compressive interengagement of the coupling pieces a respective cooperating element penetrates into a groove which is left between each lip member and the neighboring aligning element. Finally, it is advantageous if each cooperating element has two opposite parallel wedge surfaces or truncated wedge surfaces i.e. two inclined surfaces having parallel longitudinal axes, and if the edges of each aligning element and its neighboring lip(s) are parallel. Advantageously, the reference surfaces are formed on raised structures which extend axially above at least one of the coupling pieces by a height which is less than that of the ridges. For small tools (or electrodes) which are connected to the movable coupling piece, according to a refinement of the invention it is sufficient if three aligning elements are provided on the coupling piece which is intended to be attached to the machine tool, wherein these aligning elements are equidistantly disposed in the circumferential direction. The reference surfaces may be disposed in the circumferential direction between pairs of successive aligning elements, and also between pairs of successive cooperating elements. If the coupling pieces have round outer contours, the lip members may also be arcuate. Advantageously the lip members and aligning elements are in a common plane.
The coupling piece can be particularly easily adapted to workpiece dimensions which are relatively small compared to the dimensions of the coupling means provided on the machine tool, if, according to a refinement of the invention, the coupling piece intended to be fixed to the machine tool is provided with axially elastic elements on its side which is opposite to the aligning elements, wherein when said coupling piece is releasably fixed to the machine tool head said elastic elements cooperate with ridges provided on said machine tool head. This allows a substantially smaller radial dimension of said coupling piece on its side bearing the aligning elements than on its side bearing the said elastic elements.
The invention will be described in more detail hereinbelow, with reference to exemplary embodiments illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of a first coupling piece, which is connectable to a machine tool;
FIG. 2 is a schematic perspective view of a second coupling piece which is essentially axially aligned with the piece of FIG. 1 and is connectable to an electrode element for electromachining;
FIG. 3 is a bottom view of the first coupling piece according to FIG. 1;
FIG. 4 is a lateral view of the second coupling piece according to FIG. 2;
FIG. 5 is a bottom view of a second inventive embodiment of the first coupling piece;
FIG. 6 is a top view of a second inventive embodiment of the second coupling piece;
FIG. 7 is a perspective view of a third inventive embodiment, comprising a pair of coupling pieces which can be compressionally interengaged by means of a bolt; and
FIG. 8 illustrates the embodiment according to FIG. 7 during a time when the coupling pieces are in the process of becoming compressionally interengaged.
FIG. 9 is a close-up view of a rigid edge of a first coupling piece having a gently curved spherical surface.
FIG. 10 is a close-up view of a rigid edge of a ridge of a second coupling piece having a gently curved spherical surface.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The coupling support designated generally 1 in FIG. 1 is adapted to be releasably fixed to the head of an electromilling or electromachining machine, such as an electrical discharge machine (EDM) (not shown), by screw or clamp means. For this purpose, the free end face of the machine head bears posts and ridges or the like, e.g. such as described in Eur. Pat. 255,042 (U.S. Pat. No. 4,855,558). In this connection (as described in said Eur. Pat.), the upper side 2 of coupling support 1 is provided with four pairs of lip members (3, 4; 7, 8) disposed in a cross arrangement, which lip members engage the corresponding ridges disposed in a cross arrangement on the machine head when said coupling support 1 is mounted on the machine head; wherein, during the mounting of support 1 the said ridges on the machine head engage support 1 and aid in the positioning of support 1. The regions between the lip pairs on the upper side of the coupling support 1, e.g. region 5, serve as reference surfaces for the positioning of the coupling support 1 in the z-direction (which direction coincides with the major axis of coupling support 1).
The coupling support 1 has a square cross section in its upper region 6 in the plan view, and has an adjoining lower region which narrows conically to a first coupling piece 9 which has an essentially cylindrical outer periphery. Thus the diameter of piece 9 is substantially less than the length of a side of the support 1 in its upper region 6.
Three lip members (10, 14, 18) are formed on the first coupling piece 9; each of these has a circular arcuate shape as it adjoins the lateral periphery of the coupling piece 9. By virtue of deep undercutting, the lip members (10, 14, 18) are axially elastic, have a free surface on a common end face of piece 9, and are bounded radially inwardly by a deep central circular recess 22 extending axially upward (FIG. 1) from said end face. The end of each lip member (10, 14, 18) is radially parallel, e.g. designated 11 for member 10.
Three solid structures (13, 15, 17) remain on the first coupling piece 9; these terminate axially in the common plane of the lip members (10, 14, 18). Each structure (13, 15, 17) is bounded in one angular direction (counterclockwise in FIG. 1) by the respective lip member (10, 14, 18), and in the opposite angular direction by a free rigid edge (20, 12, 16) which here comprises a radially parallel edge surface which serves as an abutting or aligning element for a ridge on the second coupling piece 40. Thus a flat surface region (19, 21, 23) is provided between the lip member (10, 14, 18) and the rigid edge (20, 12, 16) on the solid structure (13, 15, 17), which flat region serves as a reference surface for the z-direction when the first coupling piece 9 is compressively engaged with a second coupling piece 40.
A slot is present between each lip member (10, 14, 18) and the neighboring rigid edge (12, 16, 20), for accommodating an opposing ridge element (described below) on the second coupling piece 40 during the engagement process. These slots all have the same gap. In FIG. 3 the center lines of the slots are designated 25, 27, and 29, respectively, and the lip members are indicated with diagonal hatching. In the inventive embodiment shown, the center lines (25, 27, 29) extend along radii at 120° intervals.
It is possible for the mutual separations of the slots in the circumferential direction to be unequal, within the scope of the invention, wherein, e.g., the circumferential angle between middle lines 25 and 27, and between middle lines 25 and 29, is 115°, and that between middle lines 27 and 29 is 130°.
The second coupling piece 40 is fixed to the center of the top end surface of an electrode element 90 for electromachining. Three ridges (42, 44, 46) equidistant in the circumferential direction project axially from the top side 47 of second coupling piece 40. Each such ridge extends radially outward from a central axially projecting ring 50 which surrounds a central bore 48, and each such ridge has two opposite radially parallel wedge surfaces or truncated wedge surfaces. At its upper face, each ridge (42, 44, 46) is narrower than the corresponding slot between a lip member (10, 14, 18) and the neighboring rigid edge (12, 16, 20) on the first coupling piece 9; and at its base (at the transition to the body of the second coupling piece 40), each ridge is wider than said corresponding slot. All of the slots have the same width, and the profiles of all of the ridges (42, 44, 46) are mutually the same. The pair of inclined surfaces (truncated wedge surfaces) on each ridge (42, 44, 46) is configured such that when the coupling pieces 9 and 40 are compressively interengaged each said pair of inclined surfaces can penetrate into the aforesaid respective slot on the first coupling piece between the free end of a lip and the neighboring rigid edge. Reference surfaces (54, 56, 58) are formed between respective pairs of ridges on the periphery of the second coupling piece 40, which surfaces are perpendicular to the axis 24 and extend an axial distance above the upper side 47 which distance is less than the height of the ridges (42, 44, 46). These reference surfaces are intended to abut against the corresponding reference surfaces (19, 21, 23) on the first coupling piece when the pieces are compressively interengaged, thereby providing alignment in the z-direction.
Of course, the angular separation of the ridges (42, 44, 46) in the circumferential direction matches that of the aforesaid middle lines (25, 27, 29).
To engage the second coupling piece 40, with or without an electrode element 90, against the first coupling piece 9, a tensile bolt (not shown) is extended through the central bore 30 of the coupling support 1 and is screwed into, e.g., an inner thread provided in bore 48. The part of the bolt extending upward from the coupling support 1 is engaged in a tensioning device disposed in the machine head, which device is described in Eur. Pat. 255,042, whereby means such as compressed air are employed to raise the bolt axially, forcibly causing the coupling support 1 to abut against the machine head and the second coupling piece 40 to abut against the first coupling piece 9, wherein the ridges (42, 44, 46) penetrate into the slots, wherein one inclined surface (truncated wedge surface) of each ridge is forcibly engaged against the corresponding rigid edge (12, 16, 20). The engagement of said inclined surface against said edge is aided by forces exerted by the lip members (10, 14, 18) which urge such engagement. The ridges (42, 44, 46) penetrate into the slots until the reference counter-surfaces (54, 56, 58) abut against the corresponding reference surfaces (19, 21, 23) on the first coupling piece 9. As a result the second coupling piece 40 is accurately positioned in the z-direction (which is the direction of the compressive engagement) and in the circumferential direction, the latter positioning being achieved by the forcible abutment of one of the inclined surfaces of each ridge against the corresponding rigid edge (12, 16, 20) under the compressive engaging force of the neighboring lip member.
The central ring 50, which projects higher over the top side 47 than do the ridges, helps to guide said ridges into the slots. In this connection, the ring 50 also has a truncated wedge profile. The outer diameter of the ring 50 is such that the ring can penetrate into the recess 22 without resistance.
To release the engagement of the second coupling piece 40 with the first coupling piece 9, piece 9 can be lowered in the direction opposite to the engagement direction, by relaxing the operative air pressure in the tensioning device. The release of piece 40 is facilitated by the relaxation of the lip members (10, 14, 18).
The rigid edges (20, 12, 16) which form the abutting or aligning surfaces may be weakly or gently curved (i.e. having a large radius of curvature) convex spherical surfaces such as surface 20' as shown in FIG. 9. Alternatively, the ridges (42, 44, 46) may have their surfaces that engage the rigid edges (20, 12, 16) also of a weakly curved spherical surface such as the ridge 44' shown in FIG. 10. This ensures that the abutment between the alignment element and ridges of the cooperating element will essentially be along a point or line.
In the second embodiment of a coupling support (60), illustrated in FIG. 5, similar to the above-described exemplary embodiment, rigid edges (62, 66, 70) are formed on the free lower end face of the first coupling piece 79, but here the rigid edges each extend parallel to a secant of the circle describing the periphery of coupling piece 79 and are essentially perpendicular to each other. A ring-shaped surface is formed which is interrupted by the three slots associated with said rigid edges. Each such rigid edge (62, 66, 70) has immediately neighboring it an axially elastic lip member (64, 68, 72) formed by undercutting material in the region 69 (and 71 and 67) of the coupling piece 79. Fixed axial reference surfaces (61, 63, 65) remain on the ring-shaped surface, each such reference surface extending between the neighboring rigid edge (62, 66, 70) and the beginning of the respective lip (72, 64, 68) (said beginning indicated by respective dotted lines (67, 69, 71)). The reference surfaces (61, 63, 65) are in a common plane which is perpendicular to the axis of the coupling support 60.
The second coupling piece 80 (FIG. 6) associated with first coupling piece 79 is here fixed to the end face of a cylindrical electrode element 91 for electromachining. Piece 80 has reference counter-surfaces (81, 83, 85) which come to abut against the corresponding reference surfaces (61, 63, 65) on the first coupling piece 79 when the two coupling pieces (79, 80) are compressively interengaged. As in the above-described embodiment, the reference counter-surfaces (81, 83, 85) are formed on structures which rise above the upper side 87 of the second coupling piece 80.
Three ridges (82, 84, 86) project from the upper side 87; these ridges have inclined lateral surfaces (truncated wedge surfaces) (not illustrated). The ridges are each parallel to a secant of the circular perimeter of the second coupling piece 80, and are mutually perpendicularly directed, and each such ridge extends inward from the circular periphery of said piece 80. When piece 80 is engaged with the first coupling piece 79, each of the ridges (82, 84, 86) engages into the unique slot corresponding thereto, between a rigid edge (62, 66, 70) and a neighboring or adjacent lip member (64, 68, 72).
It is seen from FIGS. 5 and 6 that the slots and strips respectively have nonuniform angular separation in the circumferential direction. Accordingly, there is only a single mutual orientation in which the two coupling pieces (79, 80) can be interengaged.
Three countersunk bores (92, 94, 96) are provided in the upper side 87 of the second coupling piece 80, near the reference counter-surfaces (81, 83, 85) and the ridges (82, 84, 86), for accommodating threaded bolts which may be used to attach the electrode element 91.
Finally, the second coupling piece 80 has a central threaded bore 89 in which the external thread of a tensile anchor for the tensioning device can be engaged, which anchor will extend through the central bore 78 in the first coupling piece 79 and the coupling support 60.
As in the embodiment of FIGS. 1-4, the rigid edges (62, 66, 70) which form the aligning surfaces or, alternatively, the surface of the ridges (82, 84, 86) of the cooperating elements may be gently curved spherical surfaces.
The inventive embodiment according to FIGS. 7 and 8 provides a particularly clear demonstration of the inventive principle employed for exact positioning of the second coupling piece 140 with respect to the first coupling piece 109, in both the axial direction (z-direction) and the circumferential direction (or in general the x-y plane, which is normal to the z-direction). The relative orientation achieved is very precise and has very highly repeatable accuracy--in several hundred cycles of compressive interengagement and release of the two coupling pieces the deviations in relative position will be on the order of a few microns.
As in the exemplary embodiments described above, the first coupling piece 109 can be fixed at its top side 110 to the bottom side of a coupling support of a machine head (not shown in FIGS. 7 and 8), and the second coupling piece 140 can be connected at its bottom side to an electrode element (not shown in FIGS. 7 and 8).
The first coupling piece 109 has an essentially cylindrical shape, and has three notches which extend radially inward from its lateral surface. Three aligning members (101, 102, 103) are thereby defined which are bounded in the circumferential direction by the respective pairs of such notches. Each aligning member (101, 102, 103) has one respective aligning surface, of which only one such, 104, is visible. In a plan view of the first coupling piece 109 the aligning surface in each instance is the leading surface of the aligning member if the piece 109 is in clockwise rotation. All of the said aligning surfaces are parallel to the center axis of first coupling piece 109. The notches are equidistant in the circumferential direction, have the same symmetrical right-angled shape in the plan view, and each is disposed symmetrically with respect to the center axis of the first coupling piece 109; accordingly, the aligning surfaces are also mutually equidistant in the circumferential direction and are equidistant from the center axis. Each is intended to serve as a reference surface in aligning the second coupling piece 140 with respect to the first coupling piece 109, in the circumferential direction.
In the embodiment illustrated, the second coupling piece 140 is essentially cylindrical, with the same diameter as the first coupling piece 109. Three cooperating elements (141, 142, 143) rise as prominences above the top side 130 of the second coupling piece 140; these are equidistant in the circumferential direction, have the same shape, and have a width in the circumferential direction which is less than that of a notch in the first coupling piece 109. Their height above the top side 130 is less than the axial thickness of the first coupling piece 109. The leading face of each cooperating element (141, 142, 143) in a counterclockwise rotary motion thereof considered in the plan view is the face which will engage the aligning faces (104 etc.) of the first coupling piece 109; two such cooperating faces, 144 and 145, on elements 141 and 142, respectively, are visible in FIG. 7. As seen from FIG. 7, these cooperating faces are convexly curved, in particular spherically convexly curved, to a slight degree. It is intended that when the coupling pieces 109 and 140 are compressively interengaged and urged in rotation in opposite directions around a common axis (FIG. 8), said cooperating faces will come to abut against the aligning faces (104 etc.) of the aligning members (101, 102, 103).
Three raised nubs (146, 147, 148), here cylindrical, are provided, equidistantly in the circumferential direction, on the top side 130 of the second coupling piece 140. Each of these nubs is disposed between a respective pair of the aforementioned cooperating elements (141, 142, 143). The end faces of the nubs (146, 147, 148) serve as reference surfaces and are accurately perpendicular to the center axis of the second coupling piece 140. The height of each nub (146, 147, 148) above the top side 130 is substantially less than the height of the said cooperating elements.
The bottom side (not shown) of the first coupling piece 109 also serves as a reference surface, oriented accurately perpendicular to the center axis of coupling piece 109.
Various means may be employed to compressively interengage the two coupling pieces (109, 142). Said interengaging means must be suitable to bring the pieces (109, 142) to forcibly abut against each other in the axial direction such that the z-direction reference surface of the first coupling piece 109, namely the bottom side of piece 109, comes to abut the z-direction reference surfaces of the second coupling piece 140, namely the surfaces of the nubs (146, 147, 148): further, said means must be suitable to rotate the first coupling piece 109 clockwise (arrow 112 in FIG. 8) with respect to the second coupling piece 140, and/or to rotate the second coupling piece 140 counterclockwise (arrow 114 in FIG. 8) with respect to the first coupling piece 109. This rotation brings about the forcible abutment of the cooperating faces of the cooperating elements (141, 142, 143) against the aligning faces of the aligning members (101, 102, 103).
The interengaging means may comprise, e.g., a tensile bolt of the type described in Eur. Pat. 255,042, having a foot anchorable in a central blind hole 149 in the second coupling piece 140, wherein the tensile bolt extends through the central bore 108 in the first coupling piece 109 and into a receiving means in the machine tool head, which receiving means engages the head of the bolt and urges it upward in the z-direction, thereby pulling the second coupling piece 140 upward (along with an electrode or other implement attached to piece 140) in the z-direction against the first coupling piece 109 until the z-direction reference surfaces come to mutually abut. A thrusting element, e.g. a plunger driven by pressurized air, may be provided in the machine tool head, which element acts on an axially parallel, radially displaced shoulder (not shown) on the tensile bolt and rotates said bolt in the direction of arrow 114 with respect to the first coupling piece 109, until the cooperating surfaces (144, 145, etc.) of the second coupling piece 140 are brought to abut against the aligning surfaces (104, etc.) of piece 109. When the pressurized air acting on the holding means for the tensile bolt and on the torque-exerting thrusting element is relaxed, the second coupling piece 140 can be readily separated from the first coupling piece 109 and thereby can be removed from the machine tool.
Another, simpler and more customary means of compressive engagement employs the threaded bolt 120 illustrated in FIGS. 7 and 8. The bolt shaft 122 extends through the bore 108 and its threaded region engages an inner thread in bore 149. The bolt head 124 lies on the top side 103 of the first coupling piece 109. The two coupling pieces (109, 140) are compressively engaged in the axial direction by screwing the bolt 120 into the opening 149, wherein rotation of the bolt head 124 tends to cause the first coupling piece 109 to rotate along with it in the direction of arrow 112, until eventually the reference surfaces for the circumferential alignment and the reference surfaces for positioning in the z-direction all come into respective forcible abutment.
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A compressive holding device having two coupling pieces and forcible elements for reversibly, axially, and compressively engaging the two coupling pieces in mutual engagement, wherein one of the coupling pieces has a plurality of aligning elements and the other coupling piece has a plurality of cooperating elements, such that when the compressive interengagement is carried out, the aligning elements and cooperating elements cooperate in mutual abutment to achieve accurate positioning of the coupling pieces in a circumferential direction. The aligning elements and/or the cooperating elements are subjected to a force in the circumferential direction, such that the cooperating elements and aligning elements are brought into forcible mutual abutment. The coupling pieces respectively have cooperating reference surfaces extending transversely to the direction of compressive interengagement, which reference surfaces facilitate accurate axial positioning.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from earlier filed provisional application Ser. No. 60/973,611, filed Sep. 19, 2007, entitled “Mobile Land Drilling Rig and Method of Installation by the same inventor.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to oil, gas and geothermal well drilling rigs and, more specifically, to a mobile well drilling rig and to the transport, assembly, and disassembly of such a rig.
[0004] 2. Description of the Prior Art
[0005] With the ever increasing pressure in recent years on domestic oil and gas production, it has become increasingly important to provide mobile drilling rigs which can be easily transported over the highway and which can be rapidly assembled and disassembled at the well site. For example, present well exploration and completion in the Barnett Shale region in Texas has expanded even into urban areas. In these and other settings, to be economically competitive, oil and gas drilling and exploration activities require the rapid deployment, assembly and disassembly of drilling structures. One way to accomplish these goals is to provide a mobile, highly capable rig which maximizes productive on-site drilling time in urban or rural settings, while minimizing essentially non-productive erection, disassembly and road transportation time. As a result, the transportability of components and the speed at which components can be assembled with the minimum amount of auxiliary equipment becomes a paramount concern.
[0006] A transportable drilling rig typically includes, for example, a support base, a derrick, pipe sections, and a drill floor Often times however, auxiliary support equipment such as cranes are required to facilitate the setup and takedown of large components such as the base, the drill floor, the pipe racking board, and the like, having the effect of increasing operational costs. Further, drilling sites are often located in remote areas requiring truck transportation of the components of the rig accompanied by equipment used to assemble the rig. In some cases, the process is further complicated by the need to change locations once a hole is drilled and it is determined whether the site will be sufficiently productive to merit a pumping installation, whether the site will be unproductive all together, or whether a more ideal location exists to drill a hole. Typically, site changes can occur once every several months, and, in response, prior art systems have attempted to increase the degree of mobility of rig components. Auxiliary equipment however is still necessary for performing many of the steps involved in assembly and disassembly of the rig.
[0007] Since the variable costs associated with leased support equipment, such as cranes and the like, are calculated on a per hour or per day basis, expediting the takedown, transport, and setup operations is crucial for minimizing equipment leasing costs. Typical takedown and setup time is on the order of days. With equipment leasing costs ranging from several hundred dollars per day or more, many thousands of dollars in costs may be incurred for each end of a setup and takedown operation. For larger or more complex rigs, the cost may be even higher. Even where the prior art drilling rigs are geared towards facilitating rapid setup, takedown and transport, they have still generally required external cranes, external winches, and the like which increase the overall expense.
[0008] A number of factors contributed to the takedown and setup time required by the prior art systems. For example, in the past, disassembly of the drilling rig mast assemblies normally required unstringing and removal of the traveling block cables and traveling block prior to lowering the mast from the drill rig or at least prior to disassembly or telescoping of the mast preparatory to moving on to a new well site. Also, erection of the mast assemblies of the prior art mobile drilling rigs tended to delay start-up of drilling operations since the drill-pipe cannot be moved into a suitable ground position for racking until such time as the mast is raised to the vertical and the pipe racking ground area is cleared. Further, the access road to a drilling rig normally courses directly up to the drawworks side of the rig. Where the intended well site is located on marshy ground, it is normally necessary to expend substantial time and effort in grading and stabilizing a substantial ground area completely around the rig in order to provide access and working area for the necessarily heavy equipment required to move and erect the mast. These are merely intended to be exemplary problems of the type encountered by the prior art, as there were numerous other problems associated with assembly and disassembly of drilling rigs of the type under consideration.
[0009] Although a number of prior art references exist which show purported “portable” or mobile drilling rigs, such devices tended to suffer from one or more deficiencies. One such prior art system for erecting an oil well derrick is shown in U.S. Pat. No. 3,922,825, to Eddy's et al, issued on Dec. 2, 1975. Eddy's system employs a stationary substructure base with a companion movable substructure base mounted thereon. Eddy's movable substructure base is coupled to the stationary base but swings upright into an elevated position on a series of struts that are connected to the stationary base. Eddy's movable base is otherwise stationary, since neither the stationary base nor the “movable” base are mobile or repositionable without the use of an auxiliary crane. Also, simply raising the movable substructure base and the drill mast requires the use of a winch mounted on an auxiliary winch truck.
[0010] Another prior art system for assembly of a drill rig is shown in U.S. Pat. No. 3,942,593, to Reeve, Jr., et al, issued on Mar. 9, 1976. The Reeve apparatus includes a trailerable telescoping mast and a separate sectionable substructure assembly further comprising a rig base, a working floor, and a rail means. The mast is conveyed to the top of the substructure by rollers and may be raised by hydraulic raising means to the upright position. A disadvantage of the Reeve system is the need for drawlines and a winch to raise the mast onto the working floor.
[0011] U.S. Pat. No. 4,269,395, to Newman et al., issued May 26, 1981, shows a portable rig which includes a telescoping mast for telescoping to a reduced length for transport. The mast is also cantilevered in use so that the traveling block moves vertically at one side of the mast.
[0012] U.S. Pat. No. 4,290,495, to Elliston, issued Sep. 22, 1981, shows a portable workover rig with a base platform and a collapsible mast which is movable from a reclining position during transport to an erect position in operation.
[0013] U.S. Pat. No. 4,821,816, to Willis, issued Apr. 18, 1989, shows an “Apache” modular drilling machine. The machine has a substructure skid and a platform which supports a draw works. A pipe boom is mounted on another skid and is designed to fit between skid runners on the drilling substructure skid. The drilling substructure skid supports four legs which are pivotally mounted at the platform and at the substructure. A pair of platform cylinders are provided to raise and lower the drilling platform.
[0014] U.S. Pat. No. 4,899,832, to Biersheid, issued Feb. 13, 1990, shows a modular drilling apparatus that is transported in modular units to the well site. The apparatus includes a drilling unit and two raising units that are locked to the respective opposite sides of the drilling unit. After base structures on the raising units are lowered to the ground to provide a support, the towers of the raising units and the mast of the drilling unit are simultaneously elevated to the vertical.
[0015] U.S. Pat. No. 6,634,436, to Desai, issued Oct. 21, 2003, shows a mobile land drilling rig with a mobile telescoping substructure box which assists in the rapid placement, assembly, disassembly and repositioning of the drilling rig and associated drilling equipment.
[0016] U.S. Pat. No. 6,860,337, to Orr et al., issued Mar. 1, 2005, describes a process for lowering or raising a drilling rig for transportation. The top drive is moved within the mast with a vertical guide and torque reaction mechanism to a locked position prior to transport.
[0017] As has been mentioned, a number of the devices shown in the above described prior art require the need for auxiliary equipment such as cranes, winch trucks and the like to erect the derrick. Several of the systems described above require a large substructure that must be set down with a crane prior to the imposition of any additional structure thereupon. Further movement or repositioning of the base structure requires cranes or other heavy equipment to effect movement of the component parts.
[0018] It is therefore an object of the present invention to provide a mobile land rig that is self sufficient and thus capable of being transported, erected, and disassembled without the need for extensive auxiliary equipment such as cranes and winch trucks. Such a system would save costs associated with leasing cranes and the like for periods of days during erection and disassembly of rigs.
[0019] Another object of the invention is to provide a drilling rig system with a self contained substructure base capable of being easily moved. Such a system would allow rapid placement and repositioning of the substructure base without the need for a crane or the like.
[0020] Another object of the invention is to provide such a drilling system wherein all system components are easily trailerable and transportable by truck. Such a system could be easily moved from one site to another with a minimum of setup and takedown time.
[0021] The above needs and objectives are met in the invention as described in the discussion which follows.
SUMMARY OF THE INVENTION
[0022] It is accordingly a principal object of the present invention to provide an improved mobile drill rig assembly having advantages over the prior art systems described above.
[0023] It is another object of the invention to provide a mobile drill rig assembly which is rapidly erected and dismantled at the well site.
[0024] It is yet another object of the invention to provide a drill rig assembly having good wind stability.
[0025] It is another object of the invention to provide a drill rig assembly including a support base and working floor which is trailerable and which can be rapidly erected to a working height at the well site.
[0026] It is another object of the invention to provide a one piece derrick mast assembly which is itself a trailerable component of the system.
[0027] The drilling rig of the invention is adapted for use in oil, gas and geothermal exploration and drilling operations. In particular, the present invention is a mobile land rig and method for the rapid placement, assembly, disassembly, and repositioning of such an oil and gas drilling rig and associated drilling equipment. The rig includes a variety of drilling rig components including at least a base support structure, a drawworks trailer, a one-piece derrick initially carried on the drawworks trailer, a pipe handler, a mud delivery system and a power package.
[0028] Preferably, the drawworks trailer has at least a rear axle coupled thereto, the axle having at least one set of wheels for supporting both drawworks and the derrick in rolling relation to a ground surface when the derrick is in a horizontal, transport position on the drawworks trailer. A pair of oppositely arranged hydraulic piston-cylinders are located on either of two sides of the drawworks trailer, the cylinders being pivotally connected at one end to the trailer and at an opposite end to the rig derrick, whereby activating the piston-cylinders between a retracted position and an extended position causes the derrick to move between the horizontal, transport position and a vertical, working position. Movement of the derrick from the horizontal, transport position to the vertical, working position serves to off-loading the derrick from the drawworks trailer to the base support structure.
[0029] The pipe handler which is used with the mobile land rig of the invention includes a Y-shaped yoke element with gripping jaws located at either of two opposite extents thereof, the yoke element being positionable between a horizontal pipe receiving position and a vertical pipe delivery position. The pipe handler jaws are sized to handle pipe up to 13⅝ inches in diameter.
[0030] The mobile rig of the invention also preferably includes a stationary ramp having an inclined, upper ramp surface, the ramp being delivered to the drilling site on ground engaging wheels. Driving the drawworks trailer up the inclined surface of the stationary ramp serves to raise one end thereof with respect to an opposite end of the trailer. The opposite end of the trailer is equipped with a hydraulic piston-cylinder for thereafter raising the rear end of the trailer hydraulically so that the derrick forms a horizontal plane with respect to the ground prior to the erection of the derrick.
[0031] The derrick is adapted to receive a top drive drilling apparatus.
[0032] The mud delivery system of the mobile rig of the invention includes at least one mud process tank having a curved tank bottom.
[0033] The rig components also preferably include both a bottom dog house and a top dog house. The top dog house is preferably equipped with at least one hydraulic piston-cylinder for hydraulically raising the dog house and at least one hydraulic piston cylinder to pin and secure the top dog house once raised.
[0034] The improved method for erecting, transporting, and disassembling a drilling rig on the ground from variety of rig components includes, as a first step, rolling the drilling rig components into proximity with a drilling site on ground engaging wheels, where the drilling rig components include at least a base support structure, a drawworks trailer, a one-piece derrick initially carried on the drawworks trailer, a pipe handler, a mud delivery system and a power package. The one-piece derrick is raised from a horizontal, transport position to a vertical, working position while off-loading the derrick from the drawworks trailer to the base support structure. In the preferred method of assembly and disassembly of the invention, the drilling rig components are delivered and assembled without the use of cranes.
[0035] Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a plan view of the assembled drilling rig of the invention showing the various components thereof,
[0037] FIG. 2 is an isolated, perspective view of the pipe handler component of the drilling rig of the invention;
[0038] FIG. 3 is a simplified view of a portion of the draw works trailer of the drilling rig of FIG. 1 showing the drill line spool on the opposite end of the trailer from the draw works;
[0039] FIG. 4 is a view of a portion of the mast of the drilling rig of FIG. 1 showing the integrated top drive, traveling block and components thereof;
[0040] FIG. 5 is an isolated view of the utility boom component of the drilling rig of the invention;
[0041] FIGS. 6-10 illustrate, in simplified fashion, the steps involved in assembling the base support structure and associated components of the drilling rig of FIG. 1 ;
[0042] FIGS. 11-15 are a simplified, schematic representation of the steps involved in erecting the derrick mast structure, showing the loading of the derrick being transferred from the drawworks trailer to the base support substructure of the rig;
[0043] FIG. 16 is top view of the assembled drilling rig of the invention showing the various component parts thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0044] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processes and manufacturing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the invention herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the claimed invention.
[0045] Turning to FIG. 1 of the drawings, there is shown a highly mobile and capable drilling rig that can be assembled and disassembled in record time as compared to the devices of the prior art. In one exemplary form, the total rig transports in just 16 trailer loads, saving time and money. The loads are compact and self-contained. Rig-up is faster than in the prior art and is hydraulically powered. The entire rig is designed to be moved without the use of cranes.
[0046] The mobile drilling rig of the invention is designed to streamline drilling operations with fast moves and more efficient drilling operations. The rig can be used over a broad depth range, i.e., on the order of 6,000 to 12,000 feet. The rig footprint is smaller, which means lower construction costs and less environmental impact or the necessity of extensive site preparation. The pipe handling system is mechanized and safer for rig crews to use, allowing a single operator to make a connection, if necessary.
[0047] The assembled rig, as shown in FIG. 1 , includes a horizontal pipe handler (shown in simplified fashion as 11 in FIGS. 1 , 11 , 15 and 16 ) located adjacent an upper dog house 13 and a lower dog house 15 . Once delivered on site, the upper dog house 13 is raised to a desired height by means of hydraulic cylinder legs 14 , 16 . The pipe handler 11 sits in front of the derrick 17 and the draw works trailer 19 . The pipe handling system includes a hydraulically powered, remotely operated pipe boom (best seen as 47 in FIG. 2 ). A pair of spaced jaws 49 , 51 receive a stand of horizontally stored pipe ( 53 in FIG. 16 ). The boom then pivots at the yoke end ( 55 in FIG. 16 ) between the rest position shown in FIGS. 2 and 16 and a vertical position (not shown) aligned with the derrick for making a pipe connection and inserting the joint of pipe into the string of drill pipe extending into the well bore. The pipe boom can handle tubulars from 2⅞ inches to 13⅝ inches in diameter.
[0048] As will be appreciated from FIG. 2 , the pipe boom 47 of the pipe handler has a series of upright pillars 12 , 14 and 16 , each of which forms a primary structural support for the pivoting tubular section 18 . The tubular, section 18 is pivoted in a horizontal plane as viewed in FIG. 2 by means of the hydraulic cylinders 8 , 10 . The pivoting action orients the gripping jaws 49 , 51 for gripping a stand of pipe located in the horizontal pipe racks ( 53 in FIG. 16 ). Each of the upright pillars 12 , 14 and 16 has an engagement collar ( 20 , 22 , 24 in FIG. 2 ) which can be bolted and unbolted from the top surface of the respective pillar. In this way, the entire pivoting tubular section 18 with its gripping jaws 49 , 51 can be removed and switched out with, for example, a boom having gripping jaws of a different size range for handling a different size of pipe.
[0049] Returning to FIG. 1 , immediately behind the dog houses are located a water tank 21 , a lubrication skid 23 , a hydraulics package 25 , a power unit generator package 27 , and a fuel tank 29 . The tankage provided on site in the form of the water tank 21 and fuel tank 29 comprises, for example, a 285 barrel cylindrical water tank capacity and a 500 barrel cylindrical diesel fuel tank, respectively. The power system can be, for example, a CAT C-15; CAT 455 KW (two each) generators capable of providing continuous output. This diesel engine/generator can individually produce 540 hp of maximum continuous power at a rotation speed of 1200 rpm. The output voltage of the AC generator is 60 Hz, 480 volts.
[0050] In the particular version of the invention illustrated in simplified version in FIG. 1 , the derrick 17 is a one piece mast with integrated top drive (shown in greater detail as 26 in FIG. 4 ). The mast is a single piece 72 foot structure using a split block hoisting on a 1⅛″ drill line. The wire line unit can be, for example, an Oil Works OWI-1000™ holding 12,000′ of 0.092 to 0.108 inch wire. The crown block is an IDS model having a rated capacity of 500,000 SHL. There are 7 vertical sheaves and 1 horizontal sheave. The sheaves in the crown/traveling block have been upgraded from 24 inches to 30 inches. The traveling block is a Cowan Integrated 4-Sheave Split Block™ having a rated capacity of 250 tons. There are 4 sheaves of 30″ diameter, labeled as 28 , 30 , 32 , 24 in FIG. 4 . The derrick has a set of C-shaped front rails ( 18 in FIG. 1 ) to accommodate the travel of the top drive. The top drive can be, for example, a Venture Tech XK-250™ 250 ton drive providing a maximum torque of 24,000 ft/lbs at a maximum speed of 160 RPM. The top drive has a 5,000 psi pressure rating. The dimensions of the exemplary derrick base and crown illustrated are 8′1″ wide×6′ deep.
[0051] As can be best seen in FIG. 4 , the 4 sheave traveling block and top drive 26 have oppositely arranged “bat wings” 36 , 38 which engage the C-shaped rails of the derrick structure and allow the top drive unit to move vertically along the mast. In earlier versions of the drilling rig, the utility lines 40 which extend downwardly from the top drive were found to create an undue load off one side of the mast which affected the travel of the top drive along the mast. As a result, the top portion of the bat wings have now been extended in length from the original three and one half feet to five and one half feet, the extended portion being designated as “1” in FIG. 4 . The extended length of the bat wing improves the load distribution and provides added stability for the top drive as it moves along the derrick mast legs.
[0052] The rig drawworks ( 99 in FIG. 1 ) is comprised of a Rig Tech RT-400B™ powered by a CAT C-15 engine with a rated input power of 540 hp. The drawworks is shown in greater detail in FIG. 3 . The drawworks drum 42 is a 18″×25⅛″ diameter grooved drum supported between bearing assemblies 44 , 46 , and is provided with a disk drum style brake system which provides an auto spool safety feature. The spool arrangement also allows the operator to move the wear points in the drill line 48 by slipping and cutting, e.g., 70-100 feet of line between drilling sessions. The maximum hook load of the assembly with 8 lines is 435,000 lbs. An independent fresh water cooling system is provided for the drawworks and clutch brake, such as the Eaton-Airflex Model RT-BWCS-101™.
[0053] At the derrick base there will be located a conventional make-up/break-out tool (not shown) such as the Gray EOT Floor Hand™, providing up to 80,000 ft/lbs of torque for making and breaking drill pipe connections as well as rig floor pneumatic air slips. The rotary opening of the derrick substructure is approximately 14′8″ above ground level in the exemplary illustrations. The slip bowl capacity is 250 tons with a clearance height below the slip bowl to ground level of 10′6″.
[0054] The additional rig components located in the foreground include a trip tank/choke skid 31 , a mud process skid 33 and a mud mixing skid 35 . The trip tank/choke skid 31 houses a trip tank, choke manifold and mud-gas separator. Mud pump skids 37 and 39 are located adjacent the mud mixing skid 35 A utility swing arm 41 pivots from a support point on the mud process and mixing skid.
[0055] FIG. 5 shows the utility swing arm 41 in greater detail. The swing arm 41 has opposing ends 50 , 52 and an intermediate length. The end 50 pivots about a pivot point 54 located on the mud process skid 35 . The length of the swing arm accommodates a number of different water and electrical lines, generally designated as 56 in FIG. 5 . The swing arm 41 replaces the previous arrangement of utility lines running on the surrounding ground encased in rectangular boxes, moving the lines to an unobtrusive overhead location which improves the safety aspects of the arrangement and eliminates a danger of tripping over the lines. The pivot point 54 allows the swing arm to be pivoted, between the deployed position shown in FIG. 5 , and a retracted or stowed position (not shown) aligned with the side of the mud skid for transport purposes. The opposing end of pivot point 54 also provides a “quick disconnect” point for the swing arm during rig mobilization activities. It can then be stored in the mud tank, if desired.
[0056] The mud pump skids 37 , 39 accommodate either 1,000 hp or optional 1,300 hp triplex pumps and available Caterpillar™ engines, in this case the 3508 and 3512 engines. For example, the mud pumps can be Weatherford MP10™ or MP13™ pumps driven by variable speed diesel engines. The maximum rated working pressure for the mud pumps is 5,000 psi in the example illustrated. The transfer/mixing pumps used on the unit can be, for example, two 5″×6″ W/50 H.P. Electric Motors™ mixing pumps having 11″ impellers that are rated for 80 to 110 gallons per minute flow.
[0057] These pumps are used together with two charging pumps which can be 5″×6″ MCM Pinion Shaft™ designs having an output capacity of 80 to 110 gallons per minute using 11″ impellers. The mud process skid 33 and mud mixing skid 35 feature curved bottom tanks 36 , 38 and together comprise a 700 barrel active, two tank system equipped with conventional shale shakers, a desander and a desilter (not shown).
[0058] The well blow-out preventer (best seen as 45 in FIG. 2 ) can be of conventional design such as, for example, the Townsend Type 90™ 11×5M annular type; or the Townsend Type 82™ 11×5M double ram which is used in conjunction with a M.D. Cowan 2-Rail BOP™ skid trolley.
[0059] Turning now to FIG. 6 of the drawings, there is shown, in simplified fashion, the beginning step in the assembly of the mobile drilling rig of the invention. In FIG. 6 , a semi-trailer rig has delivered and deposited the mixing skid for the process mud system. FIG. 7 shows the similar delivery of the process mud skid 33 which is aligned longitudinally with the mixing skid 35 and joined by an intermediate platform 53 and steps 55 , 57 . FIG. 8 shows the delivered mud pumps 37 , 39 , each being delivered on a skid 59 , 61
[0060] FIG. 9 shows the support base (designated generally as 63 ), drill floor 65 and oppositely arranged side extensions 67 , 69 . The pipe handler (shown in simplified fashion in FIG. 9 ) is also aligned with the well head and the support base and is positioned in a plane generally parallel to but spaced apart from the mixing skid 35 and process skid 33 of the mud system. FIG. 10 shows the side extensions 67 , 69 raised to form a horizontal support surface on either side of the drill floor 65 .
[0061] FIG. 11 shows the rig derrick 17 being delivered atop a drawworks trailer 19 The drawworks trailer is backed up a ramp substrate 71 to a point adjacent the support base 63 . Once the drawworks trailer 19 is backed up the ramp substrate 71 , the trailer cab is removed and the hydraulic legs 73 at the front end of the trailer 19 are actuated to level the front end of the trailer. With the drawworks trailer 19 in position, the rig derrick 17 can then be moved from the horizontal transport position shown in FIG. 11 to the vertical, working position shown in FIG. 12 .
[0062] FIGS. 13-15 illustrate the off-loading of the rig derrick 17 from the drawworks trailer 19 in simplified, schematic fashion. As shown in FIG. 13 , the derrick 17 is pivotally mounted on the drawworks trailer 19 by means of a pair of oppositely arranged hydraulic piston cylinders ( 75 , 77 in FIG. 12 ). Each piston cylinder, e.g., cylinder 75 in FIG. 13 is attached at opposing pivot points 79 , 81 . Movement of each piston cylinder 75 , 77 from the retracted position shown in FIG. 13 to the fully extended position (the intermediate position being shown in FIG. 15 ) causes the rig derrick 17 to be raised from the horizontal transport position to the vertical position shown in FIGS. 1 and 15 . This movement of the hydraulic piston cylinders 75 , 77 also causes the load of the derrick to be shifted off the drawworks trailer 19 and onto the support base substructure 63 of the drilling rig. While the hydraulic piston cylinders 75 , 77 might not actually be physically detached, as shown in FIG. 15 , this figure is intended to illustrate the point that the rig weight now resides on the support base 63 , rather than upon the drawworks trailer 19 , including its axles and tires 83 . Note the force vector “F” in FIG. 15 showing the direction of the weight of the drilling rig once the derrick 17 is in the fully erect position.
[0063] FIG. 16 is a top view of the fully assembly drilling rig showing the relative position of the various component parts of the rig.
[0064] Thus, the improved method for erecting, transporting and disassembling a drilling rig on the ground from variety of rig components includes, as a first step, rolling the drilling rig components into proximity with a drilling site on ground engaging wheels, where the drilling rig components include at least a base support structure, a drawworks trailer, a one-piece derrick initially carried on the drawworks trailer, a pipe handler, a mud delivery system and a power package. The one-piece derrick is raised from a horizontal, transport position to a vertical, working position while off-loading the derrick from the drawworks trailer to the base support structure. In the preferred method of assembly and disassembly of the invention, the drilling rig components are delivered and assembled without the use of cranes.
[0065] An invention has been provided with several advantages. As will be appreciated from the foregoing, the mobile rig of the invention is self sufficient in the sense that it is capable of being transported, erected, and disassembled without the need for large and extensive auxiliary equipment such as cranes. This results in a cost savings in eliminating the need for leasing cranes or other expensive erection equipment for periods of days during erection and disassembly of the rig. The rig is made up of components which are easily trailerable and transportable by tractor-trailer. As a result, the entire system can be easily moved from one site to another with a minimum of setup and takedown time. The drawworks trailer which initially transports the rig derrick is driven up a stationary ramp and leveled by means of hydraulic cylinders on the front end of the trailer. Another set of hydraulic piston-cylinders then moves the one-piece derrick from the horizontal, transport position to the vertical, working position where it is off-loaded onto the support base for the rig. This completely removes the vertical load from the drawworks trailer and places it on the more permanent and stationary support base of the rig.
[0066] While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
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A highly mobile and capable oil, gas and geothermal well drilling rig is shown which provides for the rapid placement, assembly, disassembly, and repositioning of various rig components of the drilling rig The drilling rig includes a support base and working floor which is trailerable and which can be rapidly erected to a working height at the well site. A special drawworks trailer both transports the drawworks and the rig derrick. Hydraulic cylinders on the drawworks trailer are used to move the derrick from a horizontal, transport position to a vertical, working position. At the same time, the weight of the derrick is off-loaded from the drawworks trailer to the base support structure. The selection and arrangement of the various rig components provides a faster set up and take down operation than was previously obtained.
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BACKGROUND
The invention relates generally to watertight and airtight seals and, more particularly, to a sealing device for use at the interface of a bulkhead door assembly and a concrete foundation wall.
Basement or cellar doors have a long history of use for providing means for accessing a basement or cellar of a dwelling structure from the outside by way of a set of stairs. Since these basement or cellar spaces beneath the dwelling structure are located wholly or partly below ground level, they were usually damp and seldom occupied as living spaces. As such, there was generally not a requirement for eliminating air and water seepage around the edges of the door or where the door attached to the foundation wall of the dwelling structure.
Through the use of modem construction techniques, basements have been made more habitable by eliminating moisture incursion from the surrounding soil and reducing the loss of heat. This improvement enabled the use of basement spaces for additional living space, and typically provided for bedrooms and recreation areas. Furthermore, it is very economical to finish off these spaces. These “finished” basement spaces are normally accessed from the inside of the dwelling. However, most state building codes require that a second means of egress be provided from a basement in case of a fire. Today, approximately 90% of new homes built with a basement have bulkheads that are covered by a bulkhead door assembly. These bulkhead door assemblies are usually fabricated from sheet metal and have flanges that are between 1¼ and 1½ inches wide for attaching the door assemblies to a top of a foundation wall.
Bulkhead door assemblies are prone to air and water leaks into the basements they are supposed to protect. The air and moisture causes damage to the door assembly and to the framing and structure of the house to which it is attached. The resulting problems include mold, mildew, and decay of the insulation and wood framing, as well as rust deterioration to the bulkhead door assembly itself. These problems often result from the manner in which the bulkhead door assembly is affixed to a foundation wall. The metal bulkhead door assembly is attached directly to the top of a concrete foundation wall by an attaching flange and is usually bolted down tight. The typical residential foundation wall is 10 inches thick, with about 6½ inches of level concrete wall top exposed to weather on the outside of the door assembly. Because the top of the foundation wall is flat or concave, when it rains, the water sits on the top of the wall and wicks between the concrete and the metal bulkhead door assembly into the basement. Driving rain further enhances the water leakage, which usually occurs more on the front section than on the sides of the door assembly.
It is possible to partly solve the problem of water leakage around a bulkhead door assembly by sloping the top of the concrete wall away from the bulkhead mounting flange so that water would tend to drain off the top of the foundation wall. This is not a common practice because of the difficulty and expense of providing the slope at the desired location. Another proposed solution to the leakage problem is to apply a sealant, such as silicone, to the edges of the bulkhead door assembly attaching flange to prevent air and water leakage. This solution is only temporary because the metal door attaching flange expands and contracts with temperature excursions while the foundation wall retains essentially constant dimensions. This movement eventually causes the sealant to pull away from the metal attaching flange, creating a void in the interface allowing water and air to enter. The problem is compounded in colder climates where the water that has entered freezes, causing the void in the sealant to enlarge and allow more air and water to enter. Another problem is that the top of the concrete foundation wall is uneven and not perfectly straight and level. Thus, when the flat metal of the attaching flange is placed over the uneven concrete surface, there are numerous voids between the metal flange and the concrete. These voids allow water and air to enter into the inside of the bulkhead door assembly. Therefore, the leakage problem associated with basement door assemblies has become an important issue in finished basement spaces in modem house construction.
For the foregoing reasons, there is a need, therefore for a sealing device that allows a means for effectively sealing the interface between the mounting flange of a bulkhead door assembly and the top of a concrete foundation wall to which it is attached, in order to prevent air and water from intruding into basement spaces. This device must be inexpensive to manufacture, and must be capable of being easily installed at the construction site.
SUMMARY
The present invention is directed to a device that satisfies these needs. The present invention provides for a sealing device that allows a means for effectively sealing the interface between the mounting flange of a bulkhead door assembly and the top of a concrete foundation wall to which it is attached, in order to prevent air and water from intruding into basement spaces. This device is inexpensive to manufacture, and is capable of being easily installed at the construction site.
The present invention is a manufactured sealing strip made from a flexible material, like silicone or neoprene rubber, that is very durable in all types of climates and will not break down over time. It is positioned between the bulkhead door assembly mounting flange and the top of the concrete foundation wall. The device is configured to have a cross section that may have an inner lip so that driving rain will not enter the interior of the bulkhead door assembly, a flat portion on which the metal bulkhead door mounting flange can be positioned, and a sloping surface on the outside of the door assembly to shed water off the top of the concrete wall. The device is manufactured in straight strips and can be cut at the building site to custom fit any bulkhead and door assembly. It is not only capable of providing an air tight and water tight seal when fastened down to the top of the foundation wall, but it also sheds water due to the external sloping configuration.
A device having features of the present invention comprises an elongated strip of semi-flexible material having a top surface, a bottom surface, and a thickness, the bottom surface being substantially flat for being adhesively attached to a top of a concrete foundation wall, the top surface having a shape for mating with a side bottom flange and a front channel of a bulkhead door assembly, and the thickness being compressed when the side bottom flange and the front channel is secured by an attachment means to the foundation wall. The elongated strip may be cut to predetermined lengths to match the perimeter dimensions of the side bottom flanges and the front channel of the bulkhead door assembly. Mitered comers may be formed where cut ends of the elongated strips meet at right angles. The formed mitered comers may be sealed with an seal adhesive. The elongated strip may have a width dimension that is substantially less than a width dimension of the foundation wall. The elongated strip may have a width dimension that is approximately equal to a width dimension of the foundation wall. The elongated strip may have a width dimension that is greater than a width dimension of the foundation wall for providing a drip edge that extends beyond the edge of the foundation wall. The adhesive attachment of the bottom surface to the top of the foundation wall may form an airtight and watertight seal. The top surface may have a flat surface for mating with the side bottom flange and the front channel of the bulkhead door assembly. The top surface may be flexibly mated with the side bottom flange and the front channel of the bulkhead door assembly. The mating of the side bottom flange and the front channel may form an airtight and a watertight seal. The shape of the top surface may include a vertical lip interior to the side bottom flange and front channel for blocking moisture seepage. The shape of the top surface may include a downward sloping surface exterior to the side bottom flange and front channel for draining moisture away from the bulkhead door assembly. The top surface for mating with the side bottom flange and the front channel may be recessed from the top of the downward sloping surface. The attachment means may be an expansion bolt.
In an alternate embodiment of the invention, a seal for a bulkhead door assembly comprises an elongated strip of semi-flexible material having a top surface, at least one side surface, a bottom surface, and a thickness, the top surface and side surface comprising a hard outer shell of the elongated strip, the interior and bottom surface of the elongated strip comprising a soft inner material, the top surface having a shape for mating with a side bottom flange and a front channel of a bulkhead door assembly, the bottom surface being substantially flat for being adhesively attached to a top of a concrete foundation wall, and the thickness being compressed when the side bottom flange and the front channel is secured by an attachment means to the foundation wall. The elongated strip may have a width dimension that is approximately equal to a width dimension of the foundation wall. The elongated strip may have a width dimension that is greater than a width dimension of the foundation wall for providing a drip edge that extends beyond the edge of the foundation wall. The adhesive attachment of the bottom surface to the top of the foundation wall may form an airtight and watertight seal. The top surface may have a flat surface for mating with the side bottom flange and the front channel of the bulkhead door assembly. The mating of the side bottom flange and the front channel may form an airtight and a watertight seal. The shape of the top surface may include a vertical lip interior to the side bottom flange and front channel for blocking moisture seepage. The shape of the top surface may include a downward sloping surface exterior to the side bottom flange and front channel for draining moisture away from the bulkhead door assembly. The top surface for mating with the side bottom flange and the front channel may be recessed from the top of the downward sloping surface.
In an alternate embodiment of the invention, a method for installing a seal for a bulkhead door assembly comprises cleaning a top of a concrete foundation wall, applying an adhesive to the top of the foundation wall, positioning a flat bottom of precut lengths of a bulkhead door seal on the adhesive, mounting a bulkhead door assembly on a top of the precut lengths of the bulkhead door seal, the top having a mounting surface for accepting the bulkhead door assembly, and securing the bulkhead door assembly to the foundation wall by attachment means. The precut length of the bulkhead door seal may be formed by measuring the concrete wall length dimension and cutting the door seal to the length dimension. The comer ends of the precut lengths of bulkhead door seal may be mitered and sealed to form a water tight connection. The method may further comprise providing comer adhesive strips for tighter comer connections between the ends of the precut lengths of bulkhead door seal. The attachment means may comprise forming holes in the seal and concrete wall at predetermined locations, and installing expansion bolts to compress the bulkhead door seal to form an airtight and watertight seal.
The present invention provides for a sealing device that allows a means for effectively sealing the interface between the mounting flange of a bulkhead door assembly and the top of a concrete foundation wall to which it is attached, in order to prevent air and water from intruding into basement spaces. This device is inexpensive to manufacture, and is capable of being easily installed at the construction site.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 shows an installation of a bulkhead door assembly attached to a concrete foundation wall that is typical of the existing building arts;
FIG. 2 A through FIG. 2C show sectional views of the attachment of bulkhead door assemblies to a concrete foundation wall that is typical of the existing building arts;
FIG. 3 A through FIG. 3C show sectional views of the attachment of bulkhead door assemblies to a concrete foundation wall that illustrates embodiments of the present invention;
FIG. 4 shows a partial view of a comer of a bulkhead door assembly mounted to a concrete foundation wall using existing techniques;
FIG. 5 shows a partial view of a comer of a bulkhead door assembly mounted to a concrete foundation wall using embodiments of the present invention;
FIG. 6 A through FIG. 6L show some cross-sectional variations of an embodiment of the present invention;
FIG. 7 A through FIG. 7F show some cross-sectional variations of another embodiment of the present invention; and
FIG. 8 A through FIG. 8C show the steps of installing a bulkhead door assembly on a concrete foundation wall using embodiment of the present invention.
DETAILED DESCRIPTION
Turning now to FIG. 1, FIG. 1 shows an installation 10 of a bulkhead door assembly 200 attached to a concrete foundation wall 100 that is typical of the existing building arts. The bulkhead door assembly 200 is usually fabricated of sheet steel and comprises a left side 210 , a top side 270 and a right side 220 . The top side 270 slopes downward to a top front 272 , and has a left door 240 and a right door 250 rotatably attached to it by hinges positioned towards the sides 210 , 220 . The left door 240 and the right door 250 are shown in the closed position. The left door 240 has a left door front 242 and the right door 250 has a right door front 252 . The foundation wall 100 comprises a left wall 110 , a front wall 130 , and a right wall 120 .
Turning now to FIG. 2 A through FIG. 2C, FIG. 2 A through FIG. 2C show sectional views of the attachment of bulkhead door assemblies to a concrete foundation wall that is typical of the existing building arts. FIG. 2A illustrates the right side 220 and the door 250 of the bulkhead door assembly 200 shown in FIG. 1. A side bottom flange 226 is provided for attaching the bulkhead door assembly to the foundation wall 120 . The right side 220 of the door assembly is attached to the right foundation wall 120 by bolts 222 through the side bottom flange 226 located internal to the door assembly. The bulkhead door assembly left side is similarly attached to the left foundation wall. FIG. 2B illustrates the right side 224 , the side bottom flange 226 and door 250 of another type of bulkhead door assembly that has attachment means external to the bulkhead door assembly. The right side 224 is attached to the right foundation wall 120 by bolts 222 through the side bottom flange 226 located external to the door assembly. The bulkhead door assembly left side is similarly attached to the left foundation wall. FIG. 2C illustrates the front part of a bulkhead door assembly. A front channel 280 that connects the left side to the right side of the door assembly is attached to the front foundation wall 130 by bolts 222 . Also illustrated in FIG. 2C is a partial section of the right door front 252 shown in the closed position.
Turning now to FIG. 3 A through FIG. 3C, FIG. 3 A through FIG. 3C show sectional views of the attachment of bulkhead door assemblies to a concrete foundation wall that illustrates embodiments of the present invention. The sectional views show the right side bulkhead seal 320 and the front bulkhead seal 330 shaped so that there is an inside vertical lip 321 , a flat attaching surface 322 and outside slope 323 . FIG. 3A illustrates the right side 220 and the door 250 of the bulkhead door assembly 200 shown in FIG. 1. A side bottom flange 226 is provided for attaching the bulkhead door assembly to the foundation wall 120 . Positioned between the bulkhead door assembly right side 220 and the right foundation wall 120 is a right bulkhead seal 320 , a preferred embodiment of the present invention. The right bulkhead seal 320 is attached to the top of the foundation right wall 120 with an adhesive so that this interface is both airtight and water tight. The right side 220 of the door assembly is attached to the right foundation wall 120 by bolts 222 through the side bottom flange 226 , located internal to the door assembly and that extend through the bulkhead seal 320 into the foundation wall 120 . Because of the slope of the bulkhead seal 320 causes water to drain off the bulkhead seal 320 , and the bolts 222 cause a tight fit between the door assembly right side 220 and the bulkhead seal 320 , this interface is also airtight and watertight. The bulkhead door assembly left side is similarly attached to the left foundation wall through a bulkhead seal. FIG. 3B illustrates the right side 224 and door 250 of another type of bulkhead door assembly that has attachment means external to the bulkhead door assembly. Positioned between the bulkhead door assembly right side 224 and the right foundation wall 120 is a right bulkhead seal 320 , a preferred embodiment of the present invention. The right bulkhead seal 320 is attached to the top of the foundation right wall 120 with an adhesive so that this interface is both airtight and watertight. The right side 224 of the door assembly is attached to the right foundation wall 120 by bolts 222 through the side bottom flange 226 , located external to the door assembly and that extend through the bulkhead seal into the side foundation wall 120 . Because of the slope of the bulkhead seal 320 causes water to drain off the bulkhead seal 320 , and the bolts 222 cause a tight fit between the door assembly right side 224 and the bulkhead seal 320 , this interface is also airtight and watertight. The bulkhead door assembly left side is similarly attached to the left foundation wall. FIG. 3C illustrates the front part of a bulkhead door assembly. A front channel 280 of the bulkhead door assembly connects the left side to the right side of the door assembly. Positioned between the front channel 280 and the front foundation wall 130 is a front bulkhead seal 330 , a preferred embodiment of the present invention. The front bulkhead seal 330 is attached to the top of the foundation front wall 130 with an adhesive so that the interface is airtight and watertight. The front channel 280 is attached to the front foundation wall by bolts 222 that extend through the front bulkhead seal 330 into the front foundation wall 130 . Because of the slope of the bulkhead seal 330 and the tight fit between the bulkhead seal 330 and the front channel 280 , this interface is also airtight and watertight. Also illustrated in FIG. 3C is a partial section of the right door front 252 shown in the closed position.
Turning now to FIG. 4, FIG. 4 shows a partial view of a comer of a bulkhead door assembly with doors in a closed position and mounted to a concrete foundation wall using existing techniques. Illustrated in FIG. 4 is a left foundation wall 110 and a front foundation wall 130 . The parts of the bulkhead door assembly illustrated in FIG. 4 include the left side 210 , the top side 270 , the top front 272 , the left door 240 , and the left door front 242 .
Turning now to FIG. 5, FIG. 5 shows a partial view of a comer of a bulkhead door assembly mounted to a concrete foundation wall using embodiments of the present invention. Although these figures depict the right side of a bulkhead door assembly, the left side and front are similarly attached using the same bulkhead seal configuration. FIG. 5 illustrates a left bulkhead seal 310 attached to a left foundation wall 110 with an adhesive and a front bulkhead seal 330 attached to a front foundation wall with an adhesive. The door assembly left side 210 and the top front 272 are attached to the foundation left wall 110 and the foundation front wall 130 , respectively, by bolts that are located internal to the door assembly and that extend through the bulkhead left seal 310 and front seal 330 into the foundation left wall 110 and front wall 130 . The left seal 310 and the front seal 330 have been mitered at a 45° angle and attached together with a sealing adhesive at the comer 340 . The right side of the bulkhead door assembly is similarly attached to the right foundation wall through a bulkhead seal.
Turning now to FIG. 6 A through FIG. 6L, FIG. 6 A through FIG. 6L show some cross-sectional variations of an embodiment of the present invention. All of the figures depict a sectional view of a right side 220 of a bulkhead door assembly attached through a bulkhead seal to the top of a concrete foundation wall 120 by bolts 222 through the side bottom flange 226 . FIG. 6A shows a bulkhead seal 400 that completely covers the top of the foundation wall 120 and has an interior lip 401 , a downward sloping exterior surface 403 , and a flat mounting surface 402 recessed below the interior vertical lip 401 and the exterior surface 403 . FIG. 6B shows a bulkhead seal 405 that completely covers the top of the foundation wall 120 and has a downward sloping exterior surface 407 and a flat mounting surface 406 below recessed below a top of the sloping surface 405 . FIG. 6C shows a bulkhead seal 410 that completely covers the top of the foundation wall 120 and has a flat top mounting surface 411 , and a downward sloping exterior surface 412 . FIG. 6D shows a bulkhead seal 415 that completely covers the top of the foundation wall 120 and has an interior vertical lip 416 , a downward sloping exterior surface 418 , a flat mounting surface 417 recessed below the top of the lip 416 and the top of the sloping surface 418 , and an exterior lip 419 that extends beyond the edge of the foundation wall 120 . The exterior lip 419 forms a drip edge to keep moisture away from the foundation wall 120 . FIG. 6E shows a bulkhead seal 420 that completely covers the top of the foundation wall 120 and has an interior vertical lip 421 , a downward sloping exterior surface 423 , a flat mounting surface 422 recessed below the top of the lip 4211 and an exterior lip 424 that extends beyond the edge of the foundation wall 120 . The exterior lip 424 forms a drip edge to keep moisture away from the foundation wall 120 . FIG. 6F shows a bulkhead seal 425 that completely covers the top of the foundation wall 120 and has an interior vertical lip 426 , a rounded downward sloping exterior surface 428 , and a flat mounting surface 427 recessed below the top of the interior lip 426 and the top of the exterior surface 428 . FIG. 6G shows a bulkhead seal 430 that partially covers the top of the foundation wall 120 and has an interior vertical lip 431 , a rounded downward sloping exterior surface 433 , and a flat mounting surface 432 recessed below the interior lip 431 and the top of the exterior surface 433 . FIG. 6H shows a bulkhead seal 435 that completely covers the top of the foundation wall 120 and has a rounded downward sloping exterior surface 437 , a flat mounting surface 436 recessed below the top of the exterior surface 437 , and an exterior lip 438 extending beyond the edge of the foundation wall 120 . The exterior lip 438 forms a drip edge to keep moisture away from the foundation wall 120 . FIG. 6I shows a bulkhead seal 440 that partially covers the top of the foundation wall 120 and has an interior vertical lip 441 and a flat mounting surface 442 recessed below the interior lip 441 that extends outward from the bulkhead door assembly right side 220 . FIG. 6J shows a bulkhead seal 445 that partially covers the top of the foundation wall 120 and has a rectangular cross-section, a flat interior surface 446 , a flat exterior surface 448 , and a flat mounting surface 447 that is coplanar with the interior surface 446 and the exterior surface 448 . FIG. 6K shows a bulkhead seal 450 that partially covers the top of the foundation wall 120 and has an flat interior and mounting surface 451 , and a downward sloping exterior surface 452 . FIG. 6L shows a bulkhead seal 455 that partially covers the top of the foundation wall 120 and has an rounded downward sloping interior vertical lip 456 , a rounded downward sloping exterior surface 458 , and a flat mounting surface 457 recessed below the top of the interior lip 456 and the top of the exterior surface 458 . There are many other cross-sectional configurations that may vary from those depicted, but that, nevertheless, fall within the scope of the present invention.
Turning now to FIG. 7 A through FIG. 7F, FIG. 7 A through FIG. 7F show some cross-sectional variations of another embodiment of the present invention. This embodiment includes a bulkhead seal that comprises a hard outer shell and a softer inner gasket material. Although these figures depict the right side of a bulkhead door assembly, the left side and front are similarly attached using the same bulkhead seal configuration. FIG. 7A shows a bulkhead seal 500 that completely covers the top of the foundation wall 120 and has a hard outer shell 502 and a softer inner gasket material 501 . The hard outer shell 502 may be a vinyl material and the inner gasket material 501 may be neoprene. The cross-sectional shape of the bulkhead seal 500 has an interior vertical lip 503 , a flat mounting surface 504 recessed below the top of the interior lip 503 for attaching a bulkhead door assembly right side 220 with bolts 222 through the side bottom flange 226 , and a downward sloping exterior surface 505 . FIG. 7B shows a bulkhead seal 510 that completely covers the top of the foundation wall 120 and has a hard outer shell 512 and a softer inner gasket material 511 . The cross-sectional shape of the bulkhead seal 510 has a downward sloping exterior surface 514 and a flat mounting surface 513 recessed below the top of the exterior surface for attaching a bulkhead door assembly right side 220 with bolts 222 . FIG. 7C shows a bulkhead seal 520 that completely covers the top of the foundation wall 120 and has a hard outer shell 522 and a softer inner gasket material 521 . The cross-sectional shape of the bulkhead seal 520 has a flat mounting surface 523 for attaching a bulkhead door assembly right side 220 with bolts 222 , and a downward sloping exterior surface 524 . FIG. 7D shows a bulkhead seal 530 that completely covers the top of the foundation wall 120 and has a hard outer shell 532 and a softer inner gasket material 531 . The cross-sectional shape of the bulkhead seal 530 has a continuous donwward sloping top surface 533 that provides an sloping interior surface, a sloping mounting surface for attaching a bulkhead door assembly right side 220 with bolts 222 , and a sloping exterior surface. FIG. 7E shows a bulkhead seal 540 that completely covers the top of the foundation wall 120 and has a hard outer shell 542 and a softer inner gasket material 651 . The cross-sectional shape of the bulkhead seal 540 has a flat top surface 543 that provides a flat interior surface, a flat mounting surface for attaching a bulkhead door assembly right side 220 with bolts 222 , and a flat exterior surface. FIG. 7F shows a bulkhead seal 550 that completely covers the top of the foundation wall 120 and has a hard outer shell 552 and a softer inner gasket material 551 . The cross-sectional shape of the bulkhead seal 550 has a rounded, downward sloping interior lip 553 , a float mounting surface 554 for attaching a bulkhead door assembly right side 220 worth bolts 222 , and a downward sloping exterior surface 555 . There are many other cross-sectional configurations that may vary from those depicted, but that, nevertheless, fall within the scope of the present invention.
Turning now to FIG. 8 A through FIG. 8C, FIG. 8 A through FIG. 8C show the steps of installing a bulkhead door assembly on a concrete foundation wall using embodiments of the present invention. FIG. 8A shows a section of a concrete foundation wall 100 for providing access to a basement of a building. An opening in the foundation wall 150 that supports the building is enclosed by a left foundation wall 110 a front foundation wall 130 , and a right foundation wall 120 . A stairway is normally mounted within space enclosed by these foundation walls to provide access to the basement. The tops of the foundation walls 110 , 120 , 130 are cleaned and an adhesive 160 is spread evenly over the top surfaces. FIG. 8B shows a left bulkhead seal 310 attached to the top of the left foundation wall 110 with adhesive 160 , a right bulkhead seal 320 attached to the top of the right foundation wall 120 with adhesive 160 , and a front bulkhead seal 330 attached to the top of the front foundation wall 130 with adhesive 160 . Prior to attachment to the foundation walls, the bulkhead seals are delivered to the construction site in the form of long strips. After measuring the length dimension of the tops of the left foundation wall 110 , the right foundation wall 120 , and the front foundation wall 130 , the bulkhead seal strips are cut to appropriate length, mitered at a 45° angle at the comer positions, and positioned on the adhesive 160 on the tops of the foundation walls, as shown in FIG. 8 B. Comer adhesive strips 170 positioned at the comers on top of the foundation walls prior to installing the bulkhead seals provide tighter comer connection between the mitered comers of the bulkhead seals. FIG. 8C shows a bulkhead door assembly 200 installed over the bulkhead seals 310 , 320 , 330 . The mitered comers 340 are sealed with an adhesive to provide an airtight and watertight connection. Bolt holes are drilled through the bulkhead seals and into the foundation wall tops at predetermined hole positions in the bulkhead door front and sides, and expansion bolts are installed to secure the bulkhead door assembly 200 tightly to the foundation wall 100 . This provides an airtight and watertight seal between the bulkhead door assembly 200 and the foundation wall 100 .
Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, other embodiments are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments herein.
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A bulkhead door seal is a sealing device that provides effective sealing of the interface between a bulkhead door assembly and a top of a concrete foundation wall to which it is attached. It prevents air and water from intruding into basement spaces around the bulkhead door assembly. The present invention is made of a flexible material that is very durable in all types of climates and will not break down over time. It is positioned between the bulkhead door assembly mounting flange and the top of the foundation wall. It may be configured with an inner vertical lip so that driving rain will not enter the interior of the door assembly, a flat mounting surface to accept a door assembly mounting flange, and a sloping exterior surface to shed water off the foundation wall. The device may be manufactured in strips that are cut on the building site to custom fit the bulkhead and door assembly.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, in general, to atomizers and, in particular, to a new and useful dual-fluid atomizer having a unique single exit orifice and replaceable wear materials.
2. Description of the Related Art
Generally, there are many types of atomizers that have been developed in order to atomize a fluid medium into a mist of fine particle size. Most atomizer designs are classified in one of the following categories: 1) hydraulic or mechanical atomizers wherein atomization is accomplished by discharging a fluid at high pressure through an orifice; 2) dynamic atomizers such as a high speed rotary disk or cup; and 3) dual-fluid atomizers in which fluid atomization is achieved by combining a liquid with a compressed gas such as air or steam.
Dual-fluid atomizers are further subdivided into two basic types, depending on the location where the atomizing gas and liquid are mixed, i.e. external to the atomizer or internal to the atomizer. With external mix dual-fluid atomizers, the gas and liquid streams are mixed external to the atomizer housing by impinging one jet against the other. With internal mix dual-fluid atomizers, the atomizing gas and liquid streams are mixed internal to the atomizer and discharged through single or multiple exit orifices.
For erosive applications where particle-laden liquids, i.e. slurries, are the atomized fluid, the type of atomizer is limited by practical constraints. These constraints include flow capacity, the required size of droplets in the atomized spray (i.e. particle size distribution), the size of internal flow passages, the physical durability of the atomizer components (i.e. service life), the atomizers sensitivity with respect to the degradation of performance due to dimensional change caused by the corrosive and/or erosive nature of the fluid to be atomized, and commercially acceptable energy requirements to produce the atomized spray.
There are many different internal mix dual-fluid atomizers that have been developed. U.S. Pat. Nos. 4,819,878 and 5,129,583 disclose two types of dual-fluid atomizers which are currently used.
SUMMARY OF THE INVENTION
The present invention is an extended wear life, low pressure drop, right angle, single exit orifice dual-fluid atomizer which utilizes replaceable wear materials. The unique arrangement of the present invention includes large size internal flow passages which allow for the passage of grit or other relatively large particles without clogging and at the same time produces fine atomization of the liquid fraction. The present invention also facilitates the use of corrosion/erosion resistant materials which fully line the internal wetted surfaces of the atomizer for extending the useful wear life of the atomizer while simultaneously reducing overall operating and maintenance requirements.
The present invention utilizes a gas such as compressed air or steam as the atomizing medium to produce a homogeneous mixture of finely atomized liquid droplets containing a uniform dispersion of solids. Where a liquid is not utilized, the present invention produces a fine distribution of powder particles.
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 drawing and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is a sectional view of a dual-fluid atomizer according to the present invention; and
FIG. 2 is an enlarged sectional view of the atomizer head and outlet.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention, as illustrated in FIG. 1, is a dual-fluid atomizer, generally designated 5, comprising an outer barrel 10 having an inner barrel 12 disposed therein and defining an annular space 11 therebetween. The inner barrel 12 has a port or opening 14 at one end for the entry of a slurry, solution, liquid or dry powder flow 6. The outer barrel 10 has an opening 16 for a gas, air, fluid or steam flow 8 which flows through annulus 11. The outer barrel 10 and the inner barrel 12 are connected to a mix chamber housing 18 of an atomizer housing 30. The outer barrel 10 and the inner barrel 12 are connected to the chamber housing 18 at their ends opposite openings 16 and 14, respectively. When the present invention is used in a preferred embodiment for atomizing a slurry, chamber housing 18 has an opening 15 which permits the entry of the slurry flow 6 into a primary mix chamber wear sleeve 22 and a secondary mix chamber wear sleeve 24 of the chamber housing 18. Adaptor coupling 26 secures the atomizer housing 30, the mix chamber housing 18 and outer barrel 10 and inner barrel 12.
Inner barrel 12 directs the slurry 6 at low velocities to the inlet of the primary mix chamber wear sleeve 22 where it is initially mixed with atomizing gas 8 provided by outer barrel 10 which enters the chamber 18 through gas ports 20 in the primary mix chamber wear sleeve 22.
In the primary mix chamber wear sleeve 22 of the chamber housing 18, a three-phase homogeneous mixture of gas, liquid and solid particles flow therethrough and into the secondary mix chamber wear sleeve 24 wherein it impacts a wear plug 32 located at one end of the secondary mix chamber wear sleeve 24 within the atomizer housing 30. Sleeves 22 and 24 along with wear plug 32 make up the wear-resistant material for the device, suitable wear-resistant material includes ceramic material. The homogeneous mixture is then directed to an inlet 28 of an orifice 34 in the atomizer housing 30 for eventual exit as a jet through outlet 38 of the orifice 34. Outlet 38 is provided through an end cap 36 which is provided on the atomizer housing 30.
The atomizer 5 secures the outer barrel 10 to the inner barrel 12 at an end opposite the atomizer housing 30 through the use of packing 40, a follower ring 42, a packing gland 44 and a packing gland nut 46.
The impact of the three-phase mixture of gas, liquid, and solid particles into the surface of the wear plug 32 results in the further break-up of liquid droplets and any agglomerated solid particles therein, ensuring complete homogenization of the three-phase mixture. Immediately following impact into the surface of the wear plug 32, the three-phase mixture turns 90 degrees and exits the secondary mix chamber wear sleeve 24 through port 28 where it is directed into the exit orifice 34. The three-phase mixture is then expanded through the exit orifice 34 causing the liquid phase to be atomized into a fine mist with a homogeneous distribution of solids particles as it exits at outlet 38.
Oversized particles that are contained in the slurry 6, from whatever source, are able to flow through the large atomizer ports 28 and 38 without obstruction. The large ports 28 and 38 also allow for low internal velocities, thereby minimizing both internal pressure losses and erosion. The configuration of the atomizer 5 facilitates the use of corrosion/erosion resistant materials, especially for the exit orifice 34 where velocities cannot be held below the threshold of erosion.
The wetted surfaces of the known internal mix dual-fluid atomizers are subjected to an extremely harsh operating environment due to the turbulent conditions created internally beginning at entry point where the atomizing gas and liquid or slurry are first combined together and ending at exit points for discharge. The operating pressure versus flow relationship and atomization performance characteristics of the dual-fluid atomizers are affected by dimensional changes of the internal wetted surfaces. As the wetted surfaces wear, especially the inner diameter of the discharge or exit orifice, atomization quality typically deteriorates to the point where process operations may be adversely effected, thus necessitating atomizer replacement. Furthermore, excessive internal wear may occur to the point of catastrophic atomizer failure.
Until now, the use of corrosion/erosion resistant materials to protect the wetted surfaces of internal mix dual-fluid atomizers for the purpose of extending the useful wear life while simultaneously reducing overall operating and maintenance requirements has been limited by design and/or manufacturing costs/considerations.
The present invention permits the use of replaceable corrosion/erosion resistant wear components manufactured in the form of simple shapes which are used to fully line the internal wetted surfaces of the right angle, single exit orifice dual-fluid atomizer 5 in order to extend its useful life while simultaneously reducing overall operating and maintenance requirements.
The manufacture and machining of many corrosion/erosion resistant materials such as certain alloys and ceramics can be very costly. By limiting the configuration of the mix chamber 18, exit orifice 34 and wear plug inserts 32 to that of simple cylindrical and disc shapes, not only can 100% lining of the internal wetted surfaces from the initial mix point to the point of discharge be achieved but also the difficulty and associated high costs to manufacture these components can be minimized.
The useful service life of the exit orifice insert 34 is significantly increased over that of the known designs through the addition of a straight section 35 located immediately downstream of inwardly tapered inlet end 33 of the exit orifice insert 34. The major advantage of the addition of the straight section 35 immediately downstream of the inwardly tapered inlet 33 over that of the known designs are improved wear characteristics resulting in an increase in the useful service life of the atomizer 5. With the known configurations, once the minor inner diameter (i.e. the point where the inwardly tapering inlet and the outwardly tapering outlet begins) of the exit orifice increases in diameter due to the corrosive/erosive nature of the atomized fluid, atomization performance characteristics begin to deteriorate.
For the present invention, the mix chamber inner diameter 18 is sized to maintain the velocity of the three-phase mixture of the atomizing gas, liquid, and solids in the range of 50 to 400 ft./sec. and preferably at a velocity of 200 ft./sec. The inner diameter of the mix chamber discharge port 28 is sized to maintain the velocity of the three-phase mixture of the atomizing gas, liquid, and solids in a range of 150 to 700 ft./sec. and preferably at a velocity of 400 ft./sec.
The mix chamber 18 is a simple two piece cylinder, i.e. sleeves 22 and 24 open at both ends with atomizing gas ports 20 located around its periphery. The effective length of the mix chamber 18 is defined as the distance between the point at which the centerline of the atomizing gas port 20 intersects the axial centerline of the mix chamber 18 to the point where the centerline of the discharge port 38 intersects perpendicular to the axial centerline of the mix chamber 18. The overall combined effective length of both the primary and secondary mix chamber wear sleeves 22 and 24 may be from 1.0 to 10.0 times the mix chamber internal diameter 18 with the optimum length being within a range of 2.0 to 5.0 times the mix chamber internal diameter 18.
The atomizing gas inlets 20 into the mix chamber 18 are one or more annulus, or a series of one or more holes, but not more than nine nor less than one mix chamber inner diameter upstream of the centerline of the secondary mix chamber sleeve discharge port 28. The direction of the ports must be greater than 15 degrees and not more than 90 degrees. The size of the ports is adjusted to keep the atomizing gas within the range of 100 to 700 ft./sec. The optimum number of atomizing gas ports 20 is three to four which allows for large passageways to prevent clogging by particles entrained in the atomizing gas, but still maintains balanced mixing of the atomizing gas with the fluid.
The fluid entrance port 15 in the mix chamber housing 18 is located along the axial centerline of the primary and secondary mix chamber wear sleeves 22 and 24 at the end opposite the discharge port 28. The fluid inlet must be a minimum of 0.25 times the mix chamber inner diameter upstream of the atomizing gas inlet ports 20. The size of the fluid inlet port 15 must be such so as to maintain the fluid velocity in the range of 0.5 to 40 ft./sec.
The exit orifice 34 is in an approximate FIG. 8 configured port and is formed by a tapered outlet section 37, straight section 35 and tapered inlet section 33. The included angle of the conical-shaped entrance port 33 is in a range of 15 to 120 degrees. The length of the conical-shaped entrance port 33 is in a range of 1 to 8 times the minor diameter of the exit orifice 34.
The length of the straight section 35 is from 0.5 to 5.0 times the minor inner diameter of the exit orifice 34, with the optimum length being in the range of 1.0 to 2.0 times the minor inner diameter. The included angle of the conical-shaped discharge port 37 is in a range of 3 to 14 degrees. The length of the conical-shaped discharge port 37 is in a range of 1 to 5 times the minor diameter of the exit orifice 34.
Major advantages for the present invention include the following: the configuration of the present invention permits the co-current or countercurrent injection of an atomized liquid solution, dry powder, or slurry into a gas steam flowing perpendicular or near perpendicular to the central axis (i.e. center line of the inner/outer barrels) of the atomizer; the configuration of the present invention permits the homogeneous mixing of the gas, liquid and/or solid particles to take place along the central axis (i.e. center line of the inner/outer barrels) of the atomizer before discharging at a right angle with respect to the central axis, thus minimizing the overall profile of the atomizer head; the configuration of the present invention permits the simple replacement of all internal wetted wear components; there is an improved exit orifice insert wear life resulting from lengthening the flow path of the minor diameter (i.e. addition of a straight section between the inwardly tapering inlet and the outwardly tapering outlet); and the exterior shape of the exit orifice, mix chamber and wear plug inserts are those of simple cylindrical and disc shapes, thus minimizing manufacturing costs.
While specific embodiments of the invention have 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.
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A dual-fluid low pressure drop atomizer utilizes extended wear life material and comprises a nozzle head having a secondary mix chamber therein for receiving a mixture of a first compressible fluid and a second fluid containing solids from a primary mix chamber. The nozzle head also has an orifice therein communicating with and adjacent to the secondary mix chamber for discharging a jet of the mixture. The orifice and the secondary mix chamber form an approximate right angle therebetween. An inner barrel is connected to the nozzle head at the primary mix chamber and supplies the first fluid to the nozzle head. An outer barrel is arranged around the inner barrel creating an annulus therebetween and is also connected to the nozzle head for supplying the second fluid to the nozzle head. Wear resistant material provided in the primary and secondary mix chambers reduces erosion within the atomizer head.
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