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This application is a continuation of application Ser. No. 538,168, filed Oct. 3, 1983, now abandoned.
FIELD OF THE INVENTION
This invention relates to anthropometers and more particularly to anthropometers specifically designed to measure spinal parameters for diagnosis and assessment of lordosis and scoliosis.
BACKGROUND OF THE INVENTION
Anthropometry is the science of measuring the shape of the spine and the effect of loads on the spine. One of the results of such measurements is a positive diagnosis of scoliosis and lordosis. These are conditions resulting from displacement from the normal of the spinal vertabrae. Lordosis is defined as the anteriorposterior malposition of the spinal processes whereas scoliosis is the lateral malposition thereof.
Live body anatomical measurements, particularly relative spinal position measurements fall into three categories, in vivo measurements; radiological measurements and surface mapping relative to anatomical reference points.
Three-dimensional computer-aided x-ray analysis of the human spine was reported by Shu in 1974 (J.Biomech 7,161-169). Variations were developed by Kraty in 1975 (Photogrammatica 31: 195-210) and Brown et al in 1976 (J.Biomech 9: 355-365).
Kraty located and recorded the transverse and spinous processes of each vertabra in both frontal and lateral projections and built up projection from triangles formed by connecting the transverse and spinous processes. These were extended by further connection to form polygons. This technique presented problems in patient movement during repeated repositioning of the x-ray machine.
Brown et al recorded bi-planar x-rays with a reference frame provided by radio-opaque indices embedded in Plexiglass panels located between the x-ray sources and the film. Each vertabra was thus modeled as a tetrahedron whose four vertices were the two pedicles and the superior and inferior vertabral body centers. The location data on each vertabra was digitized and the determination of the extent of curvature was made and compared with a manual determination on lateral x-ray. The angles compared favorably within 5 degrees. Projections were also plotted for visual assessment.
A study of the configuration of the spine in response to static loading was reported by Tichaner et al (J.Am Industr. Hyg Assn 34: 4(1973)) and named Lordisometry. This employed a two dimensional measuring device which consisted of two aluminum rods each hinged to an upright support. The angular displacement of each rod was measured by a sine-cosine potentimeter mounted at each hinge.
The potentimeter outputs, after electronic enhancement, were converted to X and Y coordinates of each point measured and plotted on an X-Y recorder. The reference points selected were the tip of the sacrum, L3, T8, C7, C3 and the midpoint of the superior nuchal line. From the coordinates of these points, the cervico-occipital, thoracocervical, lumbothoracic, lumbosacral and sacral angles relative to the horizontal were calculated and assessed.
A tracer for mapping anatomical surfaces for the study of carpal tunnel syndrome was developed by Armstrong et al (J.Biomech 12: 397(1979)). This mapper consisted of two orthogonally mounted linear potentimeters which rotated freely about a linear differential voltage transformer. Encoded points in space were scaled and represented as spherical coordinates. These coordinates were then converted to Cartesian coordinates, stored on a diskette and plotted. This device permitted the representation of the flexor digitorum profundus tendon (of the second digit) in flexed, intermediate and extended positions.
Gold et al as reported by Tichauer had demonstrated (17th Conference American Assoc. for Automotive Medicine at Oklahoma City OK Nov. 73) a three-axis kinesiometer which provided displacement, velocity and acceleration signatures of hand guided objects in space.
The apparatus consisted of three coplanar linear potentiometers located at the vertices of a right triangle mounted perpendicular to the task board. A pulley was mounted on the shaft of each potentiometer in conjunction with a spring-activated take up wheel. This provided constant tension in the string that was wrapped around each pulley. All three of the strings were connected to a ring which was fitted to a finger of the active hand being measured. This permitted a point by point determination of the instantaneous displacement, along with its first and second derivatives. The device was sufficiently sensitive to reproduce dangerous motion patterns and tremors.
Recently thermography has been used, Cooke et al (Clin. Orthop. 148: 172-176, 1980)), to detect minor scoliotic curvatures based on the asymmetry in spinal infra-red emission due to slightly asymmetric blood flow in scoliotic individuals. While theoretically viable, problems of calibration temperature control, equipment cost etc. militate against this method.
Moire topology has also been investigated for non-radiographic scoliosis screening by Wilner (Orthop.Scand. 50: 295 (1979)). The basic technique consists of producing interference patterns from a 1000 watt point source on the back of a subject standing in front of a vertical wire screen consisting of strands of 1 mm black nylon wire spaced 1 mm apart.
The interference of the light projected through the screen produces contour lines (shadows) at given distances from the screen on the subject's back. The contours are analagous to a topographical map with each contour proportional to the elevation of the back relative to the screen. Though slight asymmetries are detectable, fringe difference as related to Cobb angle, yield a rather large scatter. For this reason assessment of curvature progression over time with this technique is doubtful. However this method would be very useful in school screening programs. Such programs have been demonstrated as potentially effective.
Though radiography is capable of thoroughly documenting spinal geometry, the hazards associated with x-ray exposure are well-known.
Thermography and Moire topology may be of value in screening programs for scoliosis. However, neither of these techniques is able to quantify, at present, lateral displacement nor have measurements been taken to relate such displacement to underlying anatomical reference points for adequate mapping to determine subsequent progression or recession (and cure).
The Invention
The present invention is based upon the analysis from the above that three-dimensional anthropometry allows for the simple gathering of spherical coordinates from various points of the body permitting the screening, diagnosis and assessment of lordosis and scoliosis.
The device of this invention may be traced in origin to the combined principal of operation of the triaxial kinesiometer of Gold et al with the two dimensional lordisometer of Tichauer as described above. However, the manner of combining these operations and their application in the form of a simple device which provides direct interpretation of the clinical measurements for proper diagnosis and assessment of scoliosis and lordosis is unforeseen.
The device of this invention is a three-dimensional anthropometer (also alternately denoted as a combined lordisometer and scoliometer) for use in the screening and diagnosis of lordosis and scoliosis and assessing the degree of such conditions, which comprises a telescopic steel rod mounted in a fixed housing. The telescopic rod is extendable from said housing and is fitted at its distal end with a body contacting point and is connected in said housing at its proximate end to the vertex of two orthogonally mounted linear potentiometers. Displacement of said orthogonal mounting provides analog signals generated in said potentiometers indicating azimuth and elevation. A third linear potentiometer, mounted on said housing, is connected by a nylon string wrapped around a pulley and to the extensible end of the telescopic rod whereby an analog signal is generated from said third potentiometer by rotation of said pulley during passage of the nylon cord upon extension of said rod. The potentiometers are each powered by a regulated power supply. The analog signal outputs of each of said potentiometers being linearly amplified to the range of measurements of spinal positional parameters: said amplified analog signals representing elevation, azimuth and extension with respect to the fixed position of said device and the measured spinal points. The respective signals are then digitized by appropriate electronic circuits and the thus digitized signal is converted by an appropriate algorithm from the initially derived spherical coordinates to Cartesian coordinates defining the coronal and sagittal plane spinal angles. These angles, derived from the various measured points, are related to each other and their relationship is useful for the diagnosis and assessment of the conditions of scoliosis and lordosis.
A microprocessor-based data acquisition system programmed with the appropriate algorithm is utilized for calculating the sagittal and coronal plane spinal angles and then relating these derived data to angles found in normal subjects; graphically representing these relationships so that comparisons may be made and a proper diagnosis and assessment derived.
In practice the data is derived by identifying six anatomical landmarks on the subject. These landmarks are the inion (midpoint of the superior nuchal line), the third cervical spinous process, the seventh cervical spinous process, the third lumbar spinous process, and the second sacral process. For ease of measurement these are marked on the subject. Then repetative traces are recorded of these six anatomical landmarks with the subject standing erect on a foot position graticule with arms extended and holding a light paper tube. The traces are recorded by extending and positioning the telescopic tube to contact the marked landmarks on the subject. Upon contact, a pressure activated switch activates the encoding of the coordinates of the spatial points of the landmarks by the three voltages from the potentiometers r, θ and φ which are subsequently converted into the X,Y and Z cooridinates, locating each landmark in three-dimensional space with respect to the fixed base of the device and the graticle upon which the subject is standing.
The digitized voltages, encoded into the microprocessor, are called up by the algorithm (a Wait statement in a Basic program) which converts the voltage from spherical to cartesian coordinates.
To provide visual assessment of the sagittal and coronal postural adjustments during loading, plots of the digitized spinal traces are also made while the subject was holding a five pound weight instead of the paper tube. The spinal trace was also recorded in a 3-dimensional 90° rotation so that a full evaluation in both anteriorposterior as well as lateral planes is available.
BRIEF DESCRIPTION OF THE DRAWING
Details of the device of the invention and its use in the practice of this invention will be set forth below and in the associated Drawing wherein
FIG. 1 is a plan view of the spinal anthropometer of the invention making measurements on a subject;
FIG. 2 is a representation of the anatomical reference points of subjects that are measured in the practice of the invention and their included angles in the sagittal plane;
FIG. 3 has plots of the coronal and saggital planes of a normal subject before and during lift of a five pound load;
FIG. 4 has plots of the coronal and saggital planes of a scoliotic subject before and during lift of a five pound load.
FIG. 5 is a three dimensional spinal plot for a normal subject varying from coronal aspect φ=0° to the sagittal aspect φ=90°;
FIGS. 6a and 6b are a typical Data Acquisition program or algorithm in Basic machine language presented in a manner suitable for input into computers or microprocessors equipped with an Optical Character Reader (OCR);
FIGS. 7a and 7b are an OCR-ready program for Coronal and Sagittal Plane Spinal Plotting and;
FIG. 8 is an OCR-ready program for three-dimensional plotting to yield representations similar to those of FIG. 5.
DETAILED DESCRIPTION
Referring now to FIG. 1, the subject 1, is positioned by a foot graticle 2 on floor 3, a fixed distance from the spinal three-dimensional anthropometer 5 of this invention. The anthropometer is mounted on fixed base 10 at a convenient level above floor 3. On base 10 is mounted support 11 which is also the azimuth pivot 11 located centrally to azimuth plate 12 marked at its periphery with azimuth angles. Azimuth pivot 11 is coupled to azimuth reading potentiometer 16 by azimuth bearing 14 so that changes in position of pivot 11 with respect to the potentiometer 16 will modify the signal generated therein.
Affixed to azimuth pivot 11 is telescopic rod 20 so that movement thereof in the horizontal plane will provide changes in the azimuth angle θ and resultant azimuth potentiometer 16 signals. The signals are conducted from the potentiometer via lead 18 to junction box 50 which is the input portal to the computer or processor (not shown).
The mounting of telescopic rod 20 to pivot 11 is near its proximate end. The mounting of the rod 20 to azimuth pivot 11 is via elevation pivot 21 linked to elevation plate 22 and elevation reading potentiometer 26 through elevation bearing 26. The derived elevation signal from elevation potentiometer 26 is led via elevation signal leads 28 to junction box 50, the input portal to the computing device (not shown).
Telescopic rod 20 is fitted with a balance weight (or counter weight) 30 at its proximate end 34, to permit ease of rotation of rod 20 around pivot 21. At distal end 32 of rod 20 is locating pointer 35 for contact with the landmark points on patient 1 during the mapping and measuring procedure. Locating pointer 35 is fitted with switch 36 and leads 38 therefrom to junction box 50. A nylon chord 40 runs from locating pointer 35 at the distal end 32 of telescopic rod 20 to the extension indicating assembly 41 consisting of extension pulley 42 around which chord 40 is wound, extension pulley pivot 44 which actuates extension reading potentiometer 46, and the nylon chord take-up mechanism 47. Mechanism 47 may be spring or weight loaded to ensure proper tension on pulley 42 without interfering with the actuation of the extension mechanism of telescopic rod 20. The signal from extension reading potentiometer 46 is fed by leads 48 to junction box 50, the computer input.
When locating pointer 35 is properly located in juxtaposition with the landmark point on subject 1, switch 36 is activated to signal the computer to record and process the signals from each of the azimuth potentiometer 16, elevation potentiometer 26 and extension potentiometer 46.
In practice the potentiometer reading signal from each of the potentiometers 16, 26 and 46 is amplified between the junction box and the computer. Depending on the computer, the amplified signals are digitized either by separate digitizer chips external or internal to the computer.
The degree of amplification of the potentiometer outputs, varied from a regulated 5 volt input, should be such as to scale the voltages for the range of the device [(0°-50° elevation (θ), ±10° azimuth (φ), 0-12 inches (r)] and the usual allowable input of analog/digital (a/d) converters (±2.5 volts).
FIG. 2 shows the anatomical references points used in mapping the spinal shapes of the subjects. Their angles in the sagittal plane is also shown.
Table I names these landmarks and lists the abbreviations therefor shown in the FIG. 2.
TABLE I______________________________________Inion (midpoint of superior nuchal line) NThird cervical spinous process C.sub.3Seventh cervical spinous process C.sub.7Eighth Thoracic spinous process T.sub.8Third Lumbar spinous process L.sub.3Second sacral process S______________________________________
Table II lists the names and abbreviations for the spinal angles derived from the positional measurements of the landmarks listed in Table I-
TABLE 2______________________________________NAMES AND ABBREVIATIONS FOR SPINAL ANGLES______________________________________Sagittal Plane Anglescervical-occipital angle SA1thoraco-cervical angle SA2lumbo-thoracic angle SA3lumbosacral angle SA4Coronal Plane Anglescervical-occipital CA1thoraco-cervical angle CA2lumbo-thoracic angle CA3lumbosacral angle CA4______________________________________
FIGS. 3, 4 and 5 are plots of the derived angles from the mappings of the landmarks in FIG. 2 and Table I for various subjects under unstressed and loaded conditions. The subjects were diagnosed as normal or scoliotic and the effects of the clinical condition of scoliosis is clearly apparent from the plots of FIG. 4 as compared to the plots in FIG. 3. The rotational plot in FIG. 5 is particularly useful in differentiating clinical scoliosis compounded by lordosis.
A further exposition of the use of the device of this invention in diagnostic screening is found in Gross et al: (Bull.Hosp.for Joint Diseases, Orthopedic Inst. Vol. XL11 #2 (Fall, 1982) Pages 151-171).
FIGS. 6-8 are presented for the convenience of practioners using the device of this invention is conjunction with computers or microprocessors accepting processing instructions in Basic. These programs are presented in a format suitable for reading by Optical Character Readers such as manufactured by Hendrix Corp. for acceptance and entry into the processing memory. FIG. 6 handles the storage of the data acquired from mapping each of the landmark points for use in later manipulation. Such manipulation, in addition to the recording and tabulating of the data, includes manipulation to plot the coronal and sagittal planes of the mapped spines and their angles under normal and stressed conditions as shown in FIGS. 3 and 4. Such plotting instructions are shown in the program of FIG. 7. Such plotting permits observation of aberations from the normal, leading to ease of diagnosis of the conditions being screened.
FIG. 8 provides a program in machine readable form for additional useful manipulation of the data stored by the program of FIG. 6.
A useful microprocessor that has been used with the programs of FIGS. 6-8 was manufactured and sold as the SOL microcomputer. It is no longer available but these programs have also been used on the TR-80 microcomputer sold in the USA by the Radio Shack stores. The aforementioned article by Gross et al includes examples of screening and calibration results. The programs of FIGS. 6-8 are reproduced from said article which is included herein by reference to show further aspects and uses of this invention.
The invention, as above described, is not limited by the specific embodiments disclosed but includes all equivalents thereof. Such equivalents include mapping of the coordinates of the landmarks by optical means equivalent to the mechanical devices described. Utilizing other coordinate measuring means than the potentiometer described including sonic locators and optical locators.
While one specific embodiment has been described in detail and equivalent embodiments have been sufficiently alluded to, it is obvious that many modifications to the embodiments described and mentioned may be made without departing from the scope and spirit of this invention.
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A spinal anthropometer or lordosimeter is described that provides a three dimensional configuration of the spine. Point encodement and codement of spacial measurement of spinal landmarks provides data permitting representation of spinal curvatures for diagnosis and assessment of lordosis and scoliosis.
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BRIEF SUMMARY OF THE INVENTION
This invention relates generally to psychological games and, in particular, to a psychological game designed to enhance personal exploration and growth. In addition, the apparatus of the present invention may be used for processes which are intended solely for enjoyment or for focus outside the self.
Briefly, in accordance with the present invention, there is provided a base having a multiplicity of evenly spaced recesses into which spheres of uniform size may be fitted in such a way that when any two spheres are placed in any two adjacent recesses, they touch but do not crowd each other. The spheres are of varying colors and each has a portion which can be written on. They may be arranged in a single layer on the base to form so-called base patterns or stacked to form the tetrahedral formations which are especially important in carrying out the processes of the invention and which will be described in detail later.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the accompanying drawings:
FIG. 1 is an exploded perspective view showing the arrangement of spheres in each layer when the spheres are stacked in a tetrahedral formation;
FIG. 2 is a perspective view of the game when the spheres are stacked in a tetrahedral formation; and
FIG. 3 is a perspective view of one sphere showing a piece of removable tape which can be written on.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, the apparatus of the invention comprises a base, 1, having a multiplicity of evenly spaced recesses, 2, and a multiplicity of uniformly sized spheres, 3-22. In the preferred embodiment of the invention, the base has nineteen recesses and twenty spheres, although less complicated games with fewer spheres and fewer recesses in the base and more complicated games with more spheres and more recesses in the base may be used and are within the scope of this invention. The recesses in the base are uniformly spaced so that when any two spheres are placed in any two adjacent recesses, the spheres touch but do not crowd each other. Although the indentations in the base are referred to throughout as "recesses", they may in fact be holes, hollows, holders or any other type of construction which will prevent the spheres from rolling away from the position in which they are placed, and are not limited to recesses per se.
The base and spheres may be fashioned of any suitable material, e.g., wood, stone, metal, plastic or any other material which can be molded or formed to make the appropriate base and spheres. It is not necessary that the base and spheres be made of the same material.
In the preferred embodiment there are a total of twenty spheres, with five spheres of each of four colors. The preferred colors are white, blue, red, and yellow, but of course any colors or shades may be used. These spheres are a uniform size so that they fit compactly into the base and may be made of any suitable material as mentioned previously.
Additionally, each sphere includes at least one portion which can be written on. This portion may be either an area to which a piece of adhesive tape may be adhered, or an erasable surface which can be written on with a grease pencil, chalk, pencil or any other suitable writing implement and then wiped clean.
The size of the base and the spheres is not crucial, within the limitation that when the spheres are fitted into the recesses in the base, they touch but do not crowd each other. Alternatively, it is not necessary that the spheres touch so long as they are positioned close enough so that when a fourth sphere is positioned on top of any three spheres to form a tetrahedron, it remains there without falling through. The size of the entire apparatus may be scaled up or down as desired.
A process of the invention is any activity using the base and spheres. The apparatus described is especially useful as a tool to enhance personal exploration and growth. However, some processes may be intended solely for enjoyment or focus outside the self. Two examples of how the apparatus may be used for the purpose of exploration and growth are the following:
EXAMPLE I
Using the base and spheres of the preferred embodiment:
1. Respond to the question: "What are the facts or my feelings about the physical part of myself?" Write a word, phrase, or symbol that answers this question on the portion of each of four spheres of color A (any one of the four colors), which is adapted to be written on. Build a four sphere tetrahedron with these spheres in the manner in which spheres 3, 4, 5 and 6 of FIG. 1 are arranged.
2. Respond to the question: "What are the facts or my feelings about the mental part of myself?" Write a word, phrase or symbol that answers this question on the portion of each of four spheres of color B (a second of the four colors), which is adapted to be written on. Build a four sphere tetrahedron with these spheres in the manner in which spheres 7, 8, 9 and 10 of FIG. 1 are arranged.
3. In the same manner as in 1 and 2 above, respond to the question: "What are the facts or my feelings about the emotional part of myself?" Write an answer to this question on each of four spheres of color C and arrange these four spheres in the manner in which spheres 11, 12, 13 and 14 of FIG. 1 are arranged.
4. Use four spheres of color D, preferably white, to choose 1, 2, 3 or 4 areas of personal growth which in your opinion would be valuable to you and indicate one choice on each sphere. Place these spheres as shown by spheres 15, 16, 17 and 18 of FIG. 1.
5. On the fifth sphere of each of colors A, B, and C, respectively, write an answer to the question: "What am I going to do about the facts or my feelings about the physical, mental, and emotional parts of myself, respectively?" Be specific and make a personal commitment if possible. These spheres should be arranged to form the third layer, as shown by spheres 19, 20 and 21 of FIG. 1.
6. On the sphere of color D at the apex of the tetrahedron, sphere 22 of FIG. 1, answer the question: "What would I like most to do with my life or what would I like to become?"
EXAMPLE II
Using the base and spheres of the preferred embodiment:
1. Choose an issue, problem, goal or relationship to concentrate on and write it on a center sphere of color A, as shown by sphere 15 of FIG. 1.
2. Respond to the question: "What are the facts about this particular issue, problem, goal, or relationship?" Write a word, phrase or symbol which answers this question on each of four spheres of color B. Build a four sphere tetrahedron using these spheres as shown by spheres 3, 4, 5 and 6 of FIG. 1.
3. Respond to the question: "What are my feelings about this particular issue, problem, goal or relationship?" and write a word, phrase or symbol which answers this question on each of four spheres of color C. Build a four sphere tetrahedron using these spheres as shown by spheres 7, 8, 9 and 10 of FIG. 1.
4. In the same manner as in 2 and 3 above, respond to the question: "How would I like things to be with regard to this particular issue, problem, goal or relationship?" and write an answer on each of four spheres of color D. Arrange these spheres as shown by spheres 11, 12, 13 and 14 of FIG. 1.
5. Use three color A spheres to designate areas which are not in your power to change with regard to this particular issue, problem, goal or relationship. Arrange these spheres on the second layer as shown by spheres 16, 17 and 18 of FIG. 1.
6. On the fifth sphere of each of colors D, B, and C, respectively, write the answer to the question: "What areas concerning the facts, my feelings and how I would like things to be, respectively, regarding this particular issue, problem, goal or relationship are in my power to change?" Use these three spheres to form a third layer, as shown by spheres 19, 20 and 21 of FIG. 1.
7. On the apex sphere of color A, sphere 22 of FIG. 1, choose one area and make a specific commitment to yourself to change. Choose a commitment that you feel confident about in terms of being able to keep it successfully.
The steps one goes through in carrying out Examples I and II are known as processes. Honest and carefully thought out answers to the questions posed are essential if these processes are to serve their function of enhancing personal exploration and growth. The apparatus is useful as a tool in carrying out these processes because it gives the individual a means of organizing his thoughts in a tangible form and helps him evaluate and understand himself as a result. Tetrahedral symmetry is significant in aiding organization, but of course color symmetries other than the one described may be used.
It is within the contemplation of this invention that the steps for carrying out processes and for using the apparatus be recorded on magnetic tape, particularly cassette tapes, and included as part of the apparatus. These processes need not be limited to those designed to enhance personal exploration and growth, but may be intended solely for enjoyment, focus outside the self, or for two or more participants.
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A psychological game which is designed to be used mainly as a tool to enhance personal exploration and growth. The essential pieces include a base with a multiplicity of recesses and a multiplicity of spheres of varying colors which can be fitted into the recesses. Each sphere has a portion which can be writton on. The game is used by writing answers to specific questions on each sphere of the same color and then arranging all of the spheres to form a tetrahedron. The arrangement of specific color patterns adds significance when used in the processes of the invention.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates generally to lacrosse equipment. More particularly, the invention relates to an improved lacrosse stick for attachment to a lacrosse head. Specifically, the invention provides a new cross-sectional configuration for a lacrosse stick that provides both tactile feedback as to the position of the lacrosse head, and a smaller gripping section for the lead hand.
[0003] 2. Background Information
[0004] It is well known that lacrosse is a fast paced game that requires participants to make quick decisions and movements. The game is played by passing a ball back and forth between teammates, using a stick with a basket at one end. The basket is adapted to catch and throw a lacrosse ball according to the movements of a participant. If the basket is facing the wrong direction, or angled differently than expected, the participant will achieve a less accurate catch or throw of the ball. While moving, the lacrosse participant must continuously look at the end of the lacrosse stick to make sure the basket is positioned correctly.
[0005] Although there are a variety of hand sizes for lacrosse participants, lacrosse sticks tend to be a standard size and thickness. Participants with smaller hands, and a smaller circumferential grip are at a disadvantage to players with larger hands.
[0006] Thus, a need exists for an improved lacrosse stick.
BRIEF SUMMARY OF THE INVENTION
[0007] A lacrosse player generally grips a lacrosse stick with both hands, having one hand near the lacrosse head and the other near the end of the shaft. The present invention provides an enhanced grip for each hand. The invention provides a smaller circumferential distance around the shaft for an improved grip by a smaller hand at the head of the shaft. This allows players with traditionally smaller hands like women or children to more finely control the power and precision of the lacrosse shaft while throwing or catching a ball.
[0008] The other end of shaft is shaped to ergonomically fit in a player's hand while providing tactile feedback to the player on which direction lacrosse head is facing. The shaft fits into the player's palm and base of the area between the thumb and “pointer finger”. This orients the other surfaces to follow the natural hand shape of the area immediately outside the thumb base. When a player's hand is in a gripping position, the four fingers curl to make a shape adapted to receive the remaining surfaces. These surfaces combine to fit to the natural gripping shape of a player's hand, and allow the player to achieve a high level of control on the lacrosse stick.
[0009] The lacrosse head is oriented on the shaft so as to be facing outwardly from the player as the player's hand is correctly gripping the ergonomic section of the shaft. This is the natural position of the lacrosse head as a player engages in running, catching and throwing the lacrosse ball. In a constantly moving game, the player's eyes are often fixed on the location of the ball and other players. If the ball is thrown at the player and the lacrosse head is facing the wrong direction, the ball cannot be caught. The present invention allows a player to know the lacrosse head is oriented correctly through the tactile feedback of the ergonomic section, without taking the player's eyes off the interactions of the game. When a hand is correctly gripping ergonomic section, the lacrosse head is oriented correctly.
[0010] The present invention is a handle for attachment to a lacrosse head comprising a stick having a top end adapted for coupling to a lacrosse head, a bottom end opposite the top end, and a first and second grip area. The first grip area is located generally at the bottom end of the rod and the second grip area is located generally spaced from the bottom end of the rod. The shape of the first area is different from the second area.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] A preferred embodiment of the invention, illustrative of the best modes in which Applicant contemplates applying the principles, is set forth in the following description and is shown in the drawings and particularly and distinctly pointed out and set forth in the appended claims.
[0012] FIG. 1 is a top plan view of a lacrosse stick with an improved shaft;
[0013] FIG. 2 is a side plan view thereof;
[0014] FIG. 3 is a top plan view thereof;
[0015] FIG. 4 is a side plan view thereof;
[0016] FIG. 5 is a cross-sectional view of one end of the improved shaft shown in FIG. 1 , taken on line 5 - 5 ;
[0017] FIG. 6 is a cross-sectional view of one end of the improved shaft shown in FIG. 1 , taken on line 6 - 6 .
[0018] Similar numbers refer to similar parts throughout the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention relates to improved lacrosse sticks having construction providing tactile feedback regarding the position of a player's hands on the shaft. The present invention also provides for an improved grip by better conforming to a player's hand placement and ergonomics.
[0020] Referring to FIG. 1 , there is shown a lacrosse stick 2 with an improved shaft 4 in accordance with the present invention. Shaft 4 includes a head end 6 connected to a lacrosse head 10 , and a butt end 8 connected to a shaft stopper 12 . Head end 6 of shaft 4 is fitted into a hole 11 in lacrosse head 10 adapted to receive head end 6 . Shaft 4 is an elongated tubular member with a dynamic cross-sectional diameter and dynamic cross-sectional area throughout the length thereof. Shaft 4 may be fabricated from a material such as carbon fiber composite material, however any reasonable material may be used. Shaft 4 may receive a soft paint coating for an enhanced grip. In accordance with the invention, and as shown in FIGS. 2-4 , shaft 4 is comprised of six sections: a head section 14 , a cone shaped section 16 , a reduced diameter section 18 , a cone shaped section 20 , a gradient section 22 , and a butt section 24 .
[0021] Referring to FIG. 5 , a cross-sectional view of lacrosse shaft 4 is taken along line 5 - 5 in FIG. 4 , and provides an octagonal shape 50 . Octagonal shape 50 is comprised of static surfaces 30 , 31 , and 34 , which do not undergo a shape change over the length of shaft 4 . Static surfaces 30 and 34 provide the top and bottom walls of shape 50 , spaced apart and generally parallel to one another. Static surfaces 31 A and 31 B extend from each end of top wall 30 . Static surface 34 is oriented to be facing or touching a player's palm while gripping the lacrosse stick, which orients lacrosse head 10 to a position to launch the lacrosse ball outwardly from the player.
[0022] Octagonal shape 50 further comprises dynamic surfaces 32 and 33 , which undergo a shape change over the length of shaft 4 . Dynamic surfaces 32 A and 32 B provide the sidewalls of shape 50 , spaced apart and generally parallel to one another. Dynamic surfaces 33 A and 33 B provide connecting walls between 32 A/ 32 B and static bottom wall surface 34 . Over the length of shaft 4 , dynamic surfaces 32 A and 33 A gradually lose their linear shape, bow outwardly from the center of shape 50 , and merge into one curved surface (discussed further below). Dynamic surfaces 32 B and 33 B undergo the same transformation.
[0023] In accordance with one of the main features of the present invention, FIG. 6 provides a cross-sectional view of lacrosse shaft 4 taken on line 6 - 6 in FIG. 4 . FIG. 6 provides generally a “teardrop” shape 60 . In a comparison from FIG. 5 to FIG. 6 , dynamic surfaces 32 A and 33 A are replaced with a curved surface 36 A, and dynamic surfaces 32 B and 33 B are replaced with a curved surface 36 B. Static surfaces 30 , 31 and 34 are left unchanged from FIG. 5 to FIG. 6 . Curved surface 36 is a convexly arced surface that is symmetrically mirrored on each side of shape 60 . Curved surface 36 bulges outward and extends from an edge 62 to an edge 64 on each side of shape 60 .
[0024] Over the length of shaft 4 , the cross-sectional area and shape undergo multiple changes. However, there are no abrupt changes in the cross-sectional shape or area. Over the length of shaft 4 , octagonal shape 50 gradually changes into shape 60 through merging the dynamic surfaces. Likewise, gradually and proportionately increasing or decreasing the length of the sides of shape 50 results in a greater or smaller cross-sectional area.
[0025] Referring to FIGS. 3 and 4 , head section 14 begins at first end 26 of shaft 4 and extends linearly along shaft 4 , terminating at Arrow A. Head section 14 has the generally octagonal cross-sectional shape 50 shown in FIG. 5 . Head section 14 ends when the cross-sectional area of shaft 4 starts to change at Arrow A.
[0026] Cone shaped section 16 begins at Arrow A and extends linearly along shaft 4 , terminating at Arrow B. Cone shaped section 16 retains the generally octagonal cross-sectional shape 50 shown in FIG. 5 . However, cone shaped section 16 gradually transitions over the length of section 16 into a smaller cross-sectional area of octagonal shape 50 . The ratio and proportion of each surface and edge of octagonal shape 50 remain constant while transitioning from a large octagonal shape 50 A to a smaller octagonal shape 50 B.
[0027] Reduced diameter section 18 begins at Arrow B and extends linearly along shaft 4 , terminating at Arrow C. The cross-sectional area of section 18 remains constant throughout the section and is comprised of the smaller octagonal shape 50 B. Section 18 has the smallest cross-sectional area on shaft 4 . The cross-sectional area of reduced diameter section 18 is smaller to enable a lacrosse player with smaller hands to better grip shaft 4 .
[0028] A second cone shaped section 20 begins at Arrow C and extends linearly along shaft 4 , terminating at Arrow D. Cone shaped section 20 retains the generally octagonal cross-sectional shape 50 shown in FIG. 5 . However, cone shaped section 20 gradually transitions over the length of section 20 from the smaller cross-sectional area of octagonal shape 50 B to the larger cross-sectional area of octagonal shape 50 A. The ratio and proportion of each surface and edge of octagonal shape 50 remain constant while transitioning.
[0029] Gradient section 22 begins at Arrow D and extends linearly along shaft 4 , terminating at Arrow E. Gradient section 22 is the location on shaft 4 of the transition between octagonal shape 50 and teardrop shape 60 . A gradient edge 38 is formed on both sides of tubular member 5 where dynamic surface 32 and 33 meet. As shown in FIG. 4 , over the length of gradient section 22 and from Arrow D to Arrow E, dynamic surfaces 32 and 33 gradually merge to form curved surface 36 . From Arrow D to Arrow E, gradient edge 38 transitions from a sharp, angled edge, to a rounded and curved surface. Shown in FIG. 4 , as gradient edge 38 moves from Arrow D to Arrow E, it expands surface 32 , while conversely narrowing surface 33 . Gradient edge 38 continues until the surfaces 32 and 33 are merged and gradient edge 38 disappears into the curved surface 36 .
[0030] Referring to FIGS. 3 and 4 , butt section 24 begins at Arrow E and extends linearly along shaft 4 , terminating at the end of tubular member 5 . Butt section 24 has the general teardrop cross-sectional shape 60 shown in FIG. 6 . Shape 60 extends throughout butt section 24 and is tailored to ergonomically fit in a player's hand.
[0031] As can be seen, stick 4 provides a first cross-sectional shape that has an area that changes over the length of shaft 4 , and a second cross-sectional shape that transforms into the first cross-sectional shape over the length of shaft 4 . The transformations are gradual, with gradient areas on shaft 4 where one cross-sectional area or shape changes to another.
[0032] A lacrosse player generally grips lacrosse stick 2 with both hands. Traditionally, one hand is placed near head end 6 , and the other hand placed near butt end 8 . In the present invention, butt section 24 comprises a first grip area and reduced area section 18 provides a second grip area. The present invention provides an improved interaction with lacrosse stick 2 for each hand. At head end 6 of shaft 4 , reduced diameter section 18 provides a smaller circumferential distance around shaft 4 for an improved grip by a smaller hand. Improving a player's grip allows the player to throw the ball with more velocity and precision.
[0033] At butt end 8 of shaft 4 , butt section 24 is shaped to ergonomically fit in a player's hand as well as give tactile feedback to the player on which direction lacrosse head 10 is facing. Referring to FIG. 6 , palm edge 34 of shape 60 fits into the player's palm and base of the area between the thumb and “pointer finger”. This orients curved surfaces 36 A and 36 B to follow the natural hand shape of the area immediately outside the thumb base. When a player's hand is in a gripping position, the four fingers curl to make a shape adapted to receive static surfaces 30 , 31 A, and 31 B. These surfaces combine to fit to the natural gripping position of a player's hand, and allow the player to achieve a high level of control on lacrosse stick 2 .
[0034] Lacrosse head 10 is oriented on shaft 4 so as to be facing outwardly from the player as the player's hand is correctly gripping butt section 24 . This is the natural position of lacrosse head 10 as a player engages in lacrosse. In a constantly moving game, the player's eyes are often fixed on the location of the ball and other players. If the ball is thrown at the player and lacrosse head 10 is facing the wrong direction, the ball cannot be caught. The present invention allows a player to know lacrosse head 10 is oriented correctly through the tactile feedback of butt section 24 , without taking the player's eyes off the interactions of the game. When a hand is correctly gripping butt section 24 , lacrosse head 10 is oriented correctly. Butt section 24 is shaped to fit into the contours of a closed hand, with the correct orientation fitting perfectly with the ridges and pockets of the hand. Holding butt section 24 incorrectly will feel awkward and less secure compared to how shaft 4 feels when held correctly. A user will immediately be able to tell whether butt section 24 is positioned correctly through his sense of touch.
[0035] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
[0036] Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.
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A handle for attachment to a lacrosse head, comprising, a rod having a top end adapted for coupling to a lacrosse head, a bottom end opposite the top end, a first and second grip area, wherein the first grip area is located generally at the bottom end of the rod and the second grip area is located generally at the top end of the rod. A teardrop shaped handle is located at the bottom end of the rod as the first grip area, and a smaller octagon shaped grip area is located at the top end of the rod, adapted to fit smaller hands.
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GENERAL TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to the general technical field of the production of intermediate pressure plasmas excited by a microwave power.
[0002] More precisely, the invention relates to the production of the sheets of dense plasmas, with large dimensions compared with the thickness of the plasma, in the range of medium pressures or intermediate pressures, that is, about a few tenths of Pa to a few thousands of Pa, or of about a few millitorr to a few tens of torr. (1 torr is approximately equal to 133 Pa).
[0003] The present invention relates to a wide variety of applications, such as surface treatments, for example the cleaning of surfaces traveling at high speed, and above all, the deposition of diamond films by plasma-enhanced CVD (chemical vapor deposition).
[0004] In particular, the invention presents an advantage for applications requiring methods using uniform plasmas at intermediate pressures on large surfaces.
PRIOR ART
[0005] All the aforementioned applications require the prior production of a dense and uniform plasma in a chamber, for example in the one in which the application takes place.
[0006] It may be recalled that a plasma is a conducting gaseous medium, consisting of electrons, ions and neutral particles, which macroscopically is electrically neutral. A plasma is obtained in particular by the ionization of a gas by electrons.
[0007] In general, diamond deposition by plasma CVD is carried out in hydrogen plasmas, containing a small percentage of methane at a total pressure of a few tens of torr, and a substrate temperature of about 600 to 800° C. or more.
[0008] The mixture may also contain precursor gases for doping the diamond, or impurities modifying the growth of the diamond.
[0009] The plasmas used to deposit diamond films by CVD plasma are generally excited by microwaves. Two types of method for excitation in reactors are available.
[0010] 1) The plasma can be excited by a surface wave. The diagram of this type of excitor is shown in FIG. 1 . The plasma excitor comprises a microwave applicator 1 in the prolongation of which a dielectric tube 2 is fixed, in direct contact with the plasma 3 to be excited. The dielectric tube 2 comprises a bell-mouth 5 , which sends the microwaves and the plasma to the substrate 4 , which is bathed in the plasma 3 .
[0011] 2) A microwave applicator of the cavity type can be used. The diagram showing the principle of this type of applicator is shown in FIG. 2 . In a reactor 1 , the plasma 3 is produced in response to an excitation from an antenna 2 used for coupling the microwaves with the cavity. The plasma 3 is excited under a quartz dome 5 . The deposition is carried out on a substrate 4 also arranged under the dome 5 and bathed in the plasma 3 .
[0012] The two types of excitation presented can be used to produce dense plasmas (typically 10 12 /cm 3 ) allowing the deposition of diamond, particularly at a rate of a few microns per hour, on substrates a few centimeters in diameter.
[0013] However the above techniques have drawbacks.
[0014] In fact, the plasmas produced by these two techniques require power of several kW for their maintenance for a 100 mm diameter substrate, and hence the major drawback of these diamond deposition techniques is the difficulty of reactor scale-up.
[0015] As regards the surface wave discharges in FIG. 1 , the effective diameter of the plasma can be increased by flaring the silica tube 5 used beyond the microwave applicator 1 . The microwave power densities required are however such that the use of a cooling liquid without dielectric loss is indispensable. This fluid flows in the applicator, in a double-walled distribution circuit that is extremely costly.
[0016] Moreover, the scale-up of this type of reactor presents technological limitations in terms of the maximum feasible diameter. In fact, the microwave power delivered by a unit generator cannot be increased substantially. The microwave generators available in DC mode at 2.45 GHz generally do not exceed 12 kW, which is insufficient for producing plasmas for the above applications.
[0017] Finally, the standard rectangular waveguides in single propagation mode used in microwave applicators have large sides not exceeding 8.6 cm, which corresponds to the European standard.
[0018] The solution whereby the excitation frequency is reduced and the ISM (Industrial, Scientific and Medical) frequency of 915 MHz is used, serves to increase the dimensions of the waveguides—in inverse relation to the frequencies—and to obtain unit DC power outputs of up to 30 kW.
[0019] However, this is not fully satisfactory. In fact, the dimensions of microwave components—such as the short-circuit plunger, impedance matchers, bi-couplers for power measurement—are commensurately increased. Hence it appears that the technological limits have now been reached and that the maximum substrate diameters that can be treated range from about 100 to 150 mm.
[0020] As regards the microwave discharges given by the microwave applicators of the cavity type, the same problems arise.
[0021] In fact, the scale-up of the cavity demands either switching to a multimode cavity which does not allow a uniform plasma to be obtained at the substrate, or reducing the microwave frequency to 915 MHz. Decreasing the frequency procures the same advantages as above, but also the same drawbacks. It is therefore only possible to treat substrates with a maximum diameter of about 100 to 150 mm.
PRESENTATION OF THE INVENTION
[0022] The invention proposes to overcome these drawbacks.
[0023] In particular, the invention relates to the production of a slice or sheet of plasma with large dimensions in the pressure range of 1 torr, that is, of a few millitorr to a few tens of torr.
[0024] The production of this slice or sheet takes place by microwave excitation of the gas, allowing the production of plasma on a volume depending on the operating conditions, that is the pressure and microwave power injected on each applicator.
[0025] For this purpose, the invention proposes a device for producing a plasma in a chamber comprising means for producing an energy in the microwave spectrum for the excitation of the plasma, said means comprising at least one basic plasma excitation device comprising a coaxial applicator of microwave energy, of which one end is connected to a production source of microwave energy, the other end being directed to the gas to be excited within the chamber, characterized in that each basic excitation device is arranged in the wall of the chamber, each applicator comprising a central core which is substantially flush with the wall of the chamber, the central core and the thickness of the wall of the chamber being separated by a space coaxial with the central core, this space being completely filled at least at one end of each applicator with a dielectric material such that said material is substantially flush with the level of the wall of the chamber.
[0026] The invention is advantageously supplemented by the following characteristics, taken alone or in any technically feasible combination thereof:
the dielectric material is refractory; the dielectric material is made of an alloy of silica and/or of aluminum nitride and/or of alumina; the dielectric material fills the entire coaxial space; the length of the dielectric material is equal to an integral number of half-wavelength of the microwaves in the dielectric material; it comprises O-rings inserted between the dielectric, the central core of an applicator and the internal wall of the applicator; each O-ring is embedded in the internal and external walls of the coaxial structure; a central core terminates in a permanent magnet encapsulated in the central core and flush with the walls of the chamber; it comprises a dielectric plate that extends to the interior of the chamber on the internal wall thereof, said plate completely covering the plasma excitation devices; it comprises means for cooling each applicator in the chamber walls; it comprises means for cooling the applicators in the central core of each applicator; the pressure of the plasma is between a value of about 1 millitorr and a value of about a few tens of torr; it comprises a plurality of applicators, the applicators being arranged in a two-dimensional network in the wall of the chamber in order to obtain the desired applicator density for a desired pressure range.
PRESENTATION OF THE FIGURES
[0039] Other features, aims and advantages of the invention will appear from the description that follows, which is purely illustrative and non-limiting, and which should be read with reference to the drawings appended hereto in which:
[0040] FIG. 1 , already discussed, shows an excitation applicator of the surface wave type according to the prior art;
[0041] FIG. 2 , already discussed, shows a plasma excitation reactor of the cavity type according to the prior art;
[0042] FIG. 3 shows a cross section of one feasible embodiment of the invention comprising a single applicator;
[0043] FIG. 4 shows a cross section of one feasible embodiment of the invention comprising a plurality of applicators;
[0044] FIG. 5 shows a close-up arrangement of the applicators;
[0045] FIG. 6 is a front view of a square two-dimensional network of applicators;
[0046] FIG. 7 is a front view of a hexagonal two-dimensional network of applicators;
[0047] FIG. 8 shows the covering of the reactor wall with a dielectric plate;
[0048] FIG. 9 shows a feasible embodiment of the assembly of O-rings; and
[0049] FIG. 10 shows an improvement of an embodiment of the invention comprising a permanent magnet at the end of the applicator.
DETAILED DESCRIPTION OF THE INVENTION
[0050] FIG. 3 shows one feasible embodiment of a device 1 for producing a plasma.
[0051] The device 1 conventionally comprises a sealed chamber 3 equipped with numerous gas introduction and gas pumping devices, not shown but known per se. The introduction and pumping devices serve to maintain the pressure of the gas that needs to be ionized at a desired value—it may, for example, be about a few tenths of a Pa or a few thousands of pascals, that is of about a few millitorr to a few tens of torr, depending on the type of gas and the excitation frequency.
[0052] Conventionally, the wall of the chamber 3 is metallic.
[0053] According to this feasible embodiment of the invention, the production device 1 comprises a basic excitation applicator 4 .
[0054] According to a variant of this embodiment shown in FIG. 4 , the plasma production device comprises a series of basic devices or applicators 4 for exciting a plasma 16 . The applicators 4 are distributed as a function of the density and internal pressure of the chamber.
[0055] According to the invention, each basic plasma excitation device 4 consists of a coaxial microwave power applicator comprising a central core 5 surrounded by a cavity 6 added on or directly perforated in the wall of the chamber 3 .
[0056] Preferably, the central core 5 and the cavity 6 surrounding it have a symmetry of revolution.
[0057] One of the ends of the applicator 4 is connected to an energy source 7 in the microwave spectrum and outside the chamber 3 .
[0058] The other end 8 of the applicator 4 is free and terminates inside the chamber 3 . It is in contact with the gas present in the chamber 3 .
[0059] The propagation of the microwave energy from the energy source 7 to the free end 8 takes place in the cavity 6 surrounding the central core of the applicator.
[0060] In general, the central core 5 of each applicator 4 is cooled by a water circulation circuit (not shown in the figures).
[0061] Similarly, FIGS. 3 and 4 show that the spaces 12 between the applicators 4 of the wall 3 are generally cooled by water circulation through 13 .
[0062] A dielectric material 14 in the solid state is arranged inside the cavity 6 around the central core 5 . The dielectric 14 is arranged on the side of the free end 8 of the applicator 4 , substantially at the level of the chamber wall. It may slightly project from the chamber wall 3 or be slightly embedded as regards the level of the chamber wall 3 , which is preferably substantially flush with the level of the end of the central core 5 in contact with the plasma, as shown in FIG. 5 .
[0063] According to one variant, it may fill the entire space between the central core and the inside wall of the cavity.
[0064] Preferably, the length of the dielectric material is equal to a whole number of half-wavelength of the wave in the dielectric, in order to compensate for the reflections and recompositions of the waves at the interfaces. The length 1 of the dielectric is defined by:
√ε r ×1 =k×λ/ 2
where: ε r is the relative permittivity of the dielectric material
[0065] k is an integer
[0066] λ is the wavelength of the wave in the vacuum.
[0067] The dielectric 14 is advantageously a “low loss” dielectric. It is preferably refractory in order to withstand the high temperatures of certain envisioned applications. It can be made of an alloy, for example, of aluminum nitride (AlN), and/or of alumina (Al 2 O 3 ), and/or of silica (SiO 2 ).
[0068] The arrows 15 in the FIGS. 3, 4 and 5 represent the microwave propagation in the cavity 6 of each applicator 4 . They propagate toward the interior of the chamber 3 and excite the plasma 16 present in said chamber 3 .
[0069] FIGS. 4 and 5 serve to compare the influence of the spacing of the applicators with respect to one another on the formation of the plasma.
[0070] A relatively low density of applicators per unit area is needed to produce a uniform plasma when the gas pressure is relatively low. In fact, the plasma diffuses more easily when the gas pressure is not high. In this case, only one applicator 4 is necessary to produce the plasma on a given dimension.
[0071] By contrast, the higher the gas pressure, the more locally the plasma is produced. The plasma will not be uniform if the applicators are too remote, as in FIG. 4 . A relatively high density of applicators per unit area is therefore necessary, the applicators also being distributed as uniformly as possible.
[0072] This is also why the dielectric material is situated at the end of the applicator, and not set back from at this end. This avoids the formation of plasma inside the applicator (coaxial zone, use side) throughout the accessible pressure range.
[0073] The applicators 4 can be arranged in various networks.
[0074] FIG. 6 shows a front view of the inside wall of the chamber 3 . It shows the network arrangement of the free ends 8 of the applicators 4 . In this square network, the distance 17 between two free ends 8 defines the network density.
[0075] FIG. 7 shows that for the same distance 17 between two free ends 8 , a hexagonal network arrangement—indicated by the numeral 18 in the figure—serves to obtain a higher density per unit area of the applicators 4 .
[0076] A higher density permits a better uniformity of the applicators 4 , and consequently better uniformity of the plasma produced thereby. A higher microwave power density per unit area can also be supplied, at maximum power given by the applicator 4 .
[0077] For reasons of clarity, FIGS. 6 and 7 only show two ends of applicators 4 . The ends 5 are distinguished from the central cores, as well as the dielectric materials 14 .
[0078] To obtain a uniform plasma sheet 16 with very large dimensions, it is first necessary to be able to distribute the microwave power as uniformly as possible throughout the applicators 4 .
[0079] For this purpose, it is possible to use a microwave power generator that is adjustable by applicator. For example, a transistorized microwave source can be used for each applicator.
[0080] It is also possible to use a single microwave power generator and then divide this power to distribute it to each applicator 4 . The microwave power injected into each applicator 4 can be adjusted easily and independently by an impedance matcher, arranged just upstream of each applicator 4 .
[0081] Certain deposition or treatment methods require a high temperature of the application surface. Others require lower temperatures.
[0082] It should be recalled that the portions 12 located between two applicators, as well as the central cores 5 , are cooled by cooling circuits using fluids, particularly water.
[0083] In consequence, it is possible for the gases constituting the plasma to be cooled by contact with the cooled surfaces of the chamber 3 , and then in turn to cool the application surface.
[0084] Thus, independent heating of an application surface is provided, particularly for depositing diamond.
[0085] FIG. 8 shows that a low-loss dielectric plate 20 (like silica, for example) can also be inserted between the cooled portions of each applicator and the plasma, to avoid the cooling of the plasma in contact with the surfaces cooled by the circulation of fluid. The dielectric plate 20 can cover all or a portion of all the free ends 8 of the applicators 4 .
[0086] FIG. 9 shows that O-rings 21 provide a seal between the upstream (atmosphere) and downstream (plasma) portions of the applicators 4 .
[0087] The O-rings 21 are preferably embedded in the central core 5 and between the walls of the chamber 3 and the gland 3 ′, to prevent their heating by the passage of microwaves. Moreover, this type of embedding also serves to guarantee better cooling, because they benefit from the cooling distribution circuit present in the wall 3 and in each central core 5 .
[0088] The device according to the invention shown in FIGS. 1 to 9 advantageously applies to the range of medium pressures (about a few tenths of a pascal to a few thousand pascals, that is, about a few millitorr to a few tens of torr).
[0089] However, in order to extend the use of the invention for a plasma excitation in the low pressure range (about 10 −2 torr), a variant of the device can be provided.
[0090] In this variant, shown in FIG. 10 , a permanent magnet 22 is placed at the end of the central core 5 of the applicator 4 , the axis of permanent magnetization of which is advantageously along the axis of the central core. This magnet 22 is encapsulated in the central core 5 . The free end of the magnet is substantially at the level of the free end of the wall 3 in contact with the plasma 16 .
[0091] With such a permanent magnet 22 , it is easier to start the plasma in the range of the lower pressures considered by the present invention, by virtue of the confinement of the plasma or of the presence of an ECR (Electron Cyclotron Resonance) zone near the pole of the magnet.
[0092] Each permanent magnet 22 may be conventional, for example made of samarium-cobalt, of neodymium-iron-boron, or even of barium ferrite and strontium ferrite.
[0093] The plasma reactor described in the present application comprises means for pressure measurement and for desired plasma diagnosis (not shown in the figures).
[0094] Similarly, a substrate holder used for the methods put into practice comprises heating or cooling means as well as all the means (continuous, pulsed, low-frequency or radiofrequency means) for biasing the substrate necessary for the method employed.
ADVANTAGES OF THE INVENTION
[0095] One of the advantages provided by the present invention is the possibility of scale-up of the plasma sheets produced by said described technology and of producing dense plasmas in the pressure range defined in the invention.
[0096] Only a single applicator can be used.
[0097] Yet there is no limitation to increasing the number of applicators.
[0098] The applicators can be arranged in any geometry, and adapt to any configuration of the chamber, particularly cylindrical.
[0099] Similarly, it is possible to supply microwave power to as many applicators as desired by as many independent generators as necessary with or without power division.
[0100] Each applicator can be supplied via a coaxial cable, because the microwave power necessary for each applicator is relatively low, hence, the great dependability of the overall device.
[0101] A further advantage is that the microwave applicators are easy to cool by fluid circulation in the metal portion of the applicators. There is no need to supply a low-loss dielectric fluid as in the case of the surface wave discharges of the prior art.
[0102] Finally, it is easier to control the plasma/surface interaction parameters than in the devices of the prior art.
[0103] For example, if one considers a square network of coaxial microwave applicators, for example with a 16 mm inside diameter of the outer conductor arranged every two centimeters, the area of each applicator is 4 cm 2 . This area is reduced to about 3.5 cm 2 in the case of a hexagonal structure.
[0104] In the case of a 2 cm thick plasma sheet, fixed for example by the applicator/application surface distance, the volume of plasma created by each applicator is 8 cm 3 for a square network, and 7 cm 3 for a hexagonal network.
[0105] For a microwave power of 200 W per applicator, the maximum power density supplied to the plasma is 25 W/cm 3 for a square network, and 28.5 W/cm 3 for a hexagonal network.
[0106] In both cases, it is thereby possible to apply up to 5 kW per area of 100 mm×100 mm for a square network, or 25 applicators and slightly more for a hexagonal network.
[0107] A further advantage is the simplicity of construction of each basic applicator.
[0108] The microwave frequency used is not critical, and it is possible to use one of the ISM (Industrial, Scientific and Medical) frequencies such as 915 MHz or 2.45 GHz, or any other frequency.
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The invention relates to a device for the production of a plasma ( 16 ) within a housing comprising means for the generation of energy in the microwave spectrum, for the excitation of the plasma, said means comprise at least one basic plasma excitation device with a coaxial applicator ( 4 ) of microwave energy, one of the ends of which is connected to a production source ( 7 ) of microwave energy, the other end ( 8 ) of which is directed to the gas to be excited within the housing. The device is characterised in that each basic plasma excitation device is arranged in the wall ( 3 ) of the housing, each applicator ( 4 ) having a central core ( 5 ) which is essentially flush with the wall of the housing. The central core and the thickness of the wall ( 3 ) of the housing are separated by a space ( 6 ) coaxial to the central core, said space being totally filled, at least at the end of each applicator, by a dielectric material ( 14 ), such that said material is essentially flush with the level of the wall of the housing.
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[0001] This application is a continuation application claiming priority to Ser. No. 11/782,724, filed Jul. 25, 2007.
FIELD OF THE INVENTION
[0002] This invention relates to a method and system for providing regional channels in a digital broadcasting environment, particularly but not exclusively in an Internet Protocol Television (IPTV) environment.
BACKGROUND OF THE INVENTION
[0003] The provision of a television service over internet protocol (IP) is known as IPTV and utilizes a protocol known as multicast. Multicast is a protocol to address a group of addresses in order to send data from one or more sources to a multitude of addresses. This means that only a single stream broadcast is required regardless of how many receivers the multicast is addressed to.
[0004] An example of a multicast transmission and reception system is shown in FIG. 1 . The diagram shows the relative locations of HeadEnd Equipment 100 , Middleware Equipment 102 and Customer Premise equipment 104 . HeadEnd and Middleware Equipment 100 and 102 are connected to Customer Premise Equipment 104 by any appropriate network 106 which terminates at a digital subscriber line access multiplex (DSLAM) 108 . The communication to Customer Premise Equipment is then effected via a PSTN link 110 .
[0005] HeadEnd equipment 100 may include Encoders, Transcoders etc. and means (either via satellite, cable or any other appropriate manner) to broadcast the multicast that is produced. The multicast comprises a single stream for each of the different television channels that may be required to be transmitted to Customer Premise Equipment 104 .
[0006] Middleware Equipment 102 is found at the internet service provider for example, may include video on demand (VOD), unicast capabilities, time shift TV, soft switching, voice over IP (VoIP) and Network Personal Video Recording (NPVR). Middleware Equipment 102 is responsible for providing services to Customer Premise Equipment 104 as described above.
[0007] Customer Premise Equipment 104 includes a Residential Gateway (GW) 112 that is connected to other equipment, including a PC 114 , a telephone 116 and a Set Top Box 118 . Set Top Box 118 is connected to a television monitor 120 and can provide television programs to both the television monitor and PC 114 and any other monitor in the Customer Premise Equipment 104 .
[0008] Broadcasters will send the national television channels in their multicast. Regional channels may be introduced at locations closer to the user, for example at Middleware 102 or DSLAM 108 . Regional channels are channels which are relevant for a particular region. In the past regional encoders and regional channel inputs have been used to provide regional television channels to the user (customer). The drawback with this approach is that additional encoders are required at the regional locations. In fact for each different region additional encoding and transmitting equipment is required. Alternatively additional equipment is required to feed a regional stream to a DSLAM to provide these regional channels. Again this requires additional equipment in each region. This also means that some if not all, of the controls of regional channels are managed regionally, which has both advantages and disadvantages.
[0009] One object of the present invention is to provide a regional television channel service and method in the IPTV environment which at least overcomes some of the drawbacks associated with the prior art.
[0010] Another object of the present invention is to provide a regional TV method and apparatus without additional equipment than that already existing.
SUMMARY OF THE INVENTION
[0011] The present invention is directed to the method and system for delivering a regional television channel to a user.
[0012] According to a first embodiment of the present invention, there is provided a method of delivering a regional television channel to a user over an Internet Protocol Television (IPTV) service comprising the steps of forming a multicast of channels intended for delivery to a user each channel having a specific channel slot, the multicast of channels including at least one regional channel corresponding to one of the multicast channels, broadcasting the multicast channels to the user through a regional gateway, forming a regional channel control signal for scheduling and requesting broadcast of the at least one regional channel instead of the corresponding one of the multicast channels, transmitting the regional channel control signal to the regional gateway, and in accordance with the regional channel control signal, at the required time, switching the regional gateway to the at least one regional channel instead of the corresponding one of the multicast channels such that the regional channel is in the specific channel slot of the corresponding one of the multicast channels.
[0013] According to a second embodiment of the present invention, there is provided a method of broadcasting a regional television channel to a user over an Internet Protocol Television (IPTV) service from a regional location comprising the steps of receiving a multicast of channels intended for delivery to a user each channel having a specific channel slot, the multicast of channels including at least one regional channel corresponding to one of the multicast channels, broadcasting the multicast channels to the user, receiving a regional channel control signal for scheduling and requesting broadcast of the at least one regional channel instead of the corresponding one of the multicast channels, in accordance with the regional channel control signal, at the required time, switching the regional gateway to the at least one regional channel instead of the corresponding one of the multicast channels such that the regional channel is in the specific channel slot of the corresponding one of the multicast channels.
[0014] According to a third embodiment of the present invention, there is provided a method of generating a control signal for controlling the broadcast of regional television channel to a user over an Internet Protocol Television (IPTV) service, wherein the service is in the form of a multicast of channels, each channel having a specific channel slot, the multicast of channels including at least one regional channel corresponding to one of the multicast channels and the channels being broadcast to a user through a regional gateway comprising the steps of forming a regional channel control signal for scheduling and requesting broadcast of the at least one regional channel instead of the corresponding one of the multicast channels, transmitting the regional channel control signal to the regional gateway, and wherein the regional channel control signal, at the required time, causes switching of the regional gateway to the at least one regional channel instead of the corresponding one of the multicast channels such that the regional channel is in the specific channel slot of the corresponding one of the multicast channels.
[0015] According to a fourth embodiment of the present invention, there is provided a system for delivering a regional television channel to a user over an Internet Protocol Television (IPTV) service comprising means for forming a multicast of channels intended for delivery to a user each channel having a specific channel slot, the multicast of channels including at least one regional channel corresponding to one of the multicast channels, means for broadcasting the multicast channels to the user through a regional gateway, means for forming a regional channel control signal for scheduling and requesting broadcast of the at least one regional channel instead of the corresponding one of the multicast channels, means for transmitting the regional channel control signal to the regional gateway, and in accordance with the regional channel control signal, at the required time, means for switching the regional gateway to the at least one regional channel instead of the corresponding one of the multicast channels such that the regional channel is in the specific channel slot of the corresponding one of the multicast channels.
[0016] According to a fifth embodiment of the present invention, there is provided a system for broadcasting a regional television channel to a user over an Internet Protocol Television (IPTV) service from a regional location comprising means for receiving a multicast of channels intended for delivery to a user each channel having a specific channel slot, the multicast of channels including at least one regional channel corresponding to one of the multicast channels, means for broadcasting the multicast channels to the user, means for receiving a regional channel control signal for scheduling and requesting broadcast of the at least one regional channel instead of the corresponding one of the multicast channels, in accordance with the regional channel control signal, at the required time, means for switching the regional gateway to the at least one regional channel instead of the corresponding one of the multicast channels such that the regional channel is in the specific channel slot of the corresponding one of the multicast channels.
[0017] According to a sixth embodiment of the present invention, there is provided a device for broadcasting a regional television channel to a user over an Internet Protocol Television (IPTV) service from a regional location comprising means for receiving a multicast of channels intended for delivery to a user each channel having a specific channel slot, the multicast of channels including at least one regional channel corresponding to one of the multicast channels, means for broadcasting the multicast channels to the user, means for receiving a regional channel control signal for scheduling and requesting broadcast of the at least one regional channel instead of the corresponding one of the multicast channels, in accordance with the regional channel control signal, at the required time, means for switching the regional gateway to the at least one regional channel instead of the corresponding one of the multicast channels such that the regional channel is in the specific channel slot of the corresponding one of the multicast channels.
[0018] According to a seventh embodiment of the present invention, there is provided a device for generating a control signal for controlling the broadcast of regional television channel to a user over an Internet Protocol Television (IPTV) service, wherein the service is in the form of a multicast of channels, each channel having a specific channel slot, the multicast of channels including at least one regional channel corresponding to one of the multicast channels and the channels being broadcast to a user through a regional gateway comprising means for forming a regional channel control signal for scheduling and requesting broadcast of the at least one regional channel instead of the corresponding one of the multicast channels, means for transmitting the regional channel control signal to the regional gateway, and wherein the regional channel control signal, at the required time, causes means for switching of the regional gateway to the at least one regional channel instead of the corresponding one of the multicast channels such that the regional channel is in the specific channel slot of the corresponding one of the multicast channels.
[0019] According to an eighth embodiment of the present invention, there is provided a computer program comprising instructions for delivering a regional television channel to a user over an Internet Protocol Television (IPTV) service when the program is executed on a computer comprising the steps of forming a multicast of channels intended for delivery to a user each channel having a specific channel slot, the multicast of channels including at least one regional channel corresponding to one of the multicast channels, broadcasting the multicast channels to the user through a regional gateway, forming a regional channel control signal for scheduling and requesting broadcast of the at least one regional channel instead of the corresponding one of the multicast channels, transmitting the regional channel control signal to the regional gateway, and in accordance with the regional channel control signal, at the required time, switching the regional gateway to the at least one regional channel instead of the corresponding one of the multicast channels such that the regional channel is in the specific channel slot of the corresponding one of the multicast channel.
[0020] Further embodiments of the invention are provided in the appended dependent claims.
[0021] The advantages of the present invention are that a new protocol exists between HeadEnd Equipment 100 and DSLAM 108 which enables all the broadcast channels to be provided from the HeadEnd Equipment and selection to be made on regional bases at Middleware Equipment 102 . In addition, the user has the ability to select the regional channel the user would prefer to watch, for example, if this is not the user's local regional channel. Another advantage is that the present invention does not require additional hardware and instead reorganizes the channels (that are all transmitted from HeadEnd Equipment 100 ) in accordance to individual user needs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Reference will now be made by way of example to the accompanying drawings, in which
[0023] FIG. 1 is a block diagram of a general IPTV system;
[0024] FIG. 2 is a IPTV system in accordance with the present invention;
[0025] FIG. 3 is a table showing how the channels are changed for the present invention;
[0026] FIG. 4 is a block diagram showing details of a new protocol which exists in accordance with the present invention;
[0027] FIG. 5 is a table used at the HeadEnd Equipment in accordance with the present invention;
[0028] FIG. 6 is a table used at the DSLAM end of the equipment in accordance with the present invention;
[0029] FIG. 7 is a diagram showing the protocol description in accordance with the present invention;
[0030] FIG. 8 is a table for extension of the service provided in accordance with the present invention;
[0031] FIG. 9 is a block diagram of the method steps in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] FIG. 2 shows the IPTV system for delivery of regional television channels in accordance to the present invention. Equivalent equipment is found at the HeadEnd 200 , Middleware Equipment 202 and the Customer Premises End 204 similar to what was previously described with reference to FIG. 1 . The HeadEnd Equipment 200 and Middleware Equipment 202 are connected via Networks 206 , DSLAM 208 and PSTN connection 210 to the customer premises. As previously indicated Customer Premises Equipment 204 includes equipment such as PC 214 , Phone 216 , Set Top Box 218 and television monitor 220 . In addition to the standard equipment of an IPTV system, the present invention includes two additional features which are used to adapt Multicast 222 transmitting from HeadEnd equipment 200 . These two new additional elements are a Switch Regional Channel Server (SRC Server) 224 which is found in Middleware Equipment 202 and connects into Network 206 ; and a Switch Regional Channel Client (SRC Client) 226 found in DSLAM 208 . The function of SRC Server 224 and SRC Client 226 will now be described in greater detail.
[0033] Multicast 222 broadcast from the HeadEnd Equipment 200 will include a plurality of channels. Each channel will generally have a name and a channel slot on which it is broadcast. For example in France the multicast will include a plurality of channels for example TF 1 , TF 2 , TF 3 and many others. TF 3 may have timeslots during which a regional version of TF 3 may be broadcast. There may be a plurality of different regional TF 3 channels for many different areas of France, for example region 1 may relate to Nice, region 2 may relate to Alsace and region 3 may relate to Toulouse.
[0034] At certain times the broadcaster may decide to switch from the national TF 3 channel to broadcast a regional TF 3 channel. This may be to provide regional advertising or regional programming as the case may be. For example there may be a number of regional football games and each regional area may wish to watch the regional game. Also advertisers may wish to target regional customers at specific times of the day, for example a pizza delivery company may wish to target regional customers an hour before lunch or dinner.
[0035] In accordance with the present invention, Multicast 222 broadcast from HeadEnd Equipment 200 may include not only the national channel of TF 3 , but also all possible regional channels for TF 3 and any other channel where regional television may be anticipated or provided. Multicast 222 of multiple channels is broadcast and received at DSLAM 208 in any appropriate manner.
[0036] FIG. 3 shows a table 300 having a row showing Channel Names 302 and a row 304 showing the received Channel Number or slot on the DSLAM for the corresponding Channel Names. At the DSLAM if a regional channel is required to be broadcast to the end-users, the channel number for the regional channel is converted to replace the national channel number for the period of time over which the regional channel is to be transmitted. The new channel numbers or slots from the transmission end of the DSLAM are shown in row 306 of table 300 . At a time when a regional broadcast is happening it can be seen that the new channel slot for TF 3 national (NAT) has become 100 and the new channel slot for TF 3 region 1 (R 1 ) (the location of the user in question) is now channel 3 . The regional channel has thus temporarily taken the slot of the national channel. This provides an advantage for the user that when a regional program is available, the user does not need to search for the right channel to view that regional program, instead the regional program replaces the normal national transmission for that particular channel. In the case of advertising, the user will be unaware of the fact that targeted and specific advertising material in the breaks between television programs is being received. This is because, certain advertising material may be sent at certain times in accordance with advertisers requirements for a particular region. As will be described in greater detail below there is also a record kept of the number of users at any time watching a specific channel to assist with the scheduling of regional advertising or regional television programs to a time when the maximum number of users are watching.
[0037] As previously mentioned, the manner in which the regional channel and the national channel are exchanged at specific periods of time are dependent upon a new protocol which is called the Switch Regional Channel Protocol (SRCP).
[0038] FIG. 4 shows in more detail how the SRCP operates and makes the changes illustrated above. SRC Server 224 of FIG. 2 is shown at the Middleware point in the system, however it could be found at different places, for example at the HeadEnd or at the DSLAM as is appropriate for various circumstances. SRC server 400 is shown in FIG. 4 and includes an SRCP server 402 , an SRC DSLAM Table 404 and a Scheduler 406 . SRC Server 400 sends and receives commands 408 over Network 410 . Commands 408 in this instance are received by DSLAM 412 . The DSLAM supports the SRC Client (previously identified in FIG. 2 ) 414 . SRC Client 414 includes a Channel Table 416 and a Proxy Internet Group Management Protocol (IGMP) 418 . The SRCP allows a central point to request DSLAM 412 to switch to regional channel (IGMP port) for a specific period of time for the end-user connected to a given national channel (for example TF 3 as described above). As all the regional channels and national channels are multicast at all time on the network to DSLAM 412 from the HeadEnd Equipment it is at the DSLAM that the decision is made to which channel to communicate and onward broadcast to the user. This choice at DSLAM 412 is controlled by the SRCP. SRCP server 402 manages the protocol to control and demand when all requests should be sent to DSLAM 412 . SRC DSLAM Table 404 includes all the information on how to switch a channel from one slot to another. The scheduler is composed of an agenda to launch the action per hour or day as appropriate.
[0039] Referring now to FIG. 5 , SRC DSLAM Table 500 is shown in more detail. The table includes a number of columns. These columns include Location 502 , DSLAM Identifier (IP Address) 504 , Main Channel (IGMP Address) 506 , Regional Channel (IGMP Address) 508 , Start Session Time and Duration of Session 510 and On Line Switch Status 512 . Table 500 has been completed for two locations, namely Nice 514 and Strasbourg 516 where the regional channel is TF 3 Nice and Strasbourg respectively. The broadcaster wishes to transfer to the regional channel in each case at 11h30 for a duration of twenty minutes. In each case the national TF 3 channel is replaced with respective channel TF 3 Nice and TF 3 Strasbourg. The full details of all IP Addresses and IGMP Addresses are not shown but the nature and format of these will be understood by the persons skilled in the art. The table as previously indicated will be sent in the communication between the SRC server and SRC client. The table will be used by the DSLAM on receipt to transfer channel slot 3 on the DSLAM output from TF 3 national to TF 3 Nice or Strasbourg as appropriate at 11h30 for twenty minutes. The on line switch status on/off will be set as appropriate depending on whether the regional channel is off or on.
[0040] Referring now to FIG. 6 , SRC DSLAM client table 600 is shown. Table 600 includes a Main Channel (IGMP Address) 602 , a Regional Channel (IGMP Address) 604 ; a Start Session Time and Duration Session 606 and again an On Line Switch Status 608 . The content of this table will be made up in accordance with the content of the earlier presented SRC DSLAM tables as transmitted from the server.
[0041] In order for the server and client to communicate effectively, the requests and answers as carried out in accordance with the SRC protocol are now described with reference to FIG. 7 . The protocol is shown in general as 700 . Reference Numeral 702 shows an arrow indicating a communication from Server to Client while the reference 704 shows an arrow indicating the direction of communication from Client to Server. The Server is the SRC Server and the Client is the DSLAM or SRC Client in the DSLAM. The protocol commences with the server switch request SCrequest. This request comprises the information related to Main Channel, Second channel, Start Time and Duration. The client answers with an Accept SCrequest Switch that indicates the number of users (Nbuser) or Rejects the request (error code). If the request is accepted and the number of users is below a certain threshold, the broadcaster may change the Switch Request to be a STOP Request which will be described in more detail below. As previously indicated, the number of users is used by the broadcaster to determine whether there are sufficient viewers to justify broadcasting certain information or advertisements or whatever.
[0042] If the SRC Server wishes to send a Stop request, the Stop request will be sent in the from of a StopSC request which will include the same details as in the SCrequest. A client answer will be Accept-Stop request and again indicates the number of users that apply.
[0043] As previously described there are possibilities that the user may require a different regional channel than the one usually available based on the user's region. For example the user in Nice may prefer to watch the regional channel of Strasbourg. In these instances the protocol uses the third identified description (( 3 ) in FIG. 7 ). Here a Client request is sent to the Server subscribing to or requesting a different regional channel than that to which it would normally receive. This request is in the form of a Tableinfoquery. The server will then answer with an Accept-Tableinfoquery which will include the DSLAM Table extension information. In the alternative, the server may for some reason or another, reject the request and send an error code with the DSLAM Table extension information again.
[0044] The request from the user which is transmitted to the DSLAM may be made via any appropriate means for example the IP telephony link between the DSLAM and the user or any other appropriate means including e-mail, etc. Where such has been received at the Server, the SRC Server will generate an additional DSLAM Table extension 800 as is shown in FIG. 8 . SRC DSLAM Table extension 800 and the SRC DSLAM Table (shown in FIG. 5 ) are identical with the exception of column 802 . 802 the Mobile Subscriber ISDN Number (MSISDN Number) is included. This indicates the number on which the user has called to request a variation in the regional channel which is transmitted to it. This enables the DSLAM to send over the MSISDN Channel between the user and the DSLAM, the requested alternative regional channel in the form of a unicast as opposed to the multicast of all other channels. If a user makes a request for a change to the regional channel or an additional regional channel, the user may be charged for on an independent basis.
[0045] The result of the above system and method is that the user receives regional television over IPTV without the requirement of having separate encoders in regional locations. In addition, since the SRC DSLAM Tables are generated at the Middleware Equipment, the local provider can have some knowledge of the user requirement for the regional channel based on the number of users that is sent back from the DSLAM. This enables the Middleware ISP service providers to manage and control the advertising and programming provider to the user in order to maximize the number of users to which the relevant material is broadcast. This may be achieved by statistical analysis of the times at which the regional channel is generally watched. In addition, the provision of requests for the user for an alternative and/or additional regional channel means that people who are away from home or living in a new environment may still watch television programs that they enjoyed in the region from which they came.
[0046] Referring now to FIG. 9 , the main steps carried out by the method of the invention are now described. In the first step 900 , a multicast is generated and broadcast from the HeadEnd Equipment of the Broadcaster 900 . Thereafter in step 902 the Middleware Equipment under the control of the ISP or other intermediary service provider generates an SRC Server control signal including the elements set out in FIG. 4 . The remote DSLAM receives both the multicast and the control signal in step 904 . The DSLAM then uses the control signal to convert channel numbers in accordance with FIG. 2 in step 906 so that the user is broadcast on the regional channel rather than the national channel. At a certain point in time at the end of the duration in the SRC DSLAM Tables, for example, the regional programming ends at step 908 . The DSLAM reconverts channel numbers to their original position in step 910 so that the user will now view the national channel rather than the regional channel. The DSLAM then returns to the position of step 902 where it is a waiting the reception of an SRC server control signal. The regional programming may end at Step 908 due to the transmission of a Server SC Stop request as previously described.
[0047] The description has shown transmission of both the multicast and the control signals from the SRC Server to only one DSLAM. However, it would be appreciated that the same multicast and control signal could be sent to multiple DSLAM in the same region. In addition, both the middleware and the head end equipment could be located in the same place and be controlled by the same service providers. The service providers providing the services of both multicast and regionalisation could be any relevant body. The customer premise equipment set out in the figures and descriptions are shown only by way of example and may be replaced or augmented with any other equipment.
[0048] While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood that various changes inform and detail may be made therein without departing from the spirit, and scope of the invention.
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A method and system of broadcasting a regional television channel to a user. A digital subscriber line access multiplex (DSLAM) receives a broadcast of multicast channels intended for delivery to the user. The multicast channels include national channels and a regional channel. The DSLAM broadcasts the multicast channels to the user and receives a regional channel control signal specifying a broadcast during a specified period of time of the regional channel instead of a national channel previously scheduled to be broadcast to the user during the specified period of time. The DSLAM switches the multicast channels broadcasted to the user during the specified period of time from the national channel to the regional channel such that the regional channel is in a specific channel slot of the national channel during the specified period of time during broadcasting the multicast channels to the user.
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[0001] The present invention relates to a fuel injector with piezoelectric actuator.
BACKGROUND OF THE INVENTION
[0002] Fuel injectors with piezoelectric actuators have been available for many years now, i.e. fuel injectors provided with a valve that is displaced in a working direction between a closed position and an open position for activating a piezoelectric actuator.
[0003] Known piezoelectric actuators, for example of the type described in patent application DE19909451, comprise a fixed frame and an actuator body made of piezoelectric material arranged in alignment with a working direction; the actuator body has a lower base, which is arranged close to the valve, is mechanically linked to the valve itself, and is free to slide with respect to the fixed frame in the working direction, and has an upper base, which is opposite the lower base and is linked to the fixed frame. In use, the actuator body is excited with an electrical field in order to cause it to expand in the working direction and therefore displace the valve in the working direction from the closed position to the open position, in a direction in accordance with the fuel outlet direction. However, such a structure requires that in order for the valve to move from the closed position to the open position, it is displaced towards the outside of the injector putting itself into a configuration that can cause the injector to be soiled, and therefore its functions impaired.
SUMMARY OF THE INVENTION
[0004] The objective of the present invention is to produce a fuel injector with piezoelectric actuator, which does not have the drawbacks described above and, in particular, is easy and inexpensive to implement.
[0005] According to the present invention, a fuel injector with piezoelectric actuator is produced in accordance with claim 1.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present invention will now be described with reference to the attached drawings, which give a non-exhaustive illustration of a few embodiments of the invention, as follows:
[0007] [0007]FIG. 1 is a diagrammatic view, in side elevation and partial section, of a fuel injector produced according to the present invention;
[0008] [0008]FIG. 2 is a section, along the line II-II and with a few portions removed for clarity, of the injector in FIG. 1;
[0009] [0009]FIG. 3 is a diagrammatic view from above and in section of a different embodiment of a fuel injector produced according to the present invention;
[0010] [0010]FIG. 4 is a partial section along the line IV-IV of the injector in FIG. 4 [sic];
[0011] [0011]FIG. 5 is a partial section along the line V-V of the injector in FIG. 4 [sic]; and
[0012] [0012]FIG. 6 is a diagrammatic view, in side elevation and partial section, of another embodiment of a fuel injector produced according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] In FIGS. 1 and 2, the reference number 1 indicates a fuel injector as a whole, which comprises a container 2 substantially cylindrical in shape, having a central axis of symmetry 3 and a circular section; in correspondence with a lower end of the container 2 there is attached an injection pipe 4 , which is in the form of a cylindrical tube and ends in an injection port 5 regulated by a valve 6 that is moveable along the axis 3 between a closed position and an open position. Inside the container 2 there is arranged, coaxially with the axis 3 , a container 7 , which is cylindrical in shape, has a circular section and is provided with an internal chamber 8 that houses a piezoelectric actuator 9 capable of activating the valve 6 , i.e. capable of displacing the valve 6 between the aforementioned closed and open positions.
[0014] The container 7 has a diameter, i.e. a dimension transverse to the axis 3 , that is smaller than the container 2 so as to constitute, between the outer lateral surface 10 of the container 7 and the inner lateral surface 11 of the container 2 , an annular channel 12 through which the fuel can flow freely in a direction parallel to the axis 3 until it reaches the mouth of the injection pipe 4 ; in particular, the fuel is supplied under pressure to an upper portion of the annular channel 12 through a supply pipe 13 ending inside the container 2 .
[0015] The container 7 is integral with the container 2 by way of a contact zone 14 produced by welding or similar, so that the container 7 constitutes a fixed frame for the piezoelectric actuator 9 ; the piezoelectric actuator 9 comprises an actuator body 15 made of piezoelectric material, which is arranged in alignment with the axis 3 , is provided with a central hole 16 in alignment with the axis 3 , has a lower base 17 arranged close to the valve 6 and linked to the container 7 , and has an upper base 18 opposite the lower base 17 , which is free to slide with respect to the container 7 along the axis 3 .
[0016] As illustrated in FIGS. 1 and 2, the actuator body 15 is defined by two components 19 made of piezoelectric material, physically separated from one another and arranged symmetrically about the central axis 3 . According to another embodiment, not illustrated, the actuator body 15 is constituted [by] a single tubular component made of piezoelectric material arranged coaxially to the axis 3 .
[0017] Between the mobile upper base 18 and the valve 6 there is placed a mechanical transmission 20 provided with mobile equipment 21 , which is arranged in contact with the upper base 18 and is connected rigidly to the valve 6 ; in particular, the mobile equipment 21 comprises a plate 22 , which is transverse to the axis 3 , bears against the upper base 18 and is kept bearing against the upper base 18 itself by the pressure exerted along the axis 3 by a spring 23 compressed between the plate 22 and an upper portion 24 of the container 7 . A rod 25 is integral with the plate 22 , which rod is arranged inside the hole 16 along the axis 3 and is connected rigidly to the valve 6 .
[0018] Between the plate 22 and the upper base 18 there is placed an annular body 26 provided with a spherical contact surface 27 , so as to make the plate 22 floating with respect to the base 18 in order to be free to perform small oscillations about an axis perpendicular to the axis 3 ; these small free oscillations are necessary in order to allow the plate 22 to absorb without deformation, and therefore without breaking due to fatigue, any expansion differences in the components 19 made of piezoelectric material.
[0019] In order to drive the actuator body 15 , electric voltage is supplied to the actuator body 15 itself via an electric cable 28 , which passes through an appropriate open hole 29 in the upper portion 24 of the container 7 , through the central zone of the spring 23 , and through an open hole (not illustrated) in the plate 22 ; the electric cable 28 passes through the open hole (not illustrated) in the plate 22 with a certain amount of play to allow movement of the plate 22 along the axis 3 with respect to the electric cable 28 .
[0020] In use, when the actuator body 15 is non-excited, i.e. is not subject to an electrical field, the valve 6 is in the aforementioned closed position in that it is pushed downwards along the axis 3 by the pressure exerted by the spring 23 and transmitted to the valve 6 by the plate 22 and the rod 25 .
[0021] When the actuator body 15 is excited, i.e. is subject to an electrical field, the actuator body 15 itself expands along the axis 3 ; for the purposes of this expansion the lower base 17 stays still, since it is linked to the container 7 , while the upper base 18 performs an upward displacement along the axis 3 , which displacement is transmitted to the valve 6 by the plate 22 and the rod 25 and causes a displacement of the valve 6 along the axis 3 from the aforementioned closed position to the aforementioned open position.
[0022] As stated above, it is clear that the valve 6 is displaced along the axis 3 from the aforementioned closed position to the aforementioned open position in an opposite direction V 1 to that V 2 in which fuel leaves the supply pipe 13 ; therefore, in order to move from the closed position to the open position, the valve 6 is displaced towards the inside of the supply pipe 13 , putting itself in a configuration that reduces the soiling, and therefore impairment of the functions, of the injector 1 .
[0023] The internal chamber 8 of the container 7 is produced in such a way that it is isolated from the fuel; for this purpose the outer lateral surface 10 of the container 7 is continuous and has no opening, and the hole 30 in the lower portion 31 of the container 7 , to allow connection between the valve 6 and the rod 25 , is provided with a deformable holding component 32 .
[0024] The container 7 is made of sheet metal with a high thermal transmission coefficient; furthermore, the container 7 is provided with exchange means 33 capable of increasing heat exchange between the fuel and the piezoelectric actuator 9 .
[0025] As illustrated in FIGS. 1 and 2, the actuator body 15 has smaller dimensions than the dimensions of the chamber 8 , and the exchange means 33 comprise a plurality of transmission means 34 made of heat-conducting material, which have a shape and dimensions so as to be arranged between the actuator body 15 and an inner lateral surface 35 of the container 7 so as to increase heat transmission between the actuator body 15 and the container 7 . In particular, each transmission body 34 is arranged in contact with either the actuator body 15 or the inner lateral surface 35 of the container 7 .
[0026] In an embodiment not illustrated, the exchange means 33 also comprise finning of the outer lateral surface 10 of the container 7 bathed in the fuel.
[0027] As stated above, it is clear that the piezoelectric actuator 9 is arranged inside the chamber 8 , which is isolated from the fuel and has its outer lateral surface 10 bathed in the fuel itself; this configuration is particularly advantageous, since it makes it possible either to keep the piezoelectric actuator 9 isolated from the fuel, protecting the piezoelectric actuator 9 itself from the corrosive and soiling action of the fuel, or to ensure, in a simple and extremely economical manner, continuous cooling of the piezoelectric actuator 9 by transmitting the heat produced by the piezoelectric actuator 9 inside the chamber 8 to the fuel lapping the outer lateral surface 10 .
[0028] Furthermore, the use of the transmission bodies 34 makes it possible either to increase heat transmission from the piezoelectric actuator 9 to the container 7 , or to ensure correct positioning of the piezoelectric actuator 9 inside the chamber 8 , since the transmission bodies 34 also have the function of filling the empty spaces inside the chamber 8 itself.
[0029] In a preferred embodiment, the injector 1 is provided with at least one compensation component 36 having thermal expansion capable of compensating for the various heat expansions of the actuator body 15 and the mechanical transmission 20 ; in other words, through the combined effect of its own dimensions and thermal expansion coefficient (positive or negative), the compensation component 36 has heat expansion that cancels out all the various heat expansions of the actuator body 15 and the mechanical transmission 20 .
[0030] The compensation component 36 can be integrated into the container 7 , can be placed between the container 7 and the actuator body 15 (as illustrated in FIG. 1), or can be integrated into the mobile equipment 21 .
[0031] In a preferred embodiment, the compensator component 36 is made of metal with a low thermal expansion coefficient, particularly Invar.
[0032] In FIGS. 3, 4 and 5 the reference number 101 indicates a fuel injector as a whole, which comprises a container 102 substantially cylindrical in shape, having a central axis of symmetry 103 and a circular section; in correspondence with a lower end of the container 102 there is attached an injection pipe 104 , which is in the form of a cylindrical tube and ends in an injection port 105 regulated by a valve 106 that is moveable along the axis 103 between a closed position and an open position. Inside the container 102 there is arranged, coaxially with the axis 103 , a container 107 , which is cylindrical in shape, has an elliptical section and is provided with an internal chamber 108 that houses a piezoelectric actuator 109 capable of activating the valve 106 , i.e. capable of displacing the valve 106 between the aforementioned closed and open positions.
[0033] The container 107 has a dimension transverse to the axis 103 that is smaller than the container 102 so as to constitute, between the outer lateral surface 110 of the container 107 and the inner lateral surface 111 of the container 102 , an annular channel 112 through which the fuel can flow freely in a direction parallel to the axis 103 until it reaches the mouth of the injection pipe 104 ; in particular, the fuel is supplied under pressure to an upper portion of the annular channel 112 through a supply pipe 113 ending inside the container 102 .
[0034] The container 107 is integral with the container 102 by way of a contact zone 114 produced by welding or similar, so that the container 107 constitutes a fixed frame for the piezoelectric actuator 109 ; the piezoelectric actuator 109 comprises an actuator body 115 made of piezoelectric material, which is arranged in alignment with the axis 103 , has a lower base 117 arranged close to the valve 106 and linked to the container 107 , and has an upper base 118 opposite the lower base 117 and free to slide with respect to the container 107 along the axis 103 . The actuator body 115 is constituted by a single component 119 made of piezoelectric material arranged coaxially to the central axis 103 .
[0035] Between the mobile upper base 118 and the valve 106 there is placed a mechanical transmission 120 provided with mobile equipment 121 , which is arranged in contact with the upper base 117 and is connected rigidly to the valve 106 ; in particular, the mobile equipment 121 comprises a ring component 122 substantially rectangular in shape, which is moveable along the axis 3 , is arranged around the actuator body 115 and the container 107 , has an upper transverse side 123 arranged in contact with the upper base 118 , and a transverse side 124 opposite the transverse side 123 and connected rigidly to the valve 106 .
[0036] In particular, the ring component 122 is arranged so as to bear against the upper base 118 by means of the interposition of a cylindrical body 125 , and is kept bearing against the upper base 118 itself by the pressure exerted along the axis 103 by a spring 126 compressed between the upper transverse side 123 and an upper portion 127 of the container 102 . The cylindrical body 125 is arranged so as to pass through a hole 128 in the upper portion 129 of the container 107 and is coupled to the hole 128 itself by means of a holding component 130 .
[0037] In order to drive the actuator body 115 , electric voltage is supplied to the actuator body 115 itself via an electrical cable 131 , which passes through an appropriate open hole 132 of the container 102 and through an appropriate open hole 133 of the container 107 , which is coupled in a fluid-tight manner with the hole 132 . In use, when the actuator body 115 is non-excited, i.e. is not subject to an electrical field, the valve 106 is in the aforementioned closed position in that it is pushed downwards along the axis 103 by the pressure exerted by the spring 126 and transmitted to the valve 106 by the ring component 122 .
[0038] When the actuator body 115 is excited, i.e. is subject to an electrical field, the actuator body 115 itself expands along the axis 103 ; for the purposes of this expansion the lower base 117 stays still, since it is linked to the container 107 , while the upper base 118 performs an upward displacement along the axis 103 , which displacement is transmitted to the valve 106 by the cylindrical body 125 and the ring component 122 and causes a displacement of the valve 106 along the axis 103 from the aforementioned closed position to the aforementioned open position.
[0039] In FIG. 6, the reference number 201 indicates a fuel injector as a whole, which comprises a container 202 substantially cylindrical in shape, having a central axis of symmetry 203 and a circular section; in correspondence with a lower end of the container 202 there is attached an injection pipe 204 , which is in the form of a cylindrical tube and ends in an injection port 205 regulated by a valve 206 that is moveable along the axis 203 between a closed position and an open position. Inside the container 202 there is arranged, coaxially with the axis 203 , a container 207 , which is cylindrical in shape, has an circular section and is provided with an internal chamber 208 that houses a piezoelectric actuator 209 capable of activating the valve 206 , i.e. capable of displacing the valve 206 between the aforementioned closed and open positions.
[0040] The container 207 has a diameter, i.e. a dimension transverse to the axis 203 , that is smaller than the container 202 so as to constitute, between the outer lateral surface 210 of the container 207 and the inner lateral surface 211 of the container 202 , an annular channel 212 through which the fuel can flow freely in a direction parallel to the axis 203 until it reaches the mouth of the injection pipe 204 ; in particular, the fuel is supplied under pressure to an upper portion of the annular channel 212 through a supply pipe 213 ending inside the container 202 .
[0041] The container 207 is integral with the container 202 by way of a contact zone 214 produced by welding or similar, so that the container 207 constitutes a fixed frame for the piezoelectric actuator 209 ; the piezoelectric actuator 209 comprises an actuator body 215 made of piezoelectric material, which is arranged in alignment with the axis 203 , has a lower base 217 arranged close to the valve 206 and free to slide with respect to the container 207 along the axis 203 , and has an upper base 218 opposite the lower base 217 and linked to the container 207 . The actuator body 215 is constituted by a single component 219 made of piezoelectric material arranged coaxially to the central axis 203 .
[0042] Between the mobile lower base 217 and the valve 206 there is placed a mechanical transmission 220 , which is capable of inverting the direction of displacement produced by the expansion of the piezoelectric actuator 209 along the axis 203 so that, to a first displacement produced by the expansion of the piezoelectric actuator 209 along the axis 203 , there corresponds a second displacement of the valve 206 along the axis 203 in the opposite direction to the first displacement.
[0043] The mechanical transmission 220 is provided with mobile equipment 221 , which is linked to the lower base 217 and connected to the valve 206 , and is provided with a system 222 for inverting the rocking movement, which is capable to transforming a first displacement produced by the expansion of the piezoelectric actuator 209 along the axis 203 into a second displacement of the valve 206 along the axis 203 in the opposite direction to the first displacement.
[0044] The system 222 for inverting movement comprises a pair of rockers 223 arranged symmetrically on either side of the axis 203 ; each rocker 223 is supported on a respective fixed fulcrum 224 constituted by a spherical body projecting from a lower portion 226 of the container 202 , and is provided with an arm 226 arranged in contact with the mobile equipment 221 and by an arm 227 arranged in contact with a counterpart component 228 integral with the valve 206 .
[0045] The arms 226 and 227 of each rocker 223 bear against either the mobile equipment 221 or the counterpart component 228 , and are held in that condition by the pressure exerted along the axis 203 by a spring 229 compressed between the mobile equipment 221 and the counterpart component 228 .
[0046] In particular, the mobile equipment 221 comprises a plate 230 transverse to the axis 203 and integral with the lower base 217 ; integral with the plate 230 is a cylindrical body 231 , which passes through an open hole 232 of a lower portion 233 of the container 207 with the interposition of a holding component 234 . The body 231 supports a fork 235 , with two symmetrical branches 236 , each of which is held so as to bear against the end of a respective arm 226 .
[0047] In order to drive the actuator body 215 , electric voltage is supplied to the actuator body 215 itself via an electrical cable 237 .
[0048] In use, when the actuator body 215 is non-excited, i.e. is not subject to an electrical field, the valve 206 is in the aforementioned closed position in that it is pushed downwards along the axis 203 by the pressure exerted by the spring 229 .
[0049] When the actuator body 215 is excited, i.e. is subject to an electrical field, the actuator body 215 itself expands along the axis 203 ; for the purposes of this expansion the upper base 218 stays still, since it is linked to the container 207 , while the lower base 217 performs a downward displacement along the axis 203 , which displacement is transmitted to the valve 206 by the mechanical transmission 220 and causes a displacement of the valve 206 along the axis 203 from the aforementioned closed position to the aforementioned open position.
[0050] On the basis of the dimensional relationship between the arms 226 and 227 of each rocker 223 , it is possible to impose a given transmission ratio less than, greater than or equal to unity on the mechanical transmission 220 ; in particular, as illustrated in FIG. 6, the mechanical transmission 220 has an amplification factor that amplifies the displacement produced by the expansion of the actuator body 15 .
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Fuel injector provided with a piezoelectric actuator, a valve activated by the piezoelectric actuator and regulating a fuel supply that flows in a working direction, and a mechanical transmission placed between the piezoelectric actuator and the valve; an expansion of the piezoelectric actuator displaces the valve in the working direction from a closed position to an open position in an opposite direction to that of the fuel outlet.
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The present application claims priority to the PCT US98/02608 filed Feb. 12, 1998 and U.S. provisional application 60/037,609 filed Feb. 12, 1997.
FIELD OF THE INVENTION
This invention relates to novel cyclic substituted compounds, pharmaceutical compositions, processes for their preparation, and use thereof in treating IL-8, GROα, GROβ, GROγ, NAP-2, and ENA-78 mediated diseases.
BACKGROUND OF THE INVENTION
Many different names have been applied to Interleukin-8 (IL-8), such as neutrophil attractant/activation protein-1 (NAP-1), monocyte derived neutrophil chemotactic factor (MDNCF), neutrophil activating factor (NAF), and T-cell lymphocyte chemotactic factor. Interleukin-8 is a chemoattractant for neutrophils, basophils, and a subset of T-cells. It is produced by a majority of nucleated cells including macrophages, fibroblasts, endothelial and epithelial cells exposed to TNF, IL-1a, IL-1b or LPS, and by neutrophils themselves when exposed to LPS or chemotactic factors such as FMLP. M. Baggiolini et al., J. Clin. Invest . 84, 1045 (1989); J. Schroder et al, J. Immunol . 139, 3474 (1987) and J. Immunol . 144, 2223 (1990); Strieter, et al., Science 243, 1467 (1989) and J. Biol. Chem . 264, 10621 (1989); Cassatella et al., J. Immunol . 148, 3216 (1992).
GROα, GROβ, GROγand NAP-2 also belong to the chemokine a family. Like IL-8 these chemokines have also been referred to by different names. For instance GROα, β, γ have been referred to as MGSAa, b and g respectively (Melanoma Growth Stimulating Activity), see Richmond et al., J. Cell Physiology 129, 375 (1986) and Chang et al., J. Immunol 148, 451 (1992). All of the chemokines of the a-family which possess the ELR motif directly preceding the CXC motif bind to the IL-8 B receptor.
IL-8, GROα, GROβ, GROγ, NAP-2, and ENA-78 stimulate a number of functions in vitro. They have all been shown to have chemoattractant properties for neutrophils, while IL-8 and GROα have demonstrated T-lymphocytes, and basophilic chemotactic activity. In addition IL-8 can induce histamine release from basophils from both normal and atopic individuals GRO-α and IL-8 can in addition, induce lysozomal enzyme release and respiratory burst from neutrophils. IL-8 has also been shown to increase the surface expression of Mac-1 (CD11b/CD18) on neutrophils without de novo protein synthesis. This may contribute to increased adhesion of the neutrophils to vascular endothelial cells. Many known diseases are characterized by massive neutrophil infiltration. As IL-8, GROα, GROβ, GROγ and NAP-2 promote the accumulation and activation of neutrophils, these chemokines have been implicated in a wide range of acute and chronic inflammatory disorders including psoriasis and rheumatoid arthritis, Baggiolini et al., FEBS Lett . 307, 97 (1992); Miller et al., Crit. Rev. Immunol . 12, 17 (1992); Oppenheim et al., Annu. Rev. Immunol . 9, 617 (1991); Seitz et al., J. Clin. Invest . 87, 463 (1991); Miller et al., Am. Rev. Respir. Dis . 146, 427 (1992); Donnely et al., Lancet 341, 643 (1993). In addition the ELR chemokines (those containing the amino acids ELR motif just prior to the CXC motif) have also been implicated in angiostasis. Strieter et al., Science 258, 1798 (1992).
In vitro, IL-8, GROα, GROβ, GROγ and NAP-2 induce neutrophil shape change, chemotaxis, granule release, and respiratory burst, by binding to and activating receptors of the seven-transmembrane, G-protein-linked family, in particular by binding to IL-8 receptors, most notably the B-receptor. Thomas et al., J. Biol. Chem . 266, 14839 (1991); and Holmes et al., Science 253, 1278 (1991). The development of non-peptide small molecule antagonists for members of this receptor family has precedent. For a review see R. Freidinger in: Progress in Drug Research , Vol. 40, pp. 33-98, Birkhauser Verlag, Basel 1993. Hence, the IL-8 receptor represents a promising target for the development of novel anti-inflammatory agents.
Two high affinity human IL-8 receptors (77% homology) have been characterized: IL-8Ra, which binds only IL-8 with high affinity, and IL-8Rb, which has high affinity for IL-8 as well as for GROα, GROβ, GROγ and NAP-2. See Holmes et al., supra; Murphy et al., Science 253, 1280 (1991); Lee et al., J. Biol. Chem . 267, 16283 (1992); LaRosa et al., J. Biol. Chem . 267, 25402 (1992); and Gayle et al., J. Biol. Chem . 268, 7283 (1993).
There remains a need for treatment, in this field, for compounds which are capable of binding to the IL-8 a or b receptor. Therefore, conditions associated with an increase in IL-8 production (which is responsible for chemotaxis of neutrophil and T-cells subsets into the inflammatory site) would benefit by compounds which are inhibitors of IL-8 receptor binding.
SUMMARY OF THE INVENTION
This invention provides for a method of treating a chemokine mediated disease, wherein the chemokine is one which binds to an IL-8 a or b receptor and which method comprises administering an effective amount of a compound of Formula (I) or (II) or a pharmaceutically acceptable salt thereof. In particular the chemokine is IL-8.
This invention also relates to a method of inhibiting the binding of IL-8 to its receptors in a mammal in need thereof which comprises administering to said mammal an effective amount of a compound of Formula (I) or (II).
The present invention also provides for the novel compounds of Formula (I), and (II) and pharmaceutical compositions comprising a compound of Formula (I), and (II) and a pharmaceutical carrier or diluent.
Compounds of Formula (I) useful in the present invention are represented by the structure:
wherein
R is —NH—C(X 1 )—NH—(CR 13 R 14 ) v —Z;
X 1 is oxygen or sulfur;
Z is W, HET,
an optionally substituted C 1-10 alkyl, an optionally substituted C 2-10 alkenyl, or an optionally substituted C 2-10 alkynyl;
X is N—R 18 , O, C(O) or C(R 19 ) 2 ;
R 1 is independently selected from hydrogen, halogen, nitro, cyano, halosubstituted C 1-10 alkyl, C 1-10 alkyl, C 2-10 alkenyl, C 1-10 alkoxy, halosubstituted C 1-10 alkoxy, (CR 8 R 8 ) q S(O) t R 4 , hydroxy, hydroxy C 1-4 alkyl, aryl, aryl C 1-4 alkyl, aryloxy, aryl C 1-4 alkyloxy, heteroaryl, heteroarylalkyl, heterocyclic, heterocyclic C 1-4 alkyl, heteroaryl C 1-4 alkyloxy, aryl C 2-10 alkenyl, heteroaryl C 2-10 alkenyl, heterocyclic C 2-10 alkenyl, (CR 8 R 8 ) q NR 4 R 5 , C 2-10 alkenyl C(O)NR 4 R 5 , (CR 8 R 8 ) q C(O)NR 4 R 5 , (CR 8 R 8 ) q C(O)NR 4 R 10 , S(O) 3 R 8 , (CR 8 R 8 ) q C(O)R 11 , C 2-10 alkenyl C(O)R 11 , C 2-10 alkenyl C(O)OR 11 , C(O)R 11 , (CR 8 R 8 ) q C(O)OR 12 , (CR 8 R 8 ) q OC(O) R 11 , (CR 8 R 8 ) q NR 4 C(O)R 11 , (CR 8 R 8 ) q C(NR 4 )NR 4 R 5 , (CR 8 R 8 ) q NR 4 C(NR 5 )R 11 , (CR 8 R 8 ) q NHS(O) 2 R 17 , or (CR 8 R 8 ) q S(O) 2 NR 4 R 5 ; or two R 1 moieties together may form O—(CH 2 ) s —O or a 5 to 6 membered saturated or unsaturated ring; and wherein the aryl, heteroaryl, and heterocyclic containing moieties may all be optionally substituted;
n is an integer having a value of 1 to 3;
m is an integer having a value of 1 to 3;
p is an integer having a value of 1 to 3;
q is 0, or an integer having a value of 1 to 10;
s is an integer having a value of 1 to 3;
t is 0, or an integer having a value of 1 or 2;
v is 0, or an integer having a value of 1 to 4;
HET is an optionally substituted heteroaryl;
R 4 and R 5 are independently hydrogen, optionally substituted C 1-4 alkyl, optionally substituted aryl, optionally substituted aryl C 1-4 alkyl, optionally substituted heteroaryl, optionally substituted heteroaryl C 1-4 alkyl, heterocyclic, heterocyclic C 1-4 alkyl, or R 4 and R 5 together with the nitrogen to which they are attached form a 5 to 7 member ring which may optionally comprise an additional heteroatom selected from O/N/S;
R 6 is independently hydrogen, halogen, C 1-10 alkoxy, optionally substituted C 1-4 alkyl, halosubstituted C 1-4 alkyl, optionally substituted aryl, optionally substituted aryl C 1-4 alkyl, optionally substituted heteroaryl, optionally substituted heteroaryl C 1-4 alkyl, optionally substituted heterocyclic, or optionally substituted heterocyclic C 1-4 alkyl;
Y is independently selected from hydrogen, halogen, nitro, cyano, halosubstituted C 1-10 alkyl, C 1-10 alkyl, C 2-10 alkenyl, C 1-10 alkoxy, halosubstituted C 1-10 alkoxy, (CR 8 R 8 ) q S(O) t R 4 , hydroxy, hydroxyC 1-4 alkyl, aryl, aryl C 1-4 alkyl, aryloxy, arylC 1-4 alkyloxy, heteroaryl, heteroarylalkyl, heteroaryl C 1-4 alkyloxy, heterocyclic, heterocyclic C 1-4 alkyl, aryl C 2-10 alkenyl, heteroaryl C 2-10 alkenyl, heterocyclic C 2-10 alkenyl, (CR 8 R 8 ) q NR 4 R 5 , C 2-10 alkenyl C(O)NR 4 R 5 , (CR 8 R 8 ) q C(O)NR 4 R 5 , (CR 8 R 8 ) q C(O)NR 4 R 10 , S(O) 3 R 8 ; (CR 8 R 8 ) q C(O)R 11 , C 2-10 alkenyl C(O)R 11 , C 2-10 alkenyl C(O)OR 11 , (CR 8 R 8 ) q C(O)OR 12 , (CR 8 R 8 ) q OC(O) R 11 , (CR 8 R 8 ) q NR 4 C(O)R 11 , (CR 8 R 8 )qC(NR 4 )NR 4 R 5 , (CR 8 R 8 ) q NR 4 C(NR 5 )R 11 , (CR 8 R 8 ) q NHS(O) 2 R a , or (CR 8 R 8 ) q S(O) 2 NR 4 R 5 ; or two Y moieties together may form O—(CH 2 ) s —O or a 5 to 6 membered saturated or unsaturated ring; and wherein the aryl, heteroaryl, and heterocyclic containing moieties may all be optionally substituted;
R 8 is hydrogen or C 1-4 alkyl;
R 10 is C 1-10 alkyl C(O) 2 R 8 ;
R 11 is hydrogen, C 1-4 alkyl, optionally substituted aryl, optionally substituted aryl C 1-4 alkyl, optionally substituted heteroaryl, optionally substituted heteroarylC 1-4 alkyl, optionally substituted heterocyclic, or optionally substituted heterocyclicC 1-4 alkyl;
R 12 is hydrogen, C 1-10 alkyl, optionally substituted aryl or optionally substituted arylalkyl;
R 13 and R 14 are independently hydrogen, optionally substituted C 1-4 alkyl, or one of R 13 and R 14 may be optionally substituted aryl;
R 15 and R 16 are independently hydrogen or an optionally substituted C 1-4 alkyl,
R 17 is C 1-4 alkyl, optionally substituted aryl, optionally substituted aryl C 1-4 alkyl, optionally substituted heteroaryl, optionally substituted heteroarylC 1-4 alkyl, optionally substituted heterocyclic, or optionally substituted heterocyclicC 1 4alkyl;
R 18 is hydrogen, optionally substituted C 1-10 alkyl, C 1-10 alkoxy, halosubstituted C 1-10 alkoxy, hydroxy, arylC 1-4 alkyl, arylC 2-4 alkenyl, heteroaryl, heteroaryl-C 1-4 alkyl, heteroarylC 2-4 alkenyl, heterocyclic, or heterocyclicC 1-4 alkyl, wherein the aryl, heteroaryl and heterocyclic containing moieties may all be optionally substituted;
R 19 is independently hydrogen, halogen, C 1-10 alkyl, NR 4 R 5 , C 1-10 alkyl-NR 4 R 5, C(O)NR 4 R 5 , optionally substituted C 1-10 alkyl, halosubstituted C 1-10 alkyl, C 1-10 alkoxy, halosubstituted C 1-10 alkoxy, hydroxy, aryl, aryl C 1-4 alkyl, aryloxy, aryl C 1-4 alkyloxy, heteroaryl, heteroarylalkyl, heterocyclic, heterocyclic C 1-4 alkyl, or heteroaryl C 1-4 alkyloxy;
R a is NR 4 R 5 , alkyl, arylC 1-4 alkyl, arylC 2-4 alkenyl, heteroaryl, heteroaryl-C 1-4 alkyl, heteroarylC 2-4 alkenyl, heterocyclic, or heterocyclicC 1-4 alkyl; and wherein the aryl, heteroaryl and heterocyclic containing moieties may all be optionally substituted;
W is
the E containing ring is optionally selected from
the asterix * denoting point of attachment of the ring;
or a pharmaceutically acceptable salt thereof.
Compounds of Formula (II) useful in the present invention are represented by the structure:
wherein
R is —NH—C(X 1 )—NH—(CR 13 R 14 ) v —Z;
X 1 is oxygen or sulfur;
Z is W, HET,
an optionally substituted C 1-10 alkyl, an optionally substituted C 2-10 alkenyl, or an optionally substituted C 2-10 alkynyl;
X is N, or CR 6 ;
R 1 is independently selected from hydrogen, halogen, nitro, cyano, halosubstituted C 1-10 alkyl, C 1-10 alkyl, C 2-10 alkenyl, C 1-10 alkoxy, halosubstituted C 1-10 alkoxy, (CR 8 R 8 ) q S(O) t R 4 , hydroxy, hydroxy C 1-4 alkyl, aryl, aryl C 1-4 alkyl, aryloxy, aryl C 1-4 alkyloxy, heteroaryl, heteroarylalkyl, heterocyclic, heterocyclic C 1-4 alkyl, heteroaryl C 1-4 alkyloxy, aryl C 2-10 alkenyl, heteroaryl C 2-10 alkenyl, heterocyclic C 2-10 alkenyl, (CR 8 R 8 ) q NR 4 R 5 , C 2-10 alkenyl C(O)NR 4 R 5 , (CR 8 R 8 ) q C(O)NR 4 R 5 , (CR 8 R 8 ) q C(O)NR 4 R 10 , S(O) 3 R 8 , (CR 8 R 8 ) q C(O)R 11 , C 2-10 alkenyl C(O)R 11 , C 2-10 alkenyl C(O)OR 11 , C(O)R 11 , (CR 8 R 8 ) q C(O)OR 12 , (CR 8 R 8 ) q OC(O) R 11 , (CR 8 R 8 ) q NR 4 C(O)R 11 , (CR 8 R 8 ) q C(NR 4 )NR 4 R 5 , (CR 8 R 8 ) q NR 4 C(NR 5 )R 11 , (CR 8 R 8 ) q NHS(O) 2 R 17 , or (CR 8 R 8 ) q S(O) 2 NR 4 R 5 ; or two R 1 moieties together may form O—(CH 2 ) s O or a 5 to 6 membered saturated or unsaturated ring; and wherein the aryl, heteroaryl, and heterocyclic containing moieties may all be optionally substituted;
n is an integer having a value of 1 to 3;
m is an integer having a value of 1 to 3;
p is an integer having a value of 1 to 3;
q is 0, or an integer having a value of 1 to 10;
s is an integer having a value of 1 to 3;
t is 0, or an integer having a value of 1 or 2;
v is 0, or an integer having a value of 1 to 4;
HET is an optionally substituted heteroaryl;
R 4 and R 5 are independently hydrogen, optionally substituted C 1-4 alkyl, optionally substituted aryl, optionally substituted aryl C 1-4 alkyl, optionally substituted heteroaryl, optionally substituted heteroaryl C 1-4 alkyl, heterocyclic, heterocyclic C 1-4 alkyl, or R 4 and R 5 together with the nitrogen to which they are attached form a 5 to 7 member ring which may optionally comprise an additional heteroatom selected from O/N/S;
R 6 is hydrogen, halogen, C 1-10 alkoxy, optionally substituted C 1-4 alkyl, halosubstituted C 1-4 alkyl, optionally substituted aryl, optionally substituted aryl C 1-4 alkyl, optionally substituted heteroaryl, optionally substituted heteroaryl C 1-4 alkyl, optionally substituted heterocyclic, or optionally substituted heterocyclic C 1-4 alkyl;
Y is independently selected from hydrogen, halogen, nitro, cyano, halosubstituted C 1-10 alkyl, C 1-10 alkyl, C 2-10 alkenyl, C 1-10 alkoxy, halosubstituted C 1-10 alkoxy, (CR 8 R 8 ) q S(O) t R 4 , hydroxy, hydroxyC 1-4 alkyl, aryl, aryl C 1-4 alkyl, aryloxy, arylC 1-4 alkyloxy, heteroaryl, heteroarylalkyl, heteroaryl C 1-4 alkyloxy, heterocyclic, heterocyclic C 1-4 alkyl, aryl C 2-10 alkenyl, heteroaryl C 2-10 alkenyl, heterocyclic C 2-10 alkenyl, (CR 8 R 8 ) q NR 4 R 5 , C 2-10 alkenyl C(O)NR 4 R 5 , (CR 8 R 8 ) q C(O)NR 4 R 5 , (CR 8 R 8 ) q C(O)NR 4 R 10 , S(O) 3 R 8 , (CR 8 R 8 ) q C(O)R 11 , C 2-10 alkenyl C(O)R 11 , C 2-10 alkenyl C(O)OR 11 , (CR 8 R 8 ) q C(O)OR 12 , (CR 8 R 8 ) q OC(O)R 11 , (CR 8 R 8 ) q NR 4 C(O)R 11 , (CR 8 R 8 ) q C(NR 4 )NR 4 R 5 , (CR 8 R 8 ) q NR 4 C(NR 5 )R 11 , (CR 8 R 8 ) q NHS(O) 2 R a , or (CR 8 R 8 ) q S(O) 2 NR 4 R 5 ; or two Y moieties together may form O—(CH 2 ) s O or a 5 to 6 membered saturated or unsaturated ring; and wherein the aryl, heteroaryl, and heterocyclic containing moieties may all be optionally substituted;
R 8 is hydrogen or C 1-4 alkyl;
R 10 is C 1-10 alkyl C(O) 2 R 8 ;
R 11 is hydrogen, C 1-4 alkyl, optionally substituted aryl, optionally substituted aryl C 1-4 alkyl, optionally substituted heteroaryl, optionally substituted heteroarylC 1-4 alkyl, optionally substituted heterocyclic, or optionally substituted heterocyclicC 1-4 alkyl;
R 12 is hydrogen, C 1-10 alkyl, optionally substituted aryl or optionally substituted arylalkyl;
R 13 and R 14 are independently hydrogen, optionally substituted C 1-4 alkyl, or one of R 13 and R 14 may be optionally substituted aryl;
R 17 is C 1-4 alkyl, optionally substituted aryl, optionally substituted aryl C 1-4 alkyl, optionally substituted heteroaryl, optionally substituted heteroarylC 1-4 alkyl, optionally substituted heterocyclic, or optionally substituted heterocyclic C 1-4 alkyl;
R 18 is hydrogen, optionally substituted C 1-10 alkyl, C 1-10 alkoxy, halosubstituted C 1-10 alkoxy, hydroxy, arylC 1-4 alkyl, arylC 2-4 alkenyl, heteroaryl, heteroaryl-C 1-4 alkyl, heteroarylC 2 - 4 alkenyl, heterocyclic, or heterocyclicC 1-4 alkyl, wherein the aryl, heteroaryl and heterocyclic containing moieties may all be optionally substituted;
R 19 is independently hydrogen, halogen, C 1-10 alkyl, NR 4 R 5 , C 1-10 alkyl NR 4 R 5, C(O)NR 4 R 5 , optionally substituted C 1-10 alkyl, C 1-10 alkoxy, halosubstituted C 1-10 alkoxy, hydroxy, aryl, aryl C 1-4 alkyl, aryloxy, aryl C 1-4 alkyloxy, heteroaryl, heteroarylalkyl, heterocyclic, heterocyclic C 1-4 alkyl, or heteroaryl C 1-4 alkyloxy;
R a is NR 4 R 5 , alkyl, arylC 1-4 alkyl, arylC 2-4 alkenyl, heteroaryl, heteroaryl-C 1-4 alkyl, heteroarylC 2-4 alkenyl, heterocyclic, or heterocyclicC 1-4 alkyl; and wherein the aryl, heteroaryl and heterocyclic containing moieties may all be optionally substituted;
W is
the E containing ring is optionally selected from
the asterix * denoting point of attachment of the ring;
or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of Formula (I) and (II) may also be used in association with the veterinary treatment of mammals, other than. humans, in need of inhibition of IL-8 or other chemokines which bind to the IL-8 α and β receptors. Chemokine mediated diseases for treatment, therapeutically or prophylactically, in animals include disease states such as those noted herein in the Methods of Treatment section.
As readily seen, the difference between compounds of Formula (I) and (II) lies in the unsaturation of the hetero containing ring, and hence the substitutions on the X and the double bond. The remaining terms, defined below, are the same for both compounds of Formula (I) and (II) unless otherwise indicated.
Suitably R 1 is independently selected from hydrogen; halogen; nitro; cyano; halosubstituted C 1-10 alkyl, such as CF 3 ; C 1-10 alkyl, such as methyl, ethyl, isopropyl, or n-propyl; C 2-10 alkenyl; C 1-10 alkoxy, such as methoxy, or ethoxy; halosubstituted C 1-10 alkoxy, such as trifluoromethoxy; azide; (CR 8 R 8 ) q S(O) t R 4 , wherein t is 0, 1 or 2; hydroxy; hydroxy C 1-4 alkyl, such as methanol or ethanol; aryl, such as phenyl or naphthyl; aryl C 1-4 alkyl, such as benzyl; aryloxy, such as phenoxy; aryl C 1-4 alkyloxy, such as benzyloxy; heteroaryl; heteroarylalkyl; heteroaryl C 1-4 alkyloxy; aryl C 2-10 alkenyl; heteroaryl C 2-10 alkenyl; heterocyclic C 2-10 alkenyl; (CR 8 R 8 ) q NR 4 R 5 ; C 2-10 alkenyl C(O)NR 4 R 5 ; (CR 8 R 8 ) q C(O)NR 4 R 5 ; (CR 8 R 8 ) q C(O)NR 4 R 10 ; S(O) 3 H; S(O) 3 R 8 ; (CR 8 R 8 ) q C(O)R 11 ; C 2-10 alkenyl C(O)R 11 ; C 2-10 alkenyl C(O)OR 11 ; C(O)R 11 ; (CR 8 R 8 ) q C(O)OR 12 ; (CR 8 R 8 ) q OC(O)RI 1; (CR 8 R 8 ) q NR 4 C(O)R 11 ; (CR 8 R 8 ) q C(NR 4 )NR 4 R 5 ; (CR 8 R 8 ) q NR 4 C(NR 5 )R 11 ; (CR 8 R 8 ) q NHS(O) 2 R 17 ; (CR 8 R 8 ) q S(O) 2 NR 4 R 5 ; or two R 1 moieties together may form O—(CH 2 ) s —O or a 5 to 6 membered saturated or unsaturated ring. All of the aryl, heteroaryl, and heterocyclic containing moieties may be optionally substituted as defined herein below.
For use herein the term “the aryl, heteroaryl, and heterocyclic containing moieties” refers to both the ring and the alkyl, or if included, the alkenyl rings, such as aryl, arylalkyl, and aryl alkenyl rings. The term “moieties” and “rings” may be interchangeably used throughout.
It is recognized that R 1 moiety may be substituted on either the benzene ring or the X containing ring, if possible.
When R 1 forms a dioxybridge, s is preferably 1. When R 1 forms an additional unsaturated ring, it is preferably 6 membered resulting in a naphthylene ring system. This naphthylene ring may be substituted independently, 1 to 3 times by the other R 1 moieties as defined above.
Suitably, R 4 and R 5 are independently hydrogen, optionally substituted C 1-4 alkyl, optionally substituted aryl, optionally substituted aryl C 1-4 alkyl, optionally substituted heteroaryl, optionally substituted heteroaryl C 1-4 alkyl, heterocyclic, heterocyclicC 1-4 alkyl, or R 4 and R 5 together with the nitrogen to which they are attached form a 5 to 7 member ring which may optionally comprise an additional heteroatom selected from O/N/S.
Suitably, R 8 is independently hydrogen or C 1-4 alkyl.
Suitably, q is 0 or an integer having a value of 1 to 10.
Suitably, R 10 is C 1-10 alkyl C(O) 2 R 8 , such as CH 2 C(O) 2 H or CH 2 C(O) 2 CH 3 .
Suitably, R 11 is hydrogen, C 1-4 alkyl, aryl, aryl C 1-4 alkyl, heteroaryl, heteroaryl C 1-4 alkyl, heterocyclic, or heterocyclic C 1-4 alkyl.
Suitably, R 12 is hydrogen, C 1-10 alkyl, optionally substituted aryl or optionally substituted arylalkyl.
Suitably, R 13 and R 14 are independently hydrogen, or an optionally substituted C 1-4 alkyl which may be straight or branched as defined herein, or one of R 13 and R 14 are an optionally substituted aryl.
Suitably, v is 0, or an integer having a value of 1 to 4.
When R 13 or R 14 are an optionally substituted alkyl, the alkyl moiety may be substituted one to three times independently by halogen; halosubstituted C 1-4 alkyl such as trifluoromethyl; hydroxy; hydroxy C 1-4 alkyl; C 1-4 alkoxy; such as methoxy, or ethoxy; halosubstituted C 1-10 alkoxy; S(O) t R 4 ; aryl; NR 4 R 5 ; NHC(O)R 4 ; C(O)NR 4 R 5 ; or C(O)OR 8 .
Suitably, R 17 is C 1-4 alkyl, aryl, arylalkyl, heteroaryl, heteroarylC 1-4 alkyl, heterocyclic, or heterocyclicC 1-4 alkyl, wherein all of the aryl, heteroaryl and heterocyclic containing moieties may all be optionally substituted.
Suitably, Y is independently selected from hydrogen; halogen; nitro; cyano; halosubstituted C 1-10 alkyl; C 1-10 alkyl; C 2-10 alkenyl; C 1-10 alkoxy; halosubstituted C 1-10 alkoxy; azide; (CR 8 R 8 ) q S(O) t R 4 ; hydroxy; hydroxyC 1-4 alkyl; aryl; aryl C 1-4 alkyl; aryloxy; arylC 1-4 alkyloxy; heteroaryl; heteroarylalkyl; heteroaryl C 1-4 alkyloxy; heterocyclic, heterocyclic C 1-4 alkyl; aryl C 2-10 alkenyl; heteroaryl C 2-10 alkenyl; heterocyclic C 2-10 alkenyl; (CR 8 R 8 ) q NR 4 R 5 ; C 2-10 alkenyl C(O)NR 4 R 5 ; (CR 8 R 8 ) q C(O)NR 4 R 5 ; (CR 8 R 8 ) q C(O)NR 4 R 10 ; S(O) 3 H; S(O) 3 R 8 ; (CR 8 R 8 ) q C(O)R 11 ; C 2-10 alkenyl C(O)R 11 ; C 2-10 alkenyl C(O)OR 11 ; (CR 8 R 8 ) q C(O)OR 12 ; (CR 8 R 8 ) q OC(O) R 11 ; (CR 8 R 8 ) q C(NR 4 )NR 4 R 5 ; (CR 8 R 8 ) q NR 4 C(NR 5 )R 11 ; (CR 8 R 8 ) q NR 4 C(O)R 11 ; (CR 8 R 8 ) q NHS(O) 2 R a ; or (CR 8 R 8 ) q S(O) 2 NR 4 R 5 ; or two Y moieties together may form O—(CH 2 ) s —O or a 5 to 6 membered saturated or unsaturated ring. The aryl, heteroaryl and heterocyclic containing moieties noted above may all be optionally substituted as defined herein.
When Y forms a dioxybridge, s is preferably 1. When Y forms an additional unsaturated ring, it is preferably 6 membered resulting in a naphthylene ring system. These ring systems may be substituted 1 to 3 times by other Y moieties as defined above.
Suitably, R a is NR 4 R 5 , alkyl, aryl C 1-4 alkyl, arylC 2-4 alkenyl, heteroaryl, heteroaryl-C 1-4 alkyl, heteroarylC 2-4 alkenyl, heterocyclic, heterocyclicC 1-4 alkyl, wherein all of the aryl, heteroaryl and heterocyclic containing rings may all be optionally substituted.
Y is preferably a halogen, C 1-4 alkoxy, optionally substituted aryl, optionally substituted aryloxy or arylalkoxy, methylene dioxy, NR 4 R 5 , thio C 1-4 alkyl, thioaryl, halosubstituted alkoxy, optionally substituted C 1-4 alkyl, or hydroxy alkyl. Y is more preferably mono-substituted halogen, disubstituted halogen, mono-substituted alkoxy, disubstituted alkoxy, methylenedioxy, aryl, or alkyl, more preferably these groups are mono or di-substituted in the 2′- position or 2′-, 3′-position.
While Y may be substituted in any of the ring positions, n is preferably one. While both R 1 and Y can both be hydrogen, it is preferred that at least one of the rings be substituted, preferably both rings are substituted.
In compounds of Formula (I), R is —NH—C(X 1 )—NH—(CR 13 R 14 ) v —Z.
Suitably, Z is W, HET,
an optionally substituted C 1-10 alkyl, an optionally substituted C 2-10 alkenyl, or an optionally substituted C 2-10 alkynyl.
Suitably, p is an integer having a value of 1 to 3.
X 1 is oxygen or sulfur, preferably oxygen.
Suitably when Z is a heteroaryl (HET) ring, it is suitably a heteroaryl ring or ring system. If the HET moiety is a multi ring system, the ring containing the heteroatom does not need to be directly attached to the urea moiety through the (R 13 R 14 ) v linkage. Any of the ring(s) in these systems may be optionally substituted as defined herein. Preferably the HET moiety is a pyridyl, which may be 2-, 3- or 4-pyridyl. If the ring is a multi system ring it is preferably benzimidazole, dibenzothiophene, or an indole ring. Other rings of interest include, but are not limited to thiophene, furan, pyrimidine, pyrrole, pyrazole, quinoline, isoquinoline, quinazolinyl, oxazole, thiazole, thiadiazole, triazole, imidazole, or benzimidazole.
The HET ring may be optionally substituted independently one to five, preferably 1 to 3 times by Y as defined above. The substitutions may be in any of the ring(s) of the HET system, such as in a benzimidazole ring.
Suitably R 15 and R 16 are independently hydrogen, or an optionally substituted C 1-4 alkyl as defined above for R 13 and R 14 .
Suitably, W is
Suitably, the E containing ring is optionally selected from
the asterix * denoting point of attachment of the ring.
The E ring denoted by its point of attachment through the asterix (*) may optionally be present. If it is not present the ring is a phenyl moiety which is substituted by the R 1 terms as shown. The E ring may be substituted by the (Y)n moiety in any ring, saturated or unsaturated, and is shown for purposes herein substituted only in the unsaturated ring(s).
While Y in the W term may be substituted in any of the 5 ring positions of the phenyl moiety (when E is absent), Y is preferably mono-substituted in the 2′- position or 3′- position, with the 4′- preferably being unsubstituted. If the phenyl ring is disubstituted, substituents are preferably in the 2′or 3′ position of a monocyclic ring. While both R 1 and Y can both be hydrogen, it is preferred that at least one of the rings be substituted, preferably both rings are substituted.
Suitably, for compounds of Formula (I), X is N—R 18 , O, C(O) or C(R 19 ) 2 .
Suitably, R 18 is hydrogen, optionally substituted C 1-10 alkyl, C 1-10 alkoxy, halosubstituted C 1-10 alkoxy, hydroxy, arylC 1-4 alkyl, arylC 2-4 alkenyl, heteroaryl, heteroaryl-C 1-4 alkyl, heteroarylC 2-4 alkenyl, heterocyclic, or heterocyclicC 1-4 alkyl, wherein the aryl, heteroaryl and heterocyclic containing moieties may all be optionally substituted. Preferably, for compounds of formula (I), R 18 is hydrogen or alkyl, more preferably hydrogen.
Suitably, R 19 is independently hydrogen, halogen, C 1-10 alkyl, NR 4 R 5 , C 1-10 alkyl-NR 4 R 5 , C(O)NR 4 R 5 , optionally substituted C 1-10 alkyl, halosubstituted C 1-10 alkyl C 1-10 alkoxy, halosubstituted C 1-10 alkoxy, hydroxy, aryl, aryl C 1-4 alkyl, aryloxy, aryl C 1-4 alkyloxy, heteroaryl, heteroarylalkyl, heterocyclic, heterocyclic C 1-4 alkyl, or heteroaryl C 1-4 alkyloxy;
For compounds of Formula (II) X is N, or CR 6 .
Suitably, R 6 is hydrogen, halogen, C 1-10 alkoxy, optionally substituted C 1-4 alkyl, halosubstituted C 1-4 alkyl, optionally substituted aryl, optionally substituted aryl C 1-4 alkyl, optionally substituted heteroaryl, optionally substituted heteroaryl C 1-4 alkyl, optionally substituted heterocyclic, or an optionally substituted heterocyclic C 1-4 alkyl.
As used herein, “optionally substituted” unless specifically defined shall mean such groups as halogen, such as fluorine, chlorine, bromine or iodine; hydroxy; hydroxy substituted C 1-10 alkyl; C 1-10 alkoxy, such as methoxy or ethoxy; S(O) m′ C 1-10 alkyl, wherein m′ is 0, 1 or 2, such as methyl thio, methyl sulfinyl or methyl sulfonyl; amino, mono & di-substituted amino, such as in the NR 4 R 5 group; NHC(O)R 4 ; C(O)NR 4 R 5 ; C(O)OH; S(O) 2 NR 4 R 5 ; NHS(O) 2 R 20 , C 1-10 alkyl, such as methyl, ethyl, propyl, isopropyl, or t-butyl; halosubstituted C 1-10 alkyl, such CF 3 ; an optionally substituted aryl, such as phenyl, or an optionally substituted arylalkyl, such as benzyl or phenethyl, optionally substituted heterocylic, optionally substituted heterocyclicalkyl, optionally substituted heteroaryl, optionally substituted heteroaryl alkyl, wherein these aryl , heteroaryl, or heterocyclic moieties may be substituted one to two times by halogen; hydroxy; hydroxy substituted alkyl; C 1-10 alkoxy; S(O) m′ C 1-10 alkyl; amino, mono & di-substituted amino, such as in the NR 4 R 5 group; C 1-10 alkyl, or halosubstituted C 1-10 alkyl, such as CF 3 .
R 20 is suitably C 1-4 alkyl, aryl, aryl C 1-4 alkyl, heteroaryl, heteroarylC 1-4 alkyl, heterocyclic, or heterocyclicC 1-4 alkyl.
Suitable pharmaceutically acceptable salts are well known to those skilled in the art and include basic salts of inorganic and organic acids, such as hydrochloric acid, hydrobromic acid, sulphuric acid, phosphoric acid, methane sulphonic acid, ethane sulphonic acid, acetic acid, malic acid, tartaric acid, citric acid, lactic acid, oxalic acid, succinic acid, fumaric acid, maleic acid, benzoic acid, salicylic acid, phenylacetic acid and mandelic acid. In addition, pharmaceutically acceptable salts of compounds of Formula (I) may also be formed with a pharmaceutically acceptable cation, for instance, if a substituent group comprises a carboxy moiety. Suitable pharmaceutically acceptable cations are well known to those skilled in the art and include alkaline, alkaline earth, ammonium and quaternary ammonium cations.
The following terms, as used herein, refer to:
“halo”—all halogens, that is chloro, fluoro, bromo and iodo.
“C 1-10 alkyl” or “alkyl”—both straight and branched chain radicals of 1 to 10 carbon atoms, unless the chain length is otherwise limited, including, but not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, iso-butyl, tert-butyl, n-pentyl and the like.
The term “cycloalkyl” is used herein to mean cyclic radicals, preferably of 3 to 8 carbons, including but not limited to cyclopropyl, cyclopentyl, cyclohexyl, and the like.
The term “alkenyl” is used herein at all occurrences to mean straight or branched chain radical of 2-10 carbon atoms, unless the chain length is limited thereto, including, but not limited to ethenyl, 1-propenyl, 2-propenyl, 2-methyl-1-propenyl, 1-butenyl, 2-butenyl and the like.
“aryl”—phenyl and naphthyl;
“heteroaryl” (on its own or in any combination, such as “heteroaryloxy”, or “heteroaryl alkyl”)—a 5-10 membered aromatic ring system in which one or more rings contain one or more heteroatoms selected from the group consisting of N, O or S, such as, but not limited, to pyrrole, pyrazole, furan, thiophene, quinoline, isoquinoline, quinazolinyl, pyridine, pyrimidine, oxazole, thiazole, thiadiazole, triazole, imidazole, or benzimidazole.
“heterocyclic” (on its own or in any combination, such as “heterocyclicalkyl”)—a saturated or partially unsaturated 4-10 membered ring system in which one or more rings contain one or more heteroatoms selected from the group consisting of N, O, or S; such as, but not limited to, pyrrolidine, piperidine, piperazine, morpholine, tetrahydropyran, or imidazolidine.
The term “arylalkyl” or “heteroarylalkyl” or “heterocyclicalkyl” is used herein to mean C 1-10 alkyl, as defined above, attached to an aryl, heteroaryl or heterocyclic moiety, as also defined herein, unless otherwise indicated.
“sulfinyl”—the oxide S(O) of the corresponding sulfide, the term “thio” refers to the sulfide, and the term “sulfonyl” refers to the fully oxidized S(O) 2 moiety.
The term “wherein two R 1 moieties (or two Y moieties) may together form a 5 or 6 membered saturated or unsaturated ring” is used herein to mean the formation of an aromatic ring system, such as naphthalene, or is a phenyl moiety having attached a 6 membered partially saturated or unsaturated ring such as a C 6 cycloalkenyl, i.e. hexene, or a C 5 cycloalkenyl moiety, such as cyclopentene.
Exemplified compounds of Formula (I) include:
N-[8-(3,4-Dihydro-1H-2,1-benzothiazine, 2,2-dioxide)]-N′-[2-bromophenyl]urea;
N-[8-(4-Keto-3,4-dihydrosulfostyril)]-N′(2-bromophenyl)urea
Exemplified compounds of Formula (II) include:
N-[8-(Sulfostyril)]-N′-[2-bromophenyl]urea
For purposes herein the ring systems for compounds of Formula (I) and (II) are named as follows for illustration only with v=0, and Z is phenyl:
For compounds of Formula (I):
X=N, X 1 =O, v=0, and Z is an unsubstituted phenyl
N-(3,4-Dihydro-2,2-dioxido-1H-2,1,4-benzothiadiazin-8-yl)-N′-phenylurea
X=N, X 1 =S, v=0, and Z is an unsubstituted phenyl
N-(3,4-Dihydro-2,2-dioxido-1H-2,1,4-benzothiadiazin-8-yl)-N′-phenylthiourea
X=C, X 1 =O, v=0, and Z is an unsubstituted phenyl
N-(3,4-Dihydro-2,2-dioxido-1H-2,1-benzothiazin-8-yl)-N′-phenylurea
X=C, X 1 =S, v=0, and Z is an unsubstituted phenyl
N-(3,4-Dihydro-2,2-dioxido-1H-2,1-benzothiazin-8-yl)-N′-phenylthiourea
X=C(=O) i.e. carbonyl, X 1 =O, v=0, and Z is an unsubstituted phenyl
N-(3,4-Dihydro-2,2-dioxido-4-oxo-1H-2,1-benzothiazin-8-yl)-N ′-phenylurea
X=C(=O) i.e. carbonyl, X 1 =S, v=0, and Z is an unsubstituted phenyl
N-(3,4-Dihydro-2,2-dioxido-4-oxo-1H-2,1-benzothiazin-8-yl)-N′-phenylthiourea
For compounds of Formula (II):
wherein
X=N, X 1 =O, v=0, and Z is an unsubstituted phenyl
N-(2,2-Dioxido-1H-2,1,4-benzothiadiazin-8-yl)-N′-phenylurea
X=N, X 1 =S, v=0, and Z is an unsubstituted phenyl
N-(2,2-Dioxido-1H-2,1,4-benzothiadiazin-8-yl)-N′-phenylthiourea
X=C, X 1 =O, v=0, and Z is an unsubstituted phenyl
N-(2,2-Dioxido-1H-2,1-benzothiazin-8-yl)-N′-phenylurea
X=C, X 1 =S, v=0, and Z is an unsubstituted phenyl
N-(2,2-Dioxido-1H-2,1-benzothiazin-8-yl)-N′-phenylthiourea
Methods of Preparation
The compounds of Formula (I) and (II) may be obtained by applying synthetic procedures, some of which are illustrated in the Schemes below. The synthesis provided for in these Schemes is applicable for the producing of Formula (I) having a variety of different R, R 1 , and Ar groups which are reacted, employing optional substituents which are suitably protected to achieve compatibility with the reactions outlined herein. Subsequent deprotection, in those cases, then affords compounds of the nature generally disclosed. Once the urea nucleus has been established, further compounds of these formulas may be prepared by applying standard techniques for functional group interconversion, well known in the art. While the schemes are shown with compounds of Formula (I) this is merely for illustration purposes only.
If the desired heterocyclic compound 6-scheme 1 is not commercially available, the commercially available sulfonic acid can be converted to the corresponding sulfonyl chloride using a chlorinating agent such as thionyl chloride. The thionyl chloride 2-scheme 1 can be reacted with a commercially available aniline. The ester can be hydrolyzed using basic conditions such as 10% NaOH. The acid 3-scheme 1 can be cyclized under acidic or lewis acidic conditions such as polyphosphoric acid or AlCl 3 . The ketone can be converted to the double bond through formation of the hydrazine followed by rearrangement to the double bond under basic conditions. If substitution is desired on the sulfonamide ring it can be produced by alkylation of the compound 4-scheme-1 using standard conditions such as reaction with an alkyl halide in the presence of a base. The acidic nitrogen on compound 4-scheme-1 may have to be temporarily protected with a suitable protecting group such as an allyl, sulfonamide or BOM group.(Green ref) Alternatively compound 6-scheme-1 can be functionalized using a Michael reaction involving a functionalized organo cuprate. A number of other reactions can also be used to functionalize the double bond such epoxidation followed by epoxide opening, bromination followed by alkylation, and Diels-Alder reactions.
If the desired aniline 3-scheme 2 is not commercially available the corresponding nitro compound can be prepared from 1-scheme 2, under standard nitration conditions (using HNO 3 or NaNO 3 ) at 23° C. The nitro compound can then be reduced to the corresponding aniline using SnCl 2 in EtOH. (or alternately LiAlH 4 ).
If the desired aniline 2-scheme 3 is not commercially available the nitro compound can be prepared from 2-scheme 2, which can then be reduced to the corresponding aniline using H 2 /Pd in EtOH.
Ortho substituted heterocyclic phenyl ureas in 2-scheme 4 may be prepared by standard conditions involving the condensation of the commercially available optionally substituted (aryl or alkyl) isocyanate or thioisocyanate (Aldrich Chemical Co., Milwaukee, Wis.) with the corresponding aniline 1-scheme 4 in an aprotic solvent such as (DMF, toluene).
If the desired heterocyclic compound 3-scheme 5 is not commercially available then it can be prepared by condensing the commercially available sulfonyl chloride 2-scheme 1 with 2-nitro aniline followed by hydrolysis to the acid 2-scheme 5. The acid can be cyclized by treatment with SOCl 2 then AlCl 3 in CH 2 Cl 2 . The corresponding aniline and the ortho substituted phenyl urea may be prepared using conditions outlined in scheme 2 and scheme 4.
If the desired heterocycle 3-Scheme 6 is not available it can be synthesized from the corresponding commercially available amino phenol and chloromethyl sulfonyl chloride under basic conditions(such as triethyl amine or potassium carbonate). The corresponding aniline and the ortho substituted phenyl urea may be prepared using conditions outlined in scheme 2 and scheme 4. If substitution is desired on the sulfonamide ring it can be produced by alkylation of the compound 3-scheme-6 using standard conditions such as reaction with an alkyl halide in the presence of a base. The acidic nitrogen on compound 3-scheme-6 may have to be protected with a suitable protecting group such as an allyl, sulfonamide or BOM group.
If the desired heterocycle 3-Scheme 7 is not available in can be synthesized from the corresponding commercially available phenylenediamine and chloromethyl sulfonyl chloride under basic conditions(such as triethyl amine or potassium carbonate). The corresponding aniline and the ortho substituted phenyl urea may be prepared using conditions outlined in scheme 2 and scheme 4. If substitution is desired on the sulfonamide ring it can be produced by alkylation of the compound 3-scheme-7 using standard conditions such as reaction with an alkyl halide in the presence of a base. The acidic nitrogen on compound 3-scheme-7 may have to be protected with a suitable protecting group such as an allyl, sulfonamide or BOM group. In the case where R 18 is H the compound 3-scheme-7 can be oxidized to the imine using MnO 2 .
SYNTHETIC EXAMPLES
The invention will now be described by reference to the following examples which are merely illustrative and are not to be construed as a limitation of the scope of the present invention. All temperatures are given in degrees centigrade, all solvents are highest available purity and all reactions run under anhydrous conditions in an argon atmosphere unless otherwise indicated.
In the Examples, all temperatures are in degrees Centigrade (° C). Mass spectra were performed upon a VG Zab mass spectrometer using fast atom bombardment, unless otherwise indicated. 1 H-NMR (hereinafter “NMR”) spectra were recorded at 250 MHz using a Bruker AM 250 or Am 400 spectrometer. Multiplicities indicated are: s=singlet, d=doublet, t=triplet, q=quartet, m=multiplet and br indicates a broad signal. Sat. indicates a saturated solution, eq indicates the proportion of a molar equivalent of reagent relative to the principal reactant.
Example 1
Preparation of N-[8-(Sulfostyril)]-N′-[2-bromophenyl]urea
a) Preparation of Methyl Chlorosulfonyl Acetate
To a solution of sulfoacetic acid(10 g, 71.4 mmol) in 30% benzene in methanol(100 ml), the anhydrous hydrogen chloride was passed through the solution for 4 hours. The solution was then heated to reflux temperature and water was collected in a Dean-Stark trap. After the distillate cleared to one phase the solution was stirred at reflux for 1 hour. Then it was cooled to room temperature and concentrated. The residue was dissolved in thionyl chloride(12.3 g, 71.4 mmol) and was stirred at 120° C. for 3 hours. Then all solvent evaporated to give desired product(11 g, 93.5%). 1 H NMR (CDCL 3 ): δ 4.62 (s, 2H), 3.89 (s, 3H).
b) Preparation of Methyl N-Phenylsulfamoylacetate
To a solution of aniline (84.5 g, 910 mmol) in anhydrous ether (1 L), the methyl chlorosulfonyl acetate (74.7 g, 433 mmol) was added dropwise at below 10° C. The reaction mixture was stirred at room temperature for 20 hours and then filtered. The filtrate was concentrated and chromatography of the resulting solid on silica gel (50% Ethyl acetate/Hexane) gave the desired product(64 g, 64%). mp 76-78° C.
c) Preparation of N-Phenylsulfamoylacetic Acid
A solution of methyl N-phenylsulfonylacetate (17.9 g, 78.2 mmol) in 10% sodium hydroxide (180 ml) was heated for 3 hours at refluxed temperature. The solution was cooled and acidified with 3N of hydrochloric acid. The resulting solid was extracted with chloroform and the combined the organic layer was dried (MgSO 4 ) and concentrated to give the desired product (9.2 g, 55%). mp 113-115° C.
d) Preparation of 4-Keto-3,4-dihydrosulfostyril
A mixture of N-phenylsulfamoylacetic acid (2.8 g, 13 mmol) and polyphosphoric acid (65 g) was heated to 125° C. and maintained at this temperature for 5 minutes with stirring. The resulting mixture was cooled and poured into 300 ml of ice water. A tan solid precipitated, filtered to give desired product (1.9 g, 74%). mp 192-193° C.
e) Preparation of 4-Keto-3,4-dihydrosulfostyril, p-Toluenesulfonylhydrazone
A mixture of 4-keto-3,4-dihydrosulfostyril (11.3 g, 57.3 mmol), p-toluenesulfonylhydrazine (11.7 g, 63 mmol), alcohol (100 ml) and 3 drops of concentrated hydrochloric acid was heated at reflux for 3 hours. The resulting mixture was concentrated to 40 ml and then poured into 400 ml of ice water. The gum which first separated slowly crystallized. The solid was filtered and recrystallized from alcohol-water to give desired product. mp 213-214° C.
f) Preparation of Sulfostyril
To a solution of hydrazone (18.8 g, 51.5 mmol) in hot alcohol (600 ml), sodium methoxide (8.65 g, 155 mmol) was added. The reaction mixture was stirred at refluxed temperature for several minutes until precipitate was complete. Sufficient water was added to dissolve the solid, and the resulting brown solution was stirred at reflux for 20 hours. The solution was concentrated to a small volume then diluted with water. On acidification with concentrated hydrochloric acid a precipitate separated and was filtered. The solid was extracted twice with boiling water, on cooling, a white solid precipitated and this was recrystallized from chloroform to give desired product. (4.5 g, 48.4%). mp 153-155° C.
g) Preparation of 8-Nitrosulfostyril
Sulfostyril (1.0 g, 5.52 mmol) was dissolved in methylene chloride (40 ml) followed by the addition of sodium nitrate (0.516 g, 6.1 mmol). The addition of sulfuric acid (1.1 ml/3M) is then made, followed by addition of a catalytic amount of sodium nitrite. The mixture is allowed to stir. After 24 hours, the reaction mixture is diluted with methylene chloride and extracted with water. The organic layer is dried over MgSO 4 and filtered. The solvent was evaporated and chromatography of the resulting solid on silica gel (4% MeOH/CH 2 Cl 2 ) gave the desired product(260 mg, 21%). EI-MS m/z 227 (M + ).
h) Preparation of 8-Aminosulfostyril
To the solution of 8-nitrosulfostyril (130 mg, 0.57 mmol) in ethanol (10 ml), Tin (II) chloride (688 mg, 3.05 mmol) was added. The reaction mixture was stirred at refluxed temperature for 4 hours. Then was cooled to room temperature. The NaHCO 3 (aq) was added to pH=7. Then was extracted with ethyl acetate (3×). The combined organic layer was dried over MgSO 4 , filtered and concentrated under reduced pressure to give desired product (105 mg, 94%). EI-MS m/z 197 (M − ).
i) N-[8-(Sulfostyril)]-N′-[2-bromophenyl]urea
To a solution of 2-bromo phenyl isocyanate (26 mg, 0.13 mmol) in DMF (1.0 ml), the 8-aminosulfostyril (24 mg, 0.12 mmol) was added. The reaction mixture was stirred at room temperature for 16 hours. Chromatography of the resulting liquid on silica gel (50% Ethyl acetate/Hexane) gave desired product (26 mg, 54%). EI-MS m/z 395 (M + ).
Example 2
Preparation of N-[8-(3,4-Dihydro-1H-2,1-benzothiazine,2.2-dioxide)]-N′-[2-bromophenyl]urea
a) Preparation of 8-Amino-(3,4-Dihydro-1H-2,1-benzothiazine,2,2-dioxide
To a solution of 8-nitrosulfostyril (130 mg, 0.57 mmol) in ethanol(15 ml) and was added 10% Pd/C (130 mg). The mixture was flushed with argon, then the solution was stirred with a hydrogen atmosphere at balloon pressure for 2 hours. The mixture was filtered through celite and the celite was washed with ethanol. The solvent was evaporated to give the desired product(64 mg, 58%). EI-MS m/z 199 (M + ).
b) Preparation of N-[8-(3,4-Dihydro-1H-2,1-benzothiazine,2.2-dioxide)]-N′-[2-bromophenyl]urea
To a solution of 2-bromo phenyl isocyanate (74.8 mg, 0.37 mmol) in DMF (1.0 ml), the 8-amino-(3,4-Dihydro-1H-2,1-benzothiazine, 2,2-dioxide (68 mg, 0.34 mmol) was added. The reaction mixture was stirred at room temperature for 16 hours. Chromatography of the resulting liquid on silica gel (50% Ethyl acetate/Hexane) gave desired product (80 mg, 58.8%). EI-MS m/z 397 (M + ).
Using analagous methods to those indicated above, the following additional compounds may be synthesized:
Example 3
N-[8-(4-Keto-3,4-dihydrosulfostyril)]-N′(2-bromophenyl)urea: EI-MS m/z 408(M−H) − .
Method of Treatment
The compounds of Formula (I), (II) or a pharmaceutically acceptable salt thereof can be used in the manufacture of a medicament for the prophylactic or therapeutic treatment of any disease state in a human, or other mammal, which is exacerbated or caused by excessive or unregulated IL-8 cytokine production by such mammal's cell, such as but not limited to monocytes and/or macrophages, or other chemokines which bind to the IL-8 α or β receptor, also referred to as the type I or type II receptor.
For purposes herein, ther term “a compound of Formula (I)” also represents “compounds of Formula (II)”, unless specifically indicated.
Accordingly, the present invention provides a method of treating a chemokine mediated disease, wherein the chemokine is one which binds to an IL-8 α or β receptor and which method comprises administering an effective amount of a compound of Formula (I) or a pharmaceutically acceptable salt thereof. In particular, the chemokines are IL-8, GROα, GROβ, GROγ, NAP-2 or ENA-78.
The compounds of Formula (I) are administered in an amount sufficient to inhibit cytokine function, in particular IL-8, GROα, GROβ, GROγ, NAP-2 or ENA-78, such that they are biologically regulated down to normal levels of physiological function, or in some case to subnormal levels, so as to ameliorate the disease state. Abnormal levels of IL-8, GROα, GROβ, GROγ, NAP-2 or ENA-78 for instance in the context of the present invention, constitute: (i) levels of free IL-8 greater than or equal to 1 picogram per mL; (ii) any cell associated IL-8, GROα, GROβ GROγ, NAP-2 or ENA-78 above normal physiological levels; or (iii) the presence of IL-8, GROα, GROβ, GROγ, NAP-2 or ENA-78 above basal levels in cells or tissues in which IL-8, GROα, GROβ, GROγ, NAP-2 or ENA-78 respectively, is produced.
There are many disease states in which excessive or unregulated IL-8 production is implicated in exacerbating and/or causing the disease. Chemokine mediated diseases include psoriasis, atopic dermatitis, arthritis, asthma, chronic obstructive pulmonary disease, adult respiratory distress syndrome, inflammatory bowel disease, Crohn's disease, ulcerative colitis, stroke, septic shock, endotoxic shock, gram negative sepsis, toxic shock syndrome, cardiac and renal reperfusion injury, glomerulonephritis, thrombosis, graft vs. host reaction, Alzheimer's disease, allograft rejections, malaria, restinosis, angiogenesis or undesired hematopoietic stem cells release.
These diseases are primarily characterized by massive neutrophil infiltration, T-cell infiltration, or neovascular growth, and are associated with increased IL-8, GROα, GROβ, GROγ, NAP-2 or ENA-78 production which is responsible for the chemotaxis of neutrophils into the inflammatory site or the directional growth of endothelial cells. In contrast to other inflammatory cytokines (IL-1, TNF, and IL-6), IL-8, GROα, GROβ, GROγ, NAP-2 or ENA-78 has the unique property of promoting neutrophil chemotaxis, enzyme release including but not limited to elastase release as well as superoxide production and activation. The α-chemokines but particularly, GROα, GROβ, GROγ, NAP-2 or ENA-78, working through the IL-8 type I or II receptor can promote the neovascularization of tumors by promoting the directional growth of endothelial cells. Therefore, the inhibition of IL-8 induced chemotaxis or activation would lead to a direct reduction in the neutrophil infiltration.
Recent evidence also implicates the role of chemokines in the treatment of HIV infections, Littleman et al., Nature 381, pp. 661 (1996) and Koup et al., Nature 381, pp. 667 (1996).
The present invention also provides for a means of treating, in an acute setting, as well as preventing, in those individuals deemed susceptible to, CNS injuries by the chemokine receptor antagonist compounds of Formula (I).
CNS injuries as defined herein include both open or penetrating head trauma, such as by surgery, or a closed head trauma injury, such as by an injury to the head region. Also included within this definition is ischemic stroke, particularly to the brain area.
Ischemic stroke may be defined as a focal neurologic disorder that results from insufficient blood supply to a particular brain area, usually as a consequence of an embolus, thrombi, or local atheromatous closure of the blood vessel. The role of inflammatory cytokines in this are has been emerging and the present invention provides a mean for the potential treatment of these injuries. Relatively little treatment, for an acute injury such as these has been available.
TNF-α is a cytokine with proinflammatory actions, including endothelial leukocyte adhesion molecule expression. Leukocytes infiltrate into ischemic brain lesions and hence compounds which inhibit or decrease levels of TNF would be useful for treatment of ischemic brain injury. See Liu et al., Stoke, Vol. 25. No. 7, pp. 1481-88 (1994) whose disclosure is incorporated herein by reference.
Models of closed head injuries and treatment with mixed 5-LO/CO agents is discussed in Shohami et al., J. of Vaisc & Clinical Physiology and Pharmacology, Vol. 3, No. 2, pp. 99-107 (1992) whose disclosure is incorporated herein by reference. Treatment which reduced edema formation was found to improve functional outcome in those animals treated.
The compounds of Formula (I) are administered in an amount sufficient to inhibit IL-8, binding to the IL-8 alpha or beta receptors, from binding to these receptors, such as evidenced by a reduction in neutrophil chemotaxis and activation. The discovery that the compounds of Formula (I) are inhibitors of IL-8 binding is based upon the effects of the compounds of Formulas (I) in the in vitro receptor binding assays which are described herein. The compounds of Formula (I) and (II) have been shown to be inhibitors of type II IL-8 receptors.
As used herein, the term “IL-8 mediated disease or disease state” refers to any and all disease states in which IL-8, GROα, GROβ, GROγ, NAP-2 or ENA-78 plays a role, either by production of IL-8, GROα, GROβ, GROγ, NAP-2 or ENA-78 themselves, or by IL-8, GROα, GROβ, GROγ, NAP-2 or ENA-78 causing another monokine to be released, such as but not limited to IL-1, IL-6 or TNF. A disease state in which, for instance, IL-1 is a major component, and whose production or action, is exacerbated or secreted in response to IL-8, would therefore be considered a disease stated mediated by IL-8.
As used herein, the term “chemokine mediated disease or disease state” refers to any and all disease states in which a chemokine which binds to an IL-8 α or β receptor plays a role, such as but not limited to IL-8, GRO-α, GRO-β, GROγ, NAP-2 or ENA-78. This would include a disease state in which, IL-8 plays a role, either by production of IL-8 itself, or by IL-8 causing another monokine to be released, such as but not limited to IL-1, IL-6 or TNF. A disease state in which, for instance, IL-1 is a major component, and whose production or action, is exacerbated or secreted in response to IL-8, would therefore be considered a disease stated mediated by IL-8.
As used herein, the term “cytokine” refers to any secreted polypeptide that affects the functions of cells and is a molecule which modulates interactions between cells in the immune, inflammatory or hematopoietic response. A cytokine includes, but is not limited to, monokines and lymphokines, regardless of which cells produce them. For instance, a monokine is generally referred to as being produced and secreted by a mononuclear cell, such as a macrophage and/or monocyte. Many other cells however also produce monokines, such as natural killer cells, fibroblasts, basophils, neutrophils, endothelial cells, brain astrocytes, bone marrow stromal cells, epideral keratinocytes and B-lymphocytes. Lymphokines are generally referred to as being produced by lymphocyte cells. Examples of cytokines include, but are not limited to, Interleukin-1 (IL-1), Interleukin-6 (IL-6), Interleukin-8 (IL-8), Tumor Necrosis Factor-alpha (TNF-α) and Tumor Necrosis Factor beta (TNF-β).
As used herein, the term “chemokine” refers to any secreted polypeptide that affects the functions of cells and is a molecule which modulates interactions between cells in the immune, inflammatory or hematopoietic response, similar to the term “cytokine” above. A chemokine is primarily secreted through cell transmembranes and causes chemotaxis and activation of specific white blood cells and leukocytes, neutrophils, monocytes, macrophages, T-cells, B-cells, endothelial cells and smooth muscle cells. Examples of chemokines include, but are not limited to, IL-8, GRO-α, GRO-β, GRO-γ, NAP-2, ENA-78, IP-10, MIP-1α, MIP-β, PF4, and MCP 1, 2, and 3.
In order to use a compound of Formula (I) or a pharmaceutically acceptable salt thereof in therapy, it will normally be formulated into a pharmaceutical composition in accordance with standard pharmaceutical practice. This invention, therefore, also relates to a pharmaceutical composition comprising an effective, non-toxic amount of a compound of Formula (I) and a pharmaceutically acceptable carrier or diluent.
Compounds of Formula (I), pharmaceutically acceptable salts thereof and pharmaceutical compositions incorporating such may conveniently be administered by any of the routes conventionally used for drug administration, for instance, orally, topically, parenterally or by inhalation. The compounds of Formula (I) may be administered in conventional dosage forms prepared by combining a compound of Formula (I) with standard pharmaceutical carriers according to conventional procedures. The compounds of Formula (I) may also be administered in conventional dosages in combination with a known, second therapeutically active compound. These procedures may involve mixing, granulating and compressing or dissolving the ingredients as appropriate to the desired preparation. It will be appreciated that the form and character of the pharmaceutically acceptable character or diluent is dictated by the amount of active ingredient with which it is to be combined, the route of administration and other well-known variables. 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.
The pharmaceutical carrier employed may be, for example, either a solid or liquid. Exemplary of solid carriers are lactose, terra alba, sucrose, talc, gelatin, agar, pectin, acacia, magnesium stearate, stearic acid and the like. Exemplary of liquid carriers are syrup, peanut oil, olive oil, water and the like. Similarly, the carrier or diluent may include time delay material well known to the art, such as glyceryl mono-stearate or glyceryl distearate alone or with a wax.
A wide variety of pharmaceutical forms can be employed. Thus, if a solid carrier is used, the preparation can be tableted, placed in a hard gelatin capsule in powder or pellet form or in the form of a troche or lozenge. The amount of solid carrier will vary widely but preferably will be from about 25mg. to about 1 g. When a liquid carrier is used, the preparation will be in the form of a syrup, emulsion, soft gelatin capsule, sterile injectable liquid such as an ampule or nonaqueous liquid suspension.
Compounds of Formula (I) may be administered topically, that is by non-systemic administration. This includes the application of a compound of Formula (I) externally to the epidermis or the buccal cavity and the instillation of such a compound into the ear, eye and nose, such that the compound does not significantly enter the blood stream. In contrast, systemic administration refers to oral, intravenous, intraperitoneal and intramuscular administration.
Formulations suitable for topical administration include liquid or semi-liquid preparations suitable for penetration through the skin to the site of inflammation such as liniments, lotions, creams, ointments or pastes, and drops suitable for administration to the eye, ear or nose. The active ingredient may comprise, for topical administration, from 0.001% to 10% w/w, for instance from 1% to 2% by weight of the Formulation. It may however comprise as much as 10% w/w but preferably will comprise less than 5% w/w, more preferably from 0.1% to 1% w/w of the Formulation.
Lotions according to the present invention include those suitable for application to the skin or eye. An eye lotion may comprise a sterile aqueous solution optionally containing a bactericide and may be prepared by methods similar to those for the preparation of drops. Lotions or liniments for application to the skin may also include an agent to hasten drying and to cool the skin, such as an alcohol or acetone, and/or a moisturizer such as glycerol or an oil such as castor oil or arachis oil.
Creams, ointments or pastes according to the present invention are semi-solid formulations of the active ingredient for external application. They may be made by mixing the active ingredient in finely-divided or powdered form, alone or in solution or suspension in an aqueous or non-aqueous fluid, with the aid of suitable machinery, with a greasy or non-greasy base. The base may comprise hydrocarbons such as hard, soft or liquid paraffin, glycerol, beeswax, a metallic soap; a mucilage; an oil of natural origin such as almond, corn, arachis, castor or olive oil; wool fat or its derivatives or a fatty acid such as steric or oleic acid together with an alcohol such as propylene glycol or a macrogel. The formulation may incorporate any suitable surface active agent such as an anionic, cationic or non-ionic surfactant such as a sorbitan ester or a polyoxyethylene derivative thereof. Suspending agents such as natural gums, cellulose derivatives or inorganic materials such as silicaceous silicas, and other ingredients such as lanolin, may also be included.
Drops according to the present invention may comprise sterile aqueous or oily solutions or suspensions and may be prepared by dissolving the active ingredient in a suitable aqueous solution of a bactericidal and/or fungicidal agent and/or any other suitable preservative, and preferably including a surface active agent. The resulting solution may then be clarified by filtration, transferred to a suitable container which is then sealed and sterilized by autoclaving or maintaining at 98-100° C. for half an hour. Alternatively, the solution may be sterilized by filtration and transferred to the container by an aseptic technique. Examples of bactericidal and fungicidal agents suitable for inclusion in the drops are phenylmercuric nitrate or acetate (0.002%), benzalkonium chloride (0.01%) and chlorhexidine acetate (0.01%). Suitable solvents for the preparation of an oily solution include glycerol, diluted alcohol and propylene glycol.
Compounds of formula (I) may be administered parenterally, that is by intravenous, intramuscular, subcutaneous intranasal, intrarectal, intravaginal or intraperitoneal administration. The subcutaneous and intramuscular forms of parenteral administration are generally preferred. Appropriate dosage forms for such administration may be prepared by conventional techniques. Compounds of Formula (I) may also be administered by inhalation, that is by intranasal and oral inhalation administration. Appropriate dosage forms for such administration, such as an aerosol formulation or a metered dose inhaler, may be prepared by conventional techniques.
For all methods of use disclosed herein for the compounds of Formula (I), and (II) the daily oral dosage regimen will preferably be from about 0.01 to about 80 mg/kg of total body weight. The daily parenteral dosage regimen about 0.001 to about 80 mg/kg of total body weight. The daily topical dosage regimen will preferably be from 0.1 mg to 150 mg, administered one to four, preferably two or three times daily. The daily inhalation dosage regimen will preferably be from about 0.01 mg/kg to about 1 mg/kg per day. It will also be recognized by one of skill in the art that the optimal quantity and spacing of individual dosages of a compound of Formula (I) or a pharmaceutically acceptable salt thereof will be determined by the nature and extent of the condition being treated, the form, route and site of administration, and the particular patient being treated, and that such optimums can be determined by conventional techniques. It will also be appreciated by one of skill in the art that the optimal course of treatment, i.e., the number of doses of a compound of Formula (I) or a pharmaceutically acceptable salt thereof given per day for a defined number of days, can be ascertained by those skilled in the art using conventional course of treatment determination tests.
The invention will now be described by reference to the following biological examples which are merely illustrative and are not to be construed as a limitation of the scope of the present invention.
BIOLOGICAL EXAMPLES
The IL-8, and Gro-α chemokine inhibitory effects of compounds of the present invention are determined by the following in vitro assay:
Receptor Binding Assays:
[ 125 I] IL-8 (human recombinant) is obtained from Amersham Corp., Arlington Heights, Ill., with specific activity 2000 Ci/mmol. Gro-α is obtained from NEN—New England Nuclear. All other chemicals are of analytical grade. High levels of recombinant human IL-8 type α and β receptors were individually expressed in Chinese hamster ovary cells as described previously (Holmes. et al., Science , 1991, 253, 1278). The Chinese hamster ovary membranes were homogenized according to a previously described protocol (Haour, et al., J Biol Chem ., 249 pp 2195-2205 (1974)). Except that the homogenization buffer is changed to 10 mM Tris-HCL, 1 mM MgSO4, 0.5mM EDTA (ethylene-diaminetetraacetic acid), 1 m MPMSF (α-toluenesulphonyl fluoride), 0.5 mg/L Leupeptin, pH 7.5. Membrane protein concentration is determined using Pierce Co. micro-assay kit using bovine serum albumin as a standard. All assays are performed in a 96-well micro plate format. Each reaction mixture contains 125 I IL-8 (0.25 nM) or 125 I Gro-α and 0.5 μg/mL of IL-8Rα or 1.0 μg/mL of IL-8Rβ membranes in 20 mM Bis-Trispropane and 0.4 mM Tris HCl buffers, pH 8.0, containing 1.2 mM MgSO 4 , 0.1 mM EDTA, 25 mM NaCl and 0.03% CHAPS. In addition, drug or compound of interest is added which has been pre-dissolved in DMSO so as to reach a final concentration of between 0.01 nM and 100 μM. The assay is initiated by addition of 125 I-IL-8. After 1 hour at room temperature the plate is harvested using a Tomtec 96-well harvester onto a glass fiber filtermat blocked with 1% polyethylenimine/0.5% BSA and washed 3 times with 25 mM NaCl, 10 mM TrisHCI, 1 mM MgSO 4 , 0.5 mM EDTA, 0.03% CHAPS, pH 7.4. The filter is then dried and counted on the Betaplate liquid scintillation counter. The recombinant IL-8 Rα, or Type I. receptor is also referred to herein as the non-permissive receptor and the recombinant IL-8 Rβ, or Type II, receptor is referred to as the permissive receptor.
Representative compounds of Formula (I), Examples 2 and 3, and of Formula (II), Example 1, have exhibited positive inhibitory activity in this assay at IC 50 levels<30 um.
Chemotaxis Assay:
The in vitro inhibitory properties of these compounds are determined in the neutrophil chemotaxis assay as described in Current Protocols in Immunology, vol. I, Suppl 1, Unit 6.12.3., whose disclosure is incorporated herein by reference in its entirety. Neutrophils where isolated from human blood as described in Current Protocols in Immunology Vol. I, Suppl 1 Unit 7.23.1, whose disclosure is incorporated herein by reference in its entirety. The chemoattractants IL-8. GRO-α, GRO-β, GRO-γ and NAP-2 are placed in the bottom chamber of a 48 multiwell chamber (Neuro Probe, Cabin John, Md.) at a concentration between 0.1 and 100 nM. The two chambers are separated by a 5 um polycarbonate filter. When compounds of this invention are tested, they are mixed with the cells (0.001-1000 nM) just prior to the addition of the cells to the upper chamber. Incubation is allowed to proceed for between about 45 and 90 min. at about 37° C. in a humidified incubator with 5% CO 2 . At the end of the incubation period, the polycarbonate membrane is removed and the top side washed, the membrane then stained using the Diff Quick staining protocol (Baxter Products, McGaw Park, Ill., USA). Cells which have chemotaxed to the chemokine are visually counted using a microscope. Generally, four fields are counted for each sample, these numbers are averaged to give the average number of cells which had migrated. Each sample is tested in triplicate and each compound repeated at least four times. To certain cells (positive control cells) no compound is added, these cells represent the maximum chemotactic response of the cells. In the case where a negative control (unstimulated) is desired, no chemokine is added to the bottom chamber. The difference between the positive control and the negative control represents the chemotactic activity of the cells.
Elastase Release Assay:
The compounds of this invention are tested for their ability to prevent Elastase release from human neutrophils. Neutrophils are isolated from human blood as described in Current Protocols in Immunology Vol. 1, Suppl 1 Unit 7.23.1. PMNs 0.88×10 6 cells suspended in Ringer's Solution (NaCl 118, KCl 4.56, NaHCO3 25, KH2PO4 1.03, Glucose 11.1, HEPES 5 mM, pH 7.4) are placed in each well of a 96 well plate in a volume of 50 ul. To this plate is added the test compound (0.001-1000 nM) in a volume of 50 ul, Cytochalasin B in a volume of 50 ul (20 ug/ml) and Ringers buffer in a volume of 50 ul. These cells are allowed to warm (37° C., 5% CO2, 95% RH) for 5 min. before IL-8, GROα, GROβ, GROγ or NAP-2 at a final concentration of 0.01-1000 nM was added. The reaction is allowed to proceed for 45 min. before the 96 well plate is centrifuged (800×g 5 min.) and 100 ul of the supernatant removed. This supernatant is added to a second 96 well plate followed by an artificial elastase substrate (MeOSuc-Ala-Ala-Pro-Val-AMC, Nova Biochem, La Jolla, Calif.) to a final concentration of 6 ug/ml dissolved in phosphate buffered saline. Immediately, the plate is placed in a fluorescent 96 well plate reader (Cytofluor 2350, Millipore, Bedford, Mass.) and data collected at 3 min. intervals according to the method of Nakajima et al J. Biol. Chem. 254 4027 (1979). The amount of Elastase released from the PMNs is calculated by measuring the rate of MeOSuc-Ala-Ala-Pro-Val-AMC degradation.
TNF-α in Traumatic Brain Injury Assay
The present assay provides for examination of the expression of tumor necrosis factor mRNA in specific brain regions which follow experimentally induced lateral fluid-percussion traumatic brain injury (TBI) in rats. Adult Sprague-Dawley rats (n=42) were anesthetized with sodium pentobarbital (60 mg/kg, i.p.) and subjected to lateral fluid-percussion brain injury of moderate severity (2.4 atm.) centered over the left temporaparietal cortex (n=18), or “sham” treatment (anesthesia and surgery without injury, n=18). Animals are sacrificed by decapitation at 1, 6 and 24 hr. post injury, brains removed, and tissue samples of left (injured) parietal cortex (LC), corresponding area in the contralateral right cortex (RC), cortex adjacent to injured parietal cortex (LA), corresponding adjacent area in the right cortex (RA), left hippocampus (LH) and right hippocampus (RH) are prepared. Total RNA was isolated and Northern blot hybridization is performed and quantitated relative to an TNF-α positive control RNA (macrophage=100%). A marked increase of TNF-α mRNA expression is observed in LH (104±17% of positive control, p<0.05 compared with sham), LC (105±21%, p<0.05) and LA (69±8%, p<0.01) in the traumatized hemisphere 1 hr. following injury. An increased TNF-α mRNA expression is also observed in LH (46±8%, p<0.05), LC (30±3%, p<0.01) and LA (32±3%, p<0.01) at 6 hr. which resolves by 24 hr. following injury. In the contralateral hemisphere, expression of TNF-α mRNA is increased in RH (46±2%, p<0.01), RC (4±3%) and RA (22±8%) at 1 hr. and in RH (28±11%), RC (7±5%) and (26+6%, p<0.05) at 6 hr. but not at 24 hr. following injury. In sham (surgery without injury) or naive animals, no consistent changes in expression of TNF-α mRNA are observed in any of the 6 brain areas in either hemisphere at any times. These results indicate that following parasagittal fluid-percussion brain injury, the temporal expression of TNF-α mRNA is altered in specific brain regions, including those of the non-traumatized hemisphere. Since TNF-α is able to induce nerve growth factor (NGF) and stimulate the release of other cytokines from activated astrocytes, this post-traumatic alteration in gene expression of TNF-α plays an important role in both the acute and regenerative response to CNS trauma.
CNS Injury Model for IL-β mRNA
This assay characterizes the regional expression of interleukin-1β (IL-1β) mRNA in specific brain regions following experimental lateral fluid-percussion traumatic brain injury (TBI) in rats. Adult Sprague-Dawley rats (n=42) are anesthetized with sodium pentobarbital (60 mg/kg, i.p.) and subjected to lateral fluid-percussion brain injury of moderate severity (2.4 atm.) centered over the left temporaparietal cortex (n=18), or “sham” treatment (anesthesia and surgery without injury). Animals are sacrificed at 1, 6 and 24 hr. post injury, brains removed, and tissue samples of left (injured) parietal cortex (LC), corresponding area in the contralateral right cortex (RC), cortex adjacent to injured parietal cortex (LA), corresponding adjacent area in the right cortex (RA), left hippocampus (LH) and right hippocampus (RH) are prepared. Total RNA is isolated and Northern blot hybridization was performed and the quantity of brain tissue IL-1β mRNA is presented as percent relative radioactivity of IL- 1β positive macrophage RNA which was loaded on same gel. At 1 hr. following brain injury, a marked and significant increase in expression of IL-1β mRNA is observed in LC (20.0±0.7% of positive control, n=6, p<0.05 compared with sham animal), LH (24.5±0.9%, p<0.05) and LA (21.5±3.1%, p<0.05) in the injured hemisphere, which remained elevated up to 6 hr. post injury in the LC (4.0±0.4%, n=6, p<0.05) and LH (5.0±1.3%, p<0.05). In sham or naive animals, no expression of IL-1β mRNA is observed in any of the respective brain areas. These results indicate that following TBI, the temporal expression of IL-1β mRNA is regionally stimulated in specific brain regions. These regional changes in cytokines, such as IL-1β play a role in the post-traumatic.
All publications, including but not limited to patents and patent applications, cited in this specification are herein incorporated by reference as if each individual publication were specifically and individually indicated to be incorporated by reference herein as though fully set forth.
The above description fully discloses the invention including preferred embodiments thereof. Modifications and improvements of the embodiments specifically disclosed herein are within the scope of the following claims. Without further elaboration, it is believed that one skilled in the are can, using the preceding description, utilize the present invention to its fullest extent. Therefore the Examples herein are to be construed as merely illustrative and not a limitation of the scope of the present invention in any way. The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.
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The present invention involves certain 8-ureido and 8-thioureido, 1,2-benzothiazines, 1,2,4-benzothioxazines and 1,2,4-benzothiodiazines useful in the treatment of disease states mediated by the chemokine, Interleukin-8.
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FIELD OF THE INVENTION
This invention relates to a synchronizable drive system and particularly to a drive system having an electric motor whose speed is controlled by way of a supply frequency, for example, synchronous motors, reluctance motors, speed-controlled or position-controlled asynchronous motors and permanent magnet motors.
BACKGROUND OF THE INVENTION
As is known, electric motors which are controlled by way of a supply frequency are increasingly used in all kinds of textile machinery but are still under discussion for ring spinning machines.
Each individual spinning position of a ring spinning machine comprises three basic operative elements which must be moved, viz. a spindle, a drawframe and a ring carrier or ring bank. An individual spindle is usually associated with the spinning position but the drawframe and the ring bank extend over a number of spinning positions, as a rule, over the whole length of one side of the machine. For the reasons given hereinafter, endeavors have been made to "decentralize" the conventional central drive system of the ring spinning machine which has been in the form of a main driving motor having transmissions to distribute the driving power to the various operative elements.
The main reasons for these endeavors with respect to a single spindle drive are higher productivity, energy saving, noise reduction, higher speeds, and fewer yarn breakages.
For an individual drafting arrangement drive, the reasons are no change gears, simple and rapid control, the possibility of remote control and the possibility of fine adjustment.
When the three operative elements hereinbefore mentioned are considered individually, the endeavors have met with considerable success. A number of "individual drive systems" are available which drive the spindles individually (or in groups) and give the drafting arrangement its own independent drive. The ring bank can be moved either together with the drafting arrangement or by an independent drive. However, despite many such proposals, no individual drive system has yet been introduced in practice. Although the various decentralized drive systems for the spindles, drafting arrangement and ring bank can still be further improved or optimized, the main outstanding problems are the co-operation of these drives with one another and within the drive system of the drawframe, particularly for starting and stopping the machine. Deviations from the programmed speeds are very likely to occur in this phase and endanger the technological parameters of the spun yarn. Making a drive suitable for practical use is therefore a very difficult job. More particularly, the spindles have to be accelerated from a standstill to their operating speed (or brought to a standstill) with a programmed starting slope if yarn breakages are to be avoided. Further, the drafting arrangement (and ring bank) must so move relative to the spindles that no yarn breakages occur and the yarn quality produced during starting (and stopping) corresponds (is as near as possible the same as) the yarn quality produced in normal operation.
A drive system meeting these requirements must also be economic to produce if it is to be able to compete with conventional central drives.
It has long been known, for example, from DOS 2 203 833, that driving motors speed-controlled by way of the supply frequency offer possibilities of solving the problems mentioned. However, drive systems devised for such motors cannot readily meet all requirements. As soon as (or as long as) such a motor runs in synchronism with its supply frequency, the motor can be maintained (within its load limits) in a desired relationship to other such motors. However, a distinctive feature of such motors is that, if the motor is designed with a rational load bearing capacity, the motor either does not start immediately from a standstill (or decelerate to a standstill) in synchronism with the supply frequency and is instead uncontrollable below a critical speed (minimum speed or minimum frequency), and/or the motor cannot produce an adequate and exactly maintained acceleration torque from a standstill. This feature causes problems, particularly in connection with the driving of drafting arrangements, as will be described in greater detail hereinafter.
The drafting arrangement of a ring machine comprises a number of units consisting of cylinder/roller pairs. The inter-unit speed ratios determine compliance with the yarn count while the speed ratio between the front roller unit and the yarn-twisting spindle is decisive for the level of twist in the yarn. The units must start from a standstill and, a stoppage, return to a standstill "with gearwheel accuracy"--i.e., in a predetermined relationship of the angles of rotation. Also, the drafting arrangement requires a minimum starting acceleration because, at stoppage of the machine, the yarns preferably remain connected to the spindles and the spindles restart so rapidly that the yarns are tensioned and form a balloon. If the drafting arrangement cannot accelerate to its working speed fast enough in these conditions, mis-twisting and eventually massive yarn breakages occur. Also, for the same reasons, the rotations of the drafting cylinders and rollers should, at stoppage of the machine, be maintained until stoppage (or until a low speed) of the spindles. But, because of considerable differences between the moment of inertia of the spindles and that of the drafting arrangement, this requirement causes considerable problems.
Preferably, an "individual drafting arrangement drive system" comprises at least one drive for the front roller unit and one drive for the other drafting units and possibly even one drive per unit. The reasons hereinbefore set out make it impossible to embody such drive systems using low-cost motors speed-controlled by way of their supply frequency, without taking further action, to maintain the necessary relationships below a critical speed.
German O.S. 2 849 576 describes a drive system for a ring spinning machine or machines which includes two motors for each drafting unit. In addition, each motor is adapted to be coupled by way of a clutch and a belt connection to the corresponding drawframe unit. The control for these clutches is arranged to produce effects in the yarn; however, the control is not related to synchronization of the motors.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a decentralized drive system for a rotatable load.
It is another object of the invention to provide a drive system of economical construction and operation.
It is another object of the invention to provide a drive system for a ring spinning machine which can be readily synchronized for the operation of various rotatable shafts of the machine.
Briefly, the invention provides a drive system which is comprised of at least one motor, a load for performing a rotary movement from a standstill and to a standstill, controllable means selectively connecting the motor to the load for rotating the load and control means for controlling the speed of the motor in dependence on a supply frequency. The control means is also connected to the controllable means in order to actuate this means to connect the motor with the load in response to the motor being in synchronism with the supply frequency and to disconnect the motor from the load in response to the motor being out of synchronism with the supply frequency.
As described in U.S. Pat. No. 3,936,998, the controllable means may be in the form of a controllable clutch and/or switchable brake and is used to determine the transmissability of the motor speed to the load. In this respect, the drive is characterized in that the control means for the controllable means is such that the motor speed can be transmitted to the load only when the motor has been sychronized with its supply frequency.
The control and the switchable means can be so embodied that the motor speed is monitored and the load is coupled with the motor only when the motor has run up to a minimum speed and has reached synchronism, the load being disconnected from the machine only when the motor is running at a minimum speed at stoppage of the system. Preferably, the motor runs up to speed off-load below this minimum speed The motor speed and the switching of the switchable means can be determined from a common control.
These preferred variants are not essential. For example, at starting, the time which has elapsed from the initiation of an acceleration program could be monitored and the load coupled with the motor only after the predetermined period of time. Disconnecting the load from the motor could proceed correspondingly in accordance with a stoppage program. As another alternative, the motor could be permanently connected to the main load and an additional load such as a brake could be provided so that the motor can drive the main load only when the motor has been freed from the additional load. The removal of the additional load can be devised as hereinbefore described in connection with the provision and cancellation of a connection between the motor and its "operative load".
In a system according to the preferred proposal, a stationary load should be coupled with a motor which has already started and which is running slowly in a synchronized manner. If necessary, a torque transformer can be so provided between the motor and the load that the moment of inertia experienced by the motor when the load is cut in is insufficient to pull the motor out of step with the supply frequency. The torque transformer can be provided by a geared transmission. Advantageously in such a case, a damping load-transferring means, such as a toothed belt transmission, can be provided between the motor and the gearing since in some operating conditions (at low speeds) frequency-controlled three-phase motors emit torque pulses which may damage the geared transmission. As a rule, it is advantageous to provide a speed step-up or step-down of such a kind that the relative speed of the parts to be coupled together is low. The load-transmitting means mentioned can perform the latter function too. If two ratios are provided the switchable means are, with advantage, disposed between them.
The drive system can be used as the drive for at least one unit of a drafting arrangement of a ring spinning machine; preferably, the other units of the same drafting arrangement are driven by a second drive or each by an individual drive according to the present invention, the speeds of the various motors of these drives being transmitted simultaneously to their respective units.
These and other objects of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a diagrammatic view of various drives for a ring spinning machine;
FIG. 2 shows further details of the drives of FIG. 1;
FIG. 3 illustrates a control constructed in accordance with the invention, and
FIG. 4 illustrates a timing diagram for the starting and stopping of a ring spinning machine having a drive system according to this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a line 10 extends from electricity supply means (not shown) of a predetermined voltage and frequency and is connected to the drive systems of a ring spinning machine (not shown). In this case, two drive systems are provided in the machine, viz. a first system 12 for the spindle drive and a second system 14 for driving the drafting arrangements and ring bank.
The spindle drive is of secondary importance and will therefore be described only briefly. It is assumed in FIG. 1 that each spindle is driven by an individual electric motor 16. In practice, a modern ring spinning machine may have up to 600 spindles on each side of the machine. The various motors 16 are connected by way of an energy distribution system 18 to a common frequency converter 20 in the end head of the machine. The converter 20 can comprise, for example, a rectifier (not shown) and, connected thereto, an inverter (not shown). The motors 16 can be low-cost motors, for example, asynchronous motors. As already indicated, the control is not limited to such a drive system for the spindles. The spindles could be driven, for example, in groups or even by a single motor by way of tangential belts.
What is important, however, is that there must be no mechanical connection for coupling the speed ratio between the spindles and their associated drafting arrangement. This ratio is determined solely by the electrical control.
The second drive system 14 comprises three different drives 22, 24, 26. These three drives are supplied, by means such as a common rectifier 28 and intermediate dc circuit 30, with power from the line 10. Each drive 22, 24, 26 has an inverter 32, 34, 36 which, in accordance with its own set-value frequency (not specified), converts the dc energy at an input into ac energy of a predetermined frequency at an output.
The drive 26 is of secondary importance, and so, will be briefly described for the sake of greater clarity. The drive 26 is effective to move the ring banks--one ring bank per side of the machine (not shown)--and, to this end, comprises an asynchronous motor 38. The movements of the ring banks relative to the spindles are important for building up cops but present no specially difficult problems to the control and can be neglected in the context of the drive system.
Exactly the contrary is true to drafting arrangement drives 22, 24. Accurate running of the drafting rollers relative to one another is a decisive factor for maintaining the yarn count. Hence, synchronous motors 40 are preferably used in these drives. The arrangements of the drives 22, 24 will now be described in greater detail with reference to FIG. 2. A ring spinning machine normally has two drafting arrangements, one on either side of the machine. Each arrangement comprises a front roller, a middle roller and a back roller. If the machine is long--i.e., having more than 300 spindles on each side of the machine--the rollers are advantageously driven from both ends to prevent defects due to torsion effects in the machine rollers (see, for example, U.S. Pat. Nos. 4,161,862; 4,314,388; 4,568,152 and 3,339,361. An arrangement of this kind is assumed in the example of FIGS. 1 and 2. Correspondingly, two driving motors 40 are provided per front roller (not shown) and all four are supplied by the inverter 32 with electrical power at a controllable frequency. For the sake of clarity in designation, these motors are indicated in FIG. 2 by 40 L 11 (front roller 1, motor 1), 40 L 12 (front roller 1, motor 2), 40 L 21 (front roller 2, motor 1) and 40 L 22 (front roller 2, motor 2). The simple reference 40 is used when the description applies to all these motors.
An end part 42 of the drafting roller, such part being coupled with the motor 40 L 11, is shown as an example. The other motors 40 of the drive 22 are coupled similarly with the corresponding end parts of the drafting rollers. The connection between these motors 40 and their rollers 42 will be described in greater detail hereinafter but a description will first be given of the drive arrangement 24 for the central and back rollers.
FIG. 2 shows an end part 44 of a back roller and the corresponding end part 46 of a middle roller. These rollers are coupled together by a change-speed drive 48 so as to run at a speed ratio to one another predetermined by the transmission 48. The transmission 48 is driven by an input shaft 50 which is coupled, by way of a connection to be described hereinafter, with a motor 40 of the drive 24. Since there are two drafting arrangements, one on the left and on one the right, and the back and middle roller groups are driven from both ends, the drive 24 comprises four synchronous motors 40 like the drive 22 and for the sake of clarity the motors of the drive 24 have the additional references H11, H12, H21 and H22.
A description will now be given of the drive connections between the motors 40 and their respective driven shafts (the parts 42 in the drive 22 and the shafts 50 in the drive 24). Since the connections in any drive (22, 24) are the same, only a single connection will be described for each drive as an example.
In the drive 22, each of the connections comprises a motor shaft 52, a toothed-belt drive 54, a clutch 56 and a geared transmission 58 connected to the part 42. For a purpose to be described hereinafter a brake 60 is disposed between the clutch 56 and the transmission 58.
The connection between the motors 40 of the drive 24 and their corresponding shafts 50 are very similar in various respects and as far as possible like references are used for like elements. Each connection of the drive 24 comprises a motor shaft 52, toothed belt drive 54, clutch 56 and a geared transmission 63 connected to the shaft 50. No brake 60 is necessary in this case. For the sake of simplicity, all the motors 40 are identical and are supplied at the same supply frequency. The transmissions 58, 63 have appropriately different ratios to facilitate the required speed differences between the front roller 42 and the central and back rollers 46, 44.
The brakes 60 in the drive 22 prevent the front rollers 42 from rotating backwards after the machine has been stopped and the clutches 56 disengaged, in order to prevent a yarn defect or a yarn breakage. This feature is known per se but will be described hereinafter in greater detail in connection with the novel clutches 56 and the control thereof.
The toothed belt drive 54 is effective as a damping means which absorb low-speed jerks of the motor 40 and thus protects the delicate geared drive 58 (and 63). The belt drive 54 is also effective to provide a speed change means reducing the relatively high speed of the motor 40 to a lower value at the input of the clutch 56.
The geared transmission 58 or 63 together with the belt drive 54 is effective as a power transmission or torque converter so that when a clutch 56 is engaged, the corresponding motor 40 is not loaded with the high moment of inertia of the stationary rollers 42 or 44, 46.
The operation of the arrangements shown in FIG. 2 will be described with reference to FIGS. 3 and 4. FIG. 3 representing an example of the connections already described (FIG. 2) between a motor 40 and the shaft 42 or 50 driven thereby. Accordingly, FIG. 3 shows a common control 62 for the inverter 32 (or 34), the clutch 56 and (in the drive 22) the brake 60. The control 62 is energized by way of a line 65; an emergency facility (not shown) for energising the line 65 in the event of a mains failure should be provided so that the machine can run through a predetermined stop program (FIG. 4) in the event of a mains failure as well as in normal operation.
FIG. 4 shows timing diagrams of the starting phase AFP and stopping phase ALP of the motors 40, brakes 60, clutch 56 and rollers 42, 44, 46. The intermediate spinning phase SP has not been shown since it is of no importance for this invention.
It will be assumed that the drive system 12 (FIG. 1) has started before the time t1 (FIG. 4) so that the yarns (not shown) have been tensioned and the yarn balloons have formed. The control 62 switches the brakes 60 off at the time t1 so that the front rollers 42 are released for starting. The control 62 simultaneously changes its input signal to the inverter 32 (34) from a reference frequency 0 to a low reference frequency fm of e.g. 5 Hz. The motors 40 start immediately to turn the shafts 52 but not immediately at a speed corresponding to the reference frequency fm although the clutches 56 are still disengaged at this time so that the motors 40 can temporarily run up to speed and achieve synchronism off load. However, after at most a few revolutions, every motor 40 runs in step with its reference frequency, as indicated by a horizontal portion S of the starting characteristic and this is reported to the control 62 by a sensor 66 visible in FIG. 3.
Shortly after the motors 40 have been thus synchronized, the control 62 engages all the clutches 56 simultaneously at the time t2. The motor shafts 52 now experience the load of their associated and so far stationary rollers. An abrupt loading of this kind of a motor that has already started might easily cause the motor to fall out of step with the reference frequency. To prevent this, the two transmissions 54, 58 are effective as power converters to convert the relatively high moment of inertia of a stationary drafting roller that such moment has a relatively low effective value on the shaft 52, a substantial reduction of the effective value being achieved by the transmission 58 at the input of the clutch 56.
In order to ensure that, during the clutching phase the relative speed of the initially stationary shaft 42(50) and the already rotating shaft 52 is as small as possible, the high motor speed is reduced to a relatively low value via the belt transmission.
Thus, the effective moment of inertia of the new load as compared with the motor capacity can at least be mastered by the motor 40 and is preferably negligible This feature helps to reduce costs without considerable over-dimensioning of the motor 40 to deal with the acceleration load. The drafting rollers 42, 44, 46 start to rotate similarly around their longitudinal axis, all of them being rotated by way of the associated transmissions, determined by the reference frequency, the speed being, for example, the speed D of FIG. 4--i.e., in a predetermined speed relationship to one another and to the spindles. After a short steadying time at this relatively low speed, the reference frequency is increased by the control 62 in accordance with a preprogrammed acceleration curve HK so that all the drives of the machine are brought to their operating speed in step with one another.
At stoppage, the various drives are first slowed to a relatively low speed from their operating speed (portion A of the stop characteristic of FIG. 4). This low speed preferably corresponds to the same reference frequency as was used at starting to synchronize the motors. After a short steadying phase at this speed, the control 62 opens all the clutches 56 simultaneously at the time t3. Because of the braking actions in the drafting arrangements, all the rollers 42, 44, 46 stop immediately, something which can be synchronized by the control 62 with the run-out of the spindles (not shown). After this "load cast-off" the motors 40 can be stopped and then run freely to a standstill, stopping only, for example, at the time t4.
The brakes 60 are preferably actuated shortly after the clutches 56 release in order to prevent the rollers from turning backwards. For very short intervals of time and after the actuation of the clutches, the front rollers 42 are therefore free to rotate under the torsion effect; however, these intervals are too brief to lead to perceptible effects in the yarn.
The sensor 66 can be a pulse sensor, the control 62 counting the number of pulses produced by the transmitter 66 during a predetermined period of time. The control 62 initiates engagement of the clutches 56 only when such number of impulses corresponds to a predetermined value. As can be gathered form FIG. 4, however, the control 62 could operate the clutches 56 after a predetermined time (t1 to t2) has elapsed from the starting of the motors or after a predetermined low speed has been reached at stoppage.
The drive is not limited to features of the construction shown. The motors 40 need not necessarily be synchronous motors but should be synchronizable with a reference frequency. The reference frequency associated with the coupling of the motor with the load and the uncoupling of the motor from the load is preferably in the range of from 2 to 20 Hz. The drive enables such motors to be synchronized with their reference frequency without load-induced disturbances or problems. During these synchronization periods, the motor can work into a predetermined and not disturbing load but preferably runs up to speed off-load.
Preferably the motor speed is selected to correspond with a supply frequency not greater than 5 Hz, for two reasons:
1. the rotational energy in the rotating motor mass should be large as possible for the clutching step, to avoid causing loss of synchronism;
2. an a.c. motor of normal design usually only begins to run under controllable conditions at supply frequencies of 5 Hz and above.
The power supply systems can be adapted as required to the motors and the circumstances. The common inverters of FIG. 2 can be replaced by individual inverters. Each motor could even have its own inverter without intermediate circuit.
The invention provides a drive system with advantages mainly where a load must be accelerated from a standstill "with gear accuracy"--i.e., the load must make predetermined rotary movements but a mechanical form or power transmission is unsatisfactory or at least undesirable, particularly when a number of such loads have to be accelerated from a standstill simultaneously and in a predetermined relationship to one another.
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The drive system connects a servomotor via a clutch to a shaft after the motor has started up from a standstill to a speed in synchronism with the supply frequency to the servomotor. The clutch may also be actuated to disengage the servomotor from the shaft when the servomotor is slowed to a predetermined speed during stopping of the servomotor. A transmission is employed between the servomotor and the shaft to compensate for any shocks to the motor when engaging the clutch.
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FIELD OF THE INVENTION
[0001] The invention relates to an assembly of the type which can be positioned to change the direction of an appliance in the horizontal and vertical directions.
BACKGROUND OF THE INVENTION
[0002] Directionally adjustable fans have long been known. Such fans are useful when it is desirable to direct the airflow from the fan in a specific direction without moving the base of the fan.
[0003] Directionally adjustable fans that are capable of pivoting about both the vertical axis and the horizontal axis are typically designed with two pivot mechanisms—one for each axis. One type of pivot mechanism which allows adjustment of the vertical direction of the airflow includes coupling the fan assembly to rotatable mounts at each of the two ends of the diameter of the fan assembly forming an axis of rotation that is parallel to the floor of the base of the fan. Alternatively, the fan assembly is coupled to an arm which is rotatably mounted to the base, thereby allowing the fan to rotate about the horizontal axis defined by the rotatable mount. The horizontal direction of the airflow is adjusted by coupling the fan to the base through a mounting that is rotatable about the vertical axis. According to either design, adjusting the direction of airflow from the fan in both the vertical and horizontal axis requires the separate adjustment of two rotatable mountings.
[0004] Once the fan is adjusted so that the airflow generated flows in the desired direction, a mechanism is typically employed to preserve the adjustments in the event an external force is applied to the fan that would alter the position of the fan. Typically, the angular adjustments made to the fan are maintained by friction within the rotatable mount. Another way of preserving the angular adjustments is by tightening a screw coupled to each rotatable mount to increase the friction. Additionally, the screw could be loosened to allow adjustments to be made more easily. These frictional forces may be further increased by employing a gear structure of radially extending teeth between the mounting contact surfaces. However, the gear teeth decrease the precision of the adjustments since the teeth must properly mesh at predefined positions. Also, the gears increase the difficulty in making the adjustments since the mount surfaces no longer smoothly glide as the mounting is rotated.
[0005] Similar mounting devices have been provided for other appliances in addition to fans. Space heaters have been rotatably mounted to allow for adjusting the direction of the heat. Mirrors are frequently attached to a table stand and provide two or more rotatable mountings so that the mirror can be adjusted about the vertical and horizontal axis. Rotatable mirror mountings can also be fixed to a wall by an extendable arm, thereby allowing the mirror to be pulled away from the wall and rotatably adjusted.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a pivot assembly that can be used with various appliances. The pivot assembly provides three degrees of freedom when positioning the appliance. The pivot may be used, for example, with a fan that is mounted on a base such that the direction of the airflow generated can be adjusted about all three coordinate axes by manipulating a single rotatable pivot mount. Any adjustments to the positioning of the rotatable pivot mount are maintained by the friction within the rotatable pivot mount. The ability to direct airflow through the manipulation of a single rotatable pivot mount provides a fast adjustment and allows for more accurate airflow direction.
[0007] The fan assembly includes a base unit and an arm. The arm includes a mounting end to which the blower unit of the fan is detachably coupled. The opposite end of the arm is provided with a spherical cap which is received by the base unit. The base unit includes a bottom portion and a top portion. The top portion includes an opening through which the arm extends. The opening of the top portion is smaller than the diameter of the spherical cap of the arm thereby preventing the arm from being unintentionally detached from the base. The opening is shaped such that it is substantially flush with the outer surface of the spherical cap. The bottom portion of the base unit exerts a force against the spherical cap such that the friction between the spherical cap of the arm and the top portion of the base will maintain the positional adjustment made to the arm.
[0008] In another embodiment of this invention the force exerted by the bottom portion of the base against the spherical cap of the arm is transmitted through a spherical cap mount. The spherical cap mount has an outer radius roughly equal to the inner radius of the spherical cap of the arm, such that the bottom of the spherical cap of the arm rests substantially flush against the outer surface of the spherical cap mount as the arm pivots and rotates. A force can be created by tightening the coupling of the top potion of the base unit and the bottom portion of the base unit so that the spherical cap of the arm is held tightly in between. Preferably, the force is created by including a spring in the bottom portion of the base unit which exerts the force against the spherical cap of the arm directly or transmits the force through the spherical cap mount.
[0009] In another embodiment of the invention the arm is extendable thereby providing an additional way to adjust the direction of the airflow. The arm may be of a telescoping type and provided with a locking mechanism for each segment of the telescoping arm.
[0010] The fan blower may include a handle coupled to the blower by which the rotatable pivot mount may be adjusted and the fan direction altered. The handle should be positioned so that it will act as a lever when rotating the fan about any axis, thereby reducing the amount of force required to overcome the friction force created within the rotatable pivot mount.
[0011] In another embodiment of this invention the opening of the top portion of the base unit can act as a pivot guide for positioning the arm by preventing the fan from being adjusted to certain positions. If the fan is pivoted too far off the vertical axis, the center of gravity may extend beyond the support area provided by the base and the fan may become unstable and topple over. The shape of the pivot guide can be adjusted to prevent the fan from pivoting to a position where the center of gravity of the fan extends beyond the support area provided by the base.
[0012] The pivot guide also provides increased stability of the fan when adjusted to certain positions. The pivot guide can provide inlets in which the arm rests, thus complementing the support provided by the frictional force exerted by the bottom potion of the base unit. Thus, while the arm is positioned in one of the inlets provided by the pivot guide, if the assembly is disturbed by an external force, the added stability decreases the likelihood of the fan being moved out of position.
[0013] Additionally, the pivot guide may be detachable from the base unit, thus making the shape of the top portion opening modifiable. Because the shape of the opening serves a decorative purpose as well as the functional purpose described above, the decorative element can be enhanced by allowing a user to select a pivot guide to match any desired esthetic or visual appearance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The foregoing and other features of the present invention will be more readily apparent from the following detailed description and drawings of illustrative embodiments of the invention in which:
[0015] FIG. 1 is an exploded top front perspective view of a first embodiment of the invention;
[0016] FIG. 2 is a front elevation view of the first embodiment of the invention; and
[0017] FIG. 3 is a cross section view of the front view of FIG. 2 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] Referring now to the drawings the present invention is directed to a pivot mount assembly. The pivot may be used with almost any appliance, including a mirror, fan, or heater. By way of illustration, the pivot mount is discussed in conjunction with a fan assembly that allows the airflow generated to be adjusted along three axes by manipulating a single rotatable pivot mount. Any adjustments to the positioning of the rotatable pivot mount are maintained by the continuous friction at the rotatable pivot mount. The ability to direct airflow in one or more dimensions through the manipulation of a single rotatable pivot mount provides a fast adjustment and allows for more accurate airflow direction.
[0019] Referring now to FIGS. 1-3 , the fan assembly includes a base unit 80 and an arm 30 . The arm 30 includes a pivot end having a spherical cap 70 and a receiving end 140 to which the blower 10 can be detachably coupled. An axis of the arm is defined by the pivot end and the receiving end 140 . The spherical cap 70 of the pivot end of the arm 30 has an inner radius, an outer radius, and a diameter 180 . The spherical cap 70 is received by the base unit 80 . The base unit 80 includes a bottom portion 40 and a top portion 50 coupled to the bottom portion 40 . It is further contemplated that the top portion 50 can be connected to the bottom portion 40 indirectly through another fixture interposed between the top portion 50 and bottom portion 40 .
[0020] The top portion 50 of the base unit 80 includes an opening 160 through which the arm 30 extends. The opening 160 of the top portion 50 is smaller than the diameter 180 of the spherical cap 70 of the arm 30 thereby preventing the arm from being unintentionally removed from the base 80 . Additionally, the opening 160 is shaped such that it is substantially flush with the outer surface of the spherical cap 70 .
[0021] Alternatively, the top portion 50 may include a pivot guide 60 through which the arm 30 extends. The pivot guide 60 is coupled to the top portion 50 of the base unit 80 , and the opening 120 of the pivot guide 60 is smaller than the diameter 180 of the spherical cap 70 of the arm 30 . The opening 120 of the pivot guide is shaped such that it is substantially flush with the outer surface of the spherical cap 70 .
[0022] The pivot guide 60 is preferably detachable from the top portion 50 , so that the shape of the opening 120 can be modified by replacing the pivot guide 60 . Alternatively, the opening 160 of the top portion 50 may be molded to form the pivot guide 60 . The embodiment in FIG. 3 demonstrates that the pivot guide 60 can be coupled to the top portion shell 150 , from within the base unit 80 . Alternatively, the pivot guide 60 may be coupled to the top portion shell 150 from the exterior of the base unit 80 to facilitate the replacement of the pivot guide 60 . In a preferred embodiment the shape of the pivot guide 60 substantially conforms to the surface of a sphere having a radius roughly equal to the outer radius of the spherical cap 70 of the arm such that the outer surface of the spherical cap 70 of the arm is substantially flush with the inner surface of the pivot guide 60 as the arm 30 is positioned on the rotatable pivot mount. Because the shape of the opening 120 of the pivot guide 60 serves a decorative purpose as well as the functional purpose described above, the decorative aspect can be enhanced by allowing a user to select a pivot guide to match the desired esthetic or visual appearance.
[0023] The bottom portion 40 of the base unit 80 holds the spherical cap 70 of the arm 30 between the base unit 80 and the top portion 50 such that the outer surface of the spherical cap 70 will remain substantially flush with opening 120 of the top portion 50 of the base unit 80 . By tightly holding the spherical cap 70 of the arm 30 , the bottom portion 40 creates a friction force within the rotatable pivot mount that will statically maintain the position of the arm 30 as the axis of the arm is rotated into a selected orientation and angularly rotated about the selected orientation.
[0024] In one embodiment, the bottom portion 40 of the base unit 80 includes a spherical cap mount 100 which transmits a force against the spherical cap 70 of the arm 30 . The spherical cap mount 100 has an outer radius roughly equal to the inner radius of the spherical cap 70 of the arm 30 , such that when it is disposed within the bottom of the spherical cap 70 of the arm 30 , the outer surface of the spherical cap mount 100 rests substantially flush against the inner surface of the spherical cap 70 of the arm 30 as it pivots and rotates.
[0025] The frictional force created within the rotatable pivot mount can be increased or decreased by tightening or loosening the connection between the top portion 50 and the bottom portion 40 of the base unit 80 so that the force which presses the spherical cap 70 of the arm 30 within the base unit 80 is varied. In the embodiment shown in FIG. 3 the frictional force is created in part by a spring 90 in the bottom portion 40 of the base unit 80 which exerts a force against the spherical cap 70 of the arm 30 , through the spherical cap mount 100 , and against the top portion 50 . Alternatively, the force can be transmitted through multiple springs or couplings.
[0026] It is further contemplated that the spherical cap mount 100 may be coupled to the bottom portion 40 of the base unit 80 by a threaded connection allowing the vertical height of the spherical cap mount 100 to be adjusted by rotating the spherical cap mount 100 , thereby adjusting the frictional force maintaining the static position of the arm 30 . Alternatively, the force may be transmitted by one or more screws disposed within the base unit 80 pressing the spherical cap mount 100 upwards against the spherical cap 70 of the arm 30 .
[0027] In another embodiment of the invention (not shown) the arm 30 is extendable thereby providing an additional way of adjusting the direction of the airflow. The arm 30 is preferably of a telescoping type and provided with a locking mechanism for each segment of the telescoping arm.
[0028] In a preferred embodiment, the fan blower 10 includes a handle 20 coupled to the fan blower 10 by which the rotatable pivot mount may be adjusted and the airflow direction altered. It is preferable that the handle 20 does not significantly obstruct either the air intake or exhaust of the fan unit. Additionally, as shown in FIG. 1 , the handle 20 should be positioned so that it will act as a lever when rotating the fan about the vertical axis and when pivoting the fan about the spherical cap 70 of the arm 30 , thus reducing the amount of force required to overcome the friction force created within the rotatable pivot mount.
[0029] Another feature of this invention is that the pivot guide 60 of the top portion 50 of the base unit can act as a guide for positioning the arm 30 by preventing the fan from being adjusted to certain positions. If the fan blower 10 is pivoted too far off the vertical axis, the center of gravity may extend beyond the support area provided by the base unit 80 . The shape of the opening 120 of the pivot guide 60 can be adjusted to prevent the fan blower 10 from pivoting such that the center of gravity extends beyond the support area provided by the base unit 80 . If the base unit 80 is a circle, and the opening is located at the center of the base, then the opening 120 of the pivot guide 60 could be a circle having a particular radius to prevent the arm from pivoting too far. If the base unit 80 is in the shape of a triangular support, as shown in the embodiment in FIGS. 1-3 , then the pivot guide 60 could be shaped so that the angle of rotation of the fan about the pivot would be greater when positioned over one of the ground supports than when positioned between two of the ground supports.
[0030] Another feature of this invention is that the pivot guide 60 of the top portion of the base unit can increase the stability of the fan when adjusted to certain positions. The friction created at the pivot should be sufficient to hold the fan in any position to which it is adjusted. However, if the frictional force should decrease through wear of the assembly or if a sudden external force is exerted on the assembly, the static friction may be overcome and the fan could be moved out of its adjusted position. The shape of the opening 120 of the pivot guide 60 can provide inlets 170 in which the arm 30 rests thus complementing the support provided by the frictional force exerted by the bottom potion 40 of the base unit 80 . Thus, if the assembly is disturbed by an external force while the arm 30 is positioned in one of the inlets 170 provided by the pivot guide 60 , the added stability of being positioned in the inlet 170 decreases the likelihood of the fan being moved out of position.
[0031] While the invention has been shown by way of reference to a rotatable pivot mount fan and particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the present invention may be utilized in any pivotable appliance and that various changes in form and details may be made therein without departing from the spirit and scope of the invention.
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A pivot assembly that can be used with various appliances. The pivot assembly provides up to three degrees of freedom when positioning the appliance. The pivot may be used, for example, with a fan that is mounted on a base such that direction of the airflow generated can be adjusted about three coordinate axes by manipulating a single rotatable pivot mount. The fan assembly includes a base unit and an arm to which an appliance may be detachably coupled. The opposite end of the arm is provided with a spherical cap which is received by the base unit. Any adjustments to the positioning of the rotatable pivot mount are maintained by the friction within the rotatable pivot mount. Additionally, the pivot mount may include a pivot guide to restrict the degree of rotation about the pivot, thereby increasing stability.
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BACKGROUND
The present invention concerns a high voltage transistor used for various circuits such as amplifiers, power converters, instrumentation and the like.
In the prior art, high voltage p-channel metal-oxide-silicon (PMOS) transistor have been integrated onto circuits. See for example, the PMOS transistor disclosed by Vladimir Rumennik, David L. Heald, Integrated High and Low Voltage CMOS Technology, IEEE 28th Int. Electron Devices Meeting, pp. 77-80, 1982. In this prior art scheme the PMOS transistor is connected in series with an extended drain p-drift (or offset) region. P-type impurities (e.g. Boron) are introduced in the drift region by ion implantation after a polysilicon layer is formed to provide self-alignment to the gate. The charge of the p-drift region is uniquely defined by the charge matching with the underlying n-well charge. Specifically, the maximum electric field is a function of the doping level in the p-offset channel and the well and is sensitive to the charge mismatch between them. The need to control the charge in the p-drift regions requires a closely controlled Boron implant into the p-drift region.
Several difficulties exist in the above-described prior art system. For example, since the polysilicon gate is used to mask the p-type implant in the drift region, the implant energy must be limited to avoid penetrating the polysilicon. Thus, the impurity distribution in the drift region is relatively shallow. Also, only a deposited thick oxide may be used since a long thermal oxidation cycle would consume the polysilicon. The combination of a shallow diffusion in the drift region and an inferior deposited oxide leads to reduced breakdown voltages and decreased transistor reliability.
Another disadvantage is that a relatively high on-state resistance of the transistor results from the conductivity of the p-channel and the drift region being lower than the conductivity of n-channel transistors. The on-resistance of the p-channel device is significantly influenced by the net concentration of the p-type impurities. However, as discussed above, the concentration of the p-type impurities cannot be arbitrarily increased to maintain balance compensating charge as this would detrimentally affect drain break down voltage (BVD).
SUMMARY OF THE INVENTION
In accordance with the preferred embodiment of the present invention, a method for constructing a semiconducting device is presented. Within a substrate of a first conductivity type there is formed a well of second conductivity type. For example, the first conductivity type is p-type and the second conductivity type is n-type. Within the well, an extended drain region of a first conductivity type is formed.
A thick insulating region is formed over the well and extended drain regions. For example, a thick oxide layer is grown across the surface of the substrate. The thick oxide is etched to form the insulating region above the extended drain region. The etch is performed so both ends of the extended drain are exposed. A thin insulating region is formed on the surface of the substrate above the first end of the extended drain and a portion of the well. For example a thin oxide layer is grown across the surface of the substrate exposed by the prior etch.
A gate region is formed on the surface of the thin insulating region. A first side of the gate region overlaps the first end of the extended drain region. For example, this includes forming the gate region so it extends onto the thick insulating region. A drain region of the first conductivity type is formed. The drain region is in contact with the second end of the extended drain region. A source region is formed on the second side of the gate region. For example, the source region includes alternating strips of material of the first conductivity type and second conductivity type.
The preferred embodiment of the present invention is an improvement over the prior art. For example, in prior art systems, a gate is formed before implanting an extended drain region. This allows for self-alignment of the p-top region with the gate. After the implanting of the p-top region, a layer of oxide is deposited. However, in the present invention, the thick insulating region is formed before the gate region. This allows for a relatively thick (e.g. 0.8 micron) layer of field oxide to be grown over the p-top region. In the prior art, only a relatively thin (e.g. 0.1 micron) layer of field oxide could be deposited due to the limitations of the presence of the already formed polysilicon gate. Further, in the method in accordance with the preferred embodiment of the present invention the polysilicon gate is extended over the field oxide providing very efficient charge control through field plating. In the prior art, a field plate extending over the field oxide region could only be a metal layer since the polysilicon layer is formed before the field oxide regions. Such a metal field plate is much further removed from the substrate surface thus providing only partial charge control.
In an alternate embodiment of the present invention, an extended drain region of a first conductivity type is formed within a well of a second conductivity type. The well is contained within a substrate of the first conductivity type. A first insulating region is formed over a first portion of the extended drain region. A second insulating region is formed over a second portion of the extended drain region.
On a surface of the substrate a first gate region and a second gate region are formed. A first side of the first gate region is at a first end of the first portion of the extended drain region. A first side of the second gate region is at a first end of the second portion of the extended drain region.
A drain region of the first conductivity type is formed between the first portion of the extended drain region and the second portion of the extended drain region. The drain region is on a second side of the first portion of the extended drain region and is on a second side of the second portion of the extended drain region. For example, a ratio of the width of the first portion of the extended drain region to the width of the second portion of the extended drain region is at least 1:1. A first source region is formed on a second side of the first gate region. A second source region is formed on a second side of the second gate region. The first source region includes material of the first conductivity type, and the second conductivity type. The second source region includes material of the first conductivity type and the second conductivity type. This alternate embodiment has the advantage of providing an alternate current path through the well parallel to the conduction path of the first described embodiment. The advantage of the additional current path is that it provides for a decreased on-resistance of the combined structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-sectional view of a high voltage transistor in accordance with a preferred embodiment of the present invention.
FIG. 2 shows a cross-sectional view of a high voltage transistor incorporating a field plate near the drain junction in accordance with an alternate preferred embodiment of the present invention.
FIG. 3 shows a cross-sectional view of a high voltage transistor incorporating a stepped field plate near the drain whose height varies with position in accordance with another preferred embodiment of the present invention.
FIG. 4 shows an equivalent circuit representation of the high voltage transistor shown in FIG. 1 in accordance with a preferred embodiment of the present invention.
FIG. 5 shows a top view of a source region utilized for the high voltage transistor shown in FIG. 1 in accordance with a preferred embodiment of the present invention.
FIG. 6 shows a simplified top view of the high voltage transistor shown in FIG. 1 in accordance with a preferred embodiment of the present invention.
FIG. 7 shows a cross-sectional view of a high voltage transistor in accordance with an alternate preferred embodiment of the present invention.
FIG. 8 shows an equivalent circuit representation of the high voltage transistor shown in FIG. 7 in accordance with the alternate preferred embodiment of the present invention.
FIG. 9 shows a simplified top view of the high voltage transistor shown in FIG. 7 in accordance with the alternate preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a cross-sectional view of a high voltage transistor formed on a semiconductor die. A substrate 10 of a first conductivity type is, for example, made of p - -type material doped with 1×10 14 atoms per cubic centimeter. A typical thickness of substrate 10 is 500 microns. A well 11 of material of second conductivity type is formed of, for example, n-type material doped at 4×10 12 to 5×10 12 atoms per square centimeter. Well 11 extends a depth of, for example, 5 to 10 microns below a surface 9 of the semiconductor die. The doping levels and dimensions given here and below are for a device with a breakdown voltage of approximately 100 to 1000 volts.
Within well 11, a top region 14 of first conductivity type is formed. For example, region 14 is composed of p-type material doped at 2×10 12 atoms per square centimeter. Top region 14 extends downward from surface 9 to a depth of, for example, 1 micron. Top region 14 functions as an extended drain region.
Over surface 9 of well 11, a layer of insulating material is grown. The insulating material is, for example, silicon dioxide which extends upward from surface 9 approximately 0.8 microns. The layer of insulating material is etched to form insulation region 25 and to expose the drain, source and channel regions.
A gate region 21 is placed over a gate insulating region 7. Gate region 21 is, for example, n + polysilicon doped at 15 ohms per square. Gate insulating region 7 is, for example, composed of silicon dioxide and extends above surface 9 approximately 200 to 1000 Angstroms.
In the prior art, the gate was formed before implanting an extended drain region. This allowed for self-alignment of the p-top region with the gate. After the implanting of the p-top region, a layer of oxide was deposited. However, the order of steps of the present invention has several significant advantages over the prior art. For example, in the present invention, a relatively thick (e.g. 0.8 micron) layer of thermally grown oxide may be formed over top regions 14. In the prior art, only a relatively thin (e.g. 0.1 micron) layer of field oxide could be deposited due to the limitations of the presence of the already formed polysilicon gate. The above described order of the steps allows the p-top region to diffuse deeper than is possible in the prior art. With a deeper p-top region the present invention can sustain higher breakdown voltages than the prior art.
Further, in the method in accordance with the preferred embodiment of the present invention, the polysilicon gate is extended over the field oxide providing very efficient charge control. However, in the prior art, a field plate extending over the field oxide region could only be a metal layer since the polysilicon layer is formed before the field oxide regions. A metal field plate is much further removed from the substrate surface thus providing only partial charge control.
The present invention allows polysilicon field plates to be placed near the drain region. For example, FIG. 2 shows how a second gate region 321 may be placed over thick insulating region 25 near drain contact region 16. Gate region 321 is, for example, n+ polysilicon doped at 15 ohms per square. FIG. 3 shows how the height of the drain field plating may be varied by introducing a thin insulating region 307 under gate region 321. Insulating region 307 is, for example, silicon dioxide and extends above surface 9 approximately 200 to 1000 Angstroms. Drain field plates provide additional charge control near the drain junction.
In the preferred embodiment, after forming gate region 21, within well 11, a source contact region 13 of first conductivity type and a drain contact region 16 of first conductivity type are implanted. For example, source contact region 13 and drain contact region 16 each are composed of p + -type material doped at 2×10 15 atoms per square centimeter. Source contact region 13 and drain contact region 16, for example, each extend 0.6 microns below surface 9 of the semiconductor die. Drain contact region 16 is in direct contact with top region 14.
Additionally, a source contact region 32 of second conductivity type is implanted. Source contact region 32 is, for example, composed of n + -type material doped at 5×10 15 atoms per square centimeter. Source contact region 32 extends, for example, 0.6 microns below surface 9 of the semiconductor die. Source contact region 13 and source contact region 32 are representative of the "chopped" source of alternating layers of p + -type material and n + -type material, as discussed below.
A source contact 17 is placed on surface 9 in electrical contact with source contact region 13 and source contact 32. A drain contact 19 is placed in electrical contact with drain contact region 16 (and for the embodiments shown in FIG. 2 and FIG. 3, in contact with field plate 321). A gate contact 18 is placed in electrical contact with gate region 21. Metalization and passivation steps then are performed as is understood in the art.
FIG. 4 shows an equivalent circuit representation of the high voltage structure shown in FIG. 1. The high voltage structure functions as a MOSFET 51 connected in series with a JFET 52. The channel for JFET 52 is top region 14. The gate for JFET 52 is tied to the source for MOSFET 51 via well 11. JFET 52 contributes significantly to the on-resistance of the combined structure especially at high applied voltages.
As shown in FIG. 5, to further enhance the device avalanche capability the source of the device is arranged in an order of alternate n + layers 61, 63, 65 and p + layers 62, 64. Each layer has a width 49 of, for example, 3 microns.
FIG. 6 shows a simplified top view of the high voltage transistor shown in FIG. 1. The high voltage transistor is shown in FIG. 6 to have a "chopped source" consisting of alternate n + layers 61, 63, 65, 67, 69 and p + layers 62, 64, 66, 68, 70. Drain contact region 16 has a height 72 of, for example, 10 to 100 microns. Top region 14 has a width 73 of, for example 20 to 40 microns. Gate region 21 has a width 74 of, for example, 6 microns.
FIG. 7 shows a cross-sectional view of an alternate preferred embodiment of a high voltage transistor formed on a semiconductor die. The alternate embodiment provides a new structure in which an alternate current path is introduced in parallel to the main MOSFET and JFET combination thus decreasing the on-resistance of the combined structure.
As shown by FIG. 7, a substrate 110 of first conductivity type is, for example, made of p - -type material doped with 1×10 14 atoms per cubic centimeter. A typical thickness of substrate 110 is 500 microns. A well 111 of material of second conductivity type is formed of, for example, n-type material doped at 4×10 12 to 5×10 12 atoms per square centimeter. Well 111 extends a depth of, for example, 5 to 10 microns below a surface 109 of the semiconductor die. The doping levels and dimensions given here and below are for a device with a breakdown voltage of approximately 100 to 1000 volts.
Within well 111, a top region 114 of first conductivity type and a top region 214 of first conductivity type are formed. For example, region 114 and region 214 are composed of p-type material doped at 2×10 12 atoms per square centimeter. Region 114 and region 214 each extend downward from surface 109 to a depth of, for example, 1 micron.
Over surface 109 of well 111, a layer of insulating material is grown. The insulating material is, for example, silicon dioxide which extends upward from surface 109 approximately 0.8 microns. The layer of insulating material is etched to form insulation region 125, to form insulation region 225 and to expose the drain, source and channel regions.
A gate region 121 is placed over a gate insulating region 107. Likewise, a gate region 221 is placed over a gate insulating region 207. Gate region 121 and gate regions 221 are, for example, n + polysilicon doped at 15 ohms per square. Gate insulating regions 107 and 207 are, for example, composed of silicon dioxide and each extend above surface 109 approximately 200 to 1000 Angstroms.
Within well 111, a source contact region 113 of first conductivity type, a source contact region 213 of first conductivity type and a drain contact region 116 of first conductivity type are implanted. For example, source contact region 113, source contact region 213 and drain contact region 116 each are composed of p + -type material doped at 2×10 15 atoms per square centimeter. Source contact region 113, source contact region 213 and drain contact region 116, for example, each extend 0.6 microns below surface 109 of the semiconductor die. Additionally, a source contact region 132 and a source contact region 232 of second conductivity type are implanted. Source contact regions 132 and 232 are, for example, composed of n + -type material doped at 5×10 15 atoms per square centimeter. Source contact regions 132 and 232 each extend, for example, 0.6 microns below surface 109 of the semiconductor die. Source contact regions 113, 132, 213 and 232 are representative of "chopped" sources of alternating layers of p + -type material and n + -type material.
Source contacts 117 are placed on surface 109 in electrical contact with source contact region 113 and source contact 132. Source contacts 217 are placed on surface 109 in electrical contact with source contact region 213 and source contact 232. A drain contact 119 is placed on surface 109 in electrical contact with drain contact region 116. A gate contact 118 is placed in electrical contact with gate region 121. A gate contact 218 is placed in electrical contact with gate region 221. Metalization and passivation steps then are performed as is understood in the art.
FIG. 8 shows an equivalent circuit representation of the high voltage structure shown in FIG. 7. A main MOSFET 151 is connected in series with a JFET 152. The channel for JFET 152 is top region 114. The gate for JFET 152 is tied to the source for MOSFET 151 via well 111. In parallel with MOSFET 151 and JFET 152, is an auxiliary MOSFET 251 connected in series with a JFET 252 and a JFET 253. The channel for JFET 253 is well 111. The gate for JFET 253 is top regions 114 and 214 and drain contact region 116.
In the preferred embodiment, JFET 253 is a high voltage n-channel JFET with a breakdown voltage of, for example, 100 to 1000 volts. MOSFET 251 and JFET 252 together represent an auxiliary p-channel MOSFET with a breakdown voltage of, for example, 20 to 100 volts. The auxiliary MOSFET 251 and JFET 252 are formed within the drain of high voltage MOSFET 151. The portion of well 111 to which the source of auxiliary MOSFET 251 is connected is completely surrounded by top region 214, drain contact region 116 and top region 114 which together constitute the gate for JFET 253. When the voltage applied between source 117 and drain 116 exceeds the threshold voltage for JFET 253 the channel of JFET 253 will pinch off. The voltage applied to the auxiliary MOSFET 251 and JFET 252 combination is thus limited to the threshold voltage of JFET 253 which is, for example, 20 to 100 volts.
The combined structure shown in FIGS. 7 and 8 has two gates and two current paths. If the main MOSFET 151 is turned on, current will flow through the PMOS channel under gate 121 and top drift region 114 to drain 116. If auxiliary MOSFET 251 is turned on, current will flow through well 111 to source contact 232 then continue through the PMOS channel under gate 221 and top drift region 214 to drain 116. Both paths may be activated simultaneously provided the gate to channel junction (the junction between well 111 and top regions 114, 214 and drain 116) of JFET 253 is not forward biased.
FIG. 9 shows a simplified top view of the high voltage structure shown in FIG. 7. An area 230 contains a "chopped source" for MOSFET 251. Area 230 consists of alternate n + layers and p + layers. Area 230 has a length 272 of, for example, 7 to 14 microns. Gate region 221 surrounds area 230 and has a width 273 of, for example 6 microns. Top region 214 separates gate region 221 from drain region 116 a distance 274 of, for example 5 to 10 microns. Drain region 116 has a width 275 of, for example, 5 to 10 microns. Top region 114 separates gate region 121 from drain region 116 a distance 276 of, for example 20 to 40 microns for 400 volt operation. Area 130 contains a "chopped source" for MOSFET 151. Area 130 consists of alternate n + layers and p + layers. Gate region 121 surrounds area 130 and has a width 277 of, for example 6 microns.
The foregoing discussion discloses and describes merely exemplary methods and embodiments of the present invention. As will be understood by those familiar with the art, the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For example, the examples given above are for p-channel devices; however, an n-channel device can be also implemented using the reverse conduction type construction fabricated in n-type substrates. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
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In a method for constructing a semiconducting device, within a substrate of a first conductivity type there is formed a well of second conductivity type. Within the well, an extended drain region of a first conductivity type is formed. An insulating region over the extended drain region is formed. A gate region is formed on a surface of the substrate. A first side of the gate region is adjacent to a first end of the extended drain region. A drain region of the first conductivity type is formed. The drain region is in contact with a second end of the extended drain region. A source region is formed on a second side of the gate region.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This present application is a divisional of Non-Provisional patent application Ser. No. 11/635,839, filed on Dec. 8, 2006, which is incorporate herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a method and an apparatus for spinning fibers, or fiberizers, using a rotary fiber-making die system made up of thin plates, embodied by a housing fixture, configured and stacked to define slots, channels and/or grooves through which the material used to make the fibers will flow. The die system allows for the production of different size and types of fibers, including nanofibers having a diameter of less than 1 micron, and facilitates a variety of cost effective methods for extrusion. The use of plates means the dies can be manufactured cost effectively, with easier clean-outs, replacements and/or variations.
[0003] Thermoplastic resins and glass have been extruded to form fibers and webs for many years. The nonwoven webs produced are commercially useful for many applications including diapers, feminine hygiene products, medical and protective garments, filters, geotextiles, insulation, ceiling tiles, battery separator media and the like. Larger glass-type fibers have been utilized in applications such as acoustical or thermal insulation materials. The common prior art methods for producing glass fiber insulation products involve producing glass fibers from a rotary process. A single molten glass composition is forced through the orifices in the outer wall of a centrifuge or spinner, producing primarily straight glass fibers. Curly glass fibers as taught in U.S. Pat. No. 2,998,620 to Stalego, which is incorporated herein by reference, discloses a bi-component glass composition to effect the curly end product.
[0004] A highly desirable characteristic of the fiber used to make nonwoven webs for certain applications is that they be as fine as possible, in some cases where fibers less than 1 micron are required. Fibers with small diameters, less than 10 microns, result in improved coverage with higher opacity. Small diameter fibers are also desirable since they permit the use of lower basis weights or grams per square meter of nonwoven. Lower basis weight, in turn, reduces the cost of products made from nonwovens. In filtration applications small diameter fibers create correspondingly small pores which increase the filtration efficiency of the nonwoven.
[0005] The most common of the polymer-to-nonwoven processes are the well known spunbound and meltblown processes. Some of the common principles between these two processes are the use of thermoplastic polymers extruded at high temperatures through small orifices to form filaments, using air to elongate the filaments and transport them to a moving collector screen where the fibers are coalesced into a fibrous web or nonwoven. The process chosen depends on the starting material and/or on the desired properties/applications of the resultant fibers.
[0006] In the typical spunbound process the fiber is substantially continuous in length and has a fiber diameter in the range of 20 to 80 microns. The meltblow process typically produces short, discontinuous fibers that have a fiber diameter of 2 to 6 microns.
[0007] Commercial meltblown processes as taught by U.S. Pat. No. 3,849,241, incorporated herein by reference, to Butin, et al., use polymer flows of 1 to 3 grams per hole per minute at extrusion pressures from 400 to 1000 psig and heated high velocity air streams developed from an air pressure source of 60 or more psig to elongate and fragment the extruded fiber. The typical meltblown die directs air flow from two opposed nozzles situated adjacent to the orifice such that they meet at an acute angle at a fixed distance below the polymer orifice exit. Depending on the air pressure and velocity and the polymer flow rate the resultant fibers can be discontinuous or substantially discontinuous.
[0008] U.S. Pat. Nos. 4,380,570, 5,476,616 and 5,645,790, incorporated herein by reference, all further detail the melt blowing process. More particularly, they detail improvements to melt blown spinnerettes counted on the surfaces of a polygonal melt-blowing extrusion die block thereby spinning fibers away from the center of the polygon at high extrusion rates. The fibers being deflected about 90 degrees by an air stream from a circular or polygonal air ring to enhance fiber entanglement and web formation.
[0009] Nonwoven webs as taught by Fabbricante et al. U.S. Pat. No. 6,114,017, which is incorporated herein by reference, are made by a meltblown process where the material is extruded through modular dies. The patent utilizes a series of stacked plates, each containing one or more rows of die tips. Each modular area being attached to a forced air mechanism to effect an extrusion. This produces a unique nonwoven web similar to Fabbricante et al. U.S. Pat. No. 5,679,379, which is incorporated herein by reference and which details an embodiment of die plates for fiber extrusion. Advantages mentioned by the modular die extrusion method being the efficiency of a quick change if a die became clogged or of using a lower cost material to effect a cost advantageous rapid cleanout/changeout.
[0010] Conventional melt spinning processes involve molten materials (typically a polymer and/or glass) being gravity fed or pumped under pressure to a spinning head and extruded from spinneret orifices into a multiplicity of continuous fibers. Melt spinning is only available for polymers (not including glass) having a melting point temperature less than its decomposition point temperature, such as nylon, polypropylene and the like whereby the polymer material can be melted and extruded to fiber form without decomposing. Other polymers, such as acrylics, cannot be melted without blackening and decomposing. Such polymers can be dissolved in a suitable solvent of typically 20% polymer and 80% solvent. In a wet solution spinning process, the solution is pumped, at room temperature, through the spinneret which is submerged in a bath of liquid (e.g. water) in which the solvent is soluble to solidify the polymeric fibers. It is also possible to dry spin the fibers into hot air, rather than a liquid bath, to evaporate the solvent and form a skin that coagulates. Other common spinning techniques are well known and do not form a critical part of the instant inventive concepts.
[0011] The area of fiber spinning frequently involved a spinneret made from a solid metal which is extrusion die cast or drilled to create openings or orifices from which the fibers are extruded. This presents limited options in the fiber spinning area due to a limitation on distribution/flow paths. A typical spinning method is disclosed in U.S. Pat. No. 5,785,996 to Snyder, which is incorporated herein by reference, and details a glass making invention with a spinning head comprised of drilled or machined holes to spin out the fibers. The fibers being aided in movement by the centrifugal force and/or by sending pressured air through the system.
[0012] After spinning, the fibers are commonly attenuated by withdrawing them from the spinning device at a faster speed than the extrusion speed, thereby producing fibers which are finer and, depending upon the polymer, possibly more crystalline in nature and thereby stronger. The fibers may be attenuated by melt blowing the fibers, that is, contacting the fibers as they emanate from the spinneret orifices with a fluid such as air. The air being under pressure to draw the same into fine fibers, commonly collected as an entangled web of fibers on a continuously moving surface, such as an internal or external conveyor belt or a drum surface, for subsequent processing.
[0013] The extruded fibrous web may be gathered into sheet, tube or roll form which may be pleated to increase the surface area for certain filtering applications. Alternatively, the web or fibers may be gathered together and passed through forming stations, such as calendaring rolls, steam treating and cooling stations, which may bond the fibers at their points of contact to form a continuous porous element defining a tortuous path for passage of a fluid material.
[0014] While earlier techniques and equipment for spinning fibers have commonly extruded one or more polymer materials directly through an array of spinneret orifices to produce a web of monocomponent fibers or a web of multicomponent fibers, recent developments incorporate a pack of disposable distribution or spin plates juxtaposed to each other, with distribution paths being either etched, grooved, scored, indented, laser cut or slotted into upstream and/or downstream surfaces of the plates to direct streams of one or more polymer materials to and through spinneret orifices at the distal end of the spinning system. Such a manner provides a reasonably inexpensive way to manufacture highly sophisticated spinning equipment and to produce a high density of continuous fibers formed of more than one polymeric material. As an example, a spinning fiberglass die lasts typically 100 hours in production, therefore reducing the cost of this production method will provide financial savings to the user.
[0015] One embodiment of current spinplate technology involves circular dies which are cast or drilled with a straight extrusion path. Control over these expensive dies is limited. Such a die is typically made from a block of steel which various channels and die tips required for directing flow of molten polymer are machined, cast or drilled. In order to reduce the degree of metal working needed, in many cases other machined blocks of steel are conjoined to the basic die body to carry the thermoplastic or other fluids required by the particular extrusion process. As extrusion dies grow larger and more complicated due to the use of multiple thermoplastic melts and drawing fluids, the complexity of machining increases geometrically as well as the costs for manufacturing the die.
[0016] Another factor adding to the costs of using such dies is the need for frequent cleaning of the residual carbonaceous matter created by the oxidation of the thermoplastics due to high temperature. This requires the availability of additional dies as spares. Dies also have limited life due to the erosion of the die tip tolerances due to the high temperatures and the wear of the fluids flowing through the dies under high pressures. An interchangeable and cost effective die which allows for a variety of configurations is desired in the art.
SUMMARY OF THE INVENTION
[0017] The present invention is directed to a fiber spinning device which incorporates a series of one or more thin plates configured and stacked to define slots, channels and/or grooves to create a path through which material flows to form the fibers. Thus, the stacked plates define the outflow (or die extrusion) edge of the spinning device. The plates can be stacked into the housing in a manner allowing for various configurations of flow paths, and are typically made from thin sheet, low cost materials allowing for a versatile and cost effective spinning method.
[0018] The present invention provides a fiber spinning device mountable to rotate on a shaft in a fiberizer comprising: one or more stacked, thin circular plates, a housing unit containing the one or more plates, at least one of the plates or the housing unit having a central opening to receive material to be formed into fibers, at least one of the plates having an outflow edge peripheral to the plate, the one or more plates and housing unit cooperating to form a chamber for receiving the fiber forming material and to allow the flow of material along a radial path whereby said outflow edge will define a spinneret orifice through which fibers can be extruded.
[0019] The present invention also provides a method of spinning fibers comprising the steps of: providing a material for use in forming fibers, providing a fiberizer with a spinneret capable of being spun about a shaft comprising one or more stacked, thin circular plates, providing a housing device containing the one or more plates, at least one of the plates or the housing unit having a central opening to receive material to be formed into fibers, at least one of the plates having an outflow edge peripheral to the plate, the one or more plates and housing unit cooperating to form a chamber for receiving the fiber forming material and to allow the flow of material along a radial path whereby the outflow edge will define a spinneret orifice through which fibers can be extruded, delivering the material to said spinneret with a rotating means, moving the material through said spinneret and utilizing the plates so as to define a distribution path, extruding the material via an outflow edge located on one of the plates and peripheral to the plate, and collecting the spun fibers.
[0020] The present invention also provides an apparatus for spinning fibers comprising: at least one source of fiber forming material, a spinneret comprising one or more stacked, thin circular plates, at least one of the plates having a central opening to receive material to be formed into fibers, at least one of the plates having an outflow edge peripheral to the plate, said plates cooperating to form a chamber for receiving the fiber forming material and to allow the flow of material along a radial path whereby said outflow edge will define a spinneret orifice through which fibers can be extruded, means for transporting fiber making material to the spinneret, means for axially rotating the spinneret where the rotating means is on the same axis as the central opening, and means for collecting and removing the fibers formed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 a and FIG. 1 b are a drawing showing the supply means, the operation of the spinning apparatus and the takeaway means. FIG. 1 a details a gravity fed supply means. FIG. 1 b details a pressurized extruder type supply means.
[0022] FIG. 2 is a drawing detailing the internal workings of the spinning apparatus with gas being blown at a high velocity, attenuating the fibers as they exit the spinning head;
[0023] FIG. 3 is a drawing detailing the internal working of the spinning apparatus with a suction or vacuum method drawing the fibers exiting the spinning head onto a substrate;
[0024] FIG. 4 is a drawing detailing the serpentine flow pattern effected by stacking the plates, the material flowing from the central opening to the outflow edges;
[0025] FIG. 5 is a drawing of a fiber making plate and a space plate similar to those used in FIG. 4 ;
[0026] FIG. 6 are two drawings of the spinning device with two different type spinning plates, FIG. 6 a showing similarly stacked plates and FIG. 6 b detailing separate concentric chambers of a stacked plate design;
[0027] FIG. 7 is a drawing of the spinning plates tilted at an angle from the axis of rotation;
[0028] FIG. 8 is a drawing showing various plates used;
[0029] FIG. 9 is a drawing of one embodiment of the plate design detailing two fiber making plates and a spacer plate;
[0030] FIGS. 10 a and 10 b are drawings of the takeaway means of the system, in which FIG. 10 a is a side view, with part of it being broken away, and FIG. 10 b is a top view; and
[0031] FIG. 11 is a drawing of another embodiment of the takeaway means from the apparatus, this embodiment detailing a continuous takeaway.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The present invention generally relates to an apparatus for extruding and spinning fibers and relates more particularly to the production of a homogeneous web of fibers. The plate configuration on the apparatus is of particular importance, as it allows production of nanofibers and other larger fibers by centrifugal force. The stacked, thin plates and the interchangeability of these plates, along with the variations of slots, holes or grooves for extrusion of fluid materials is novel to the art of spinning fibers. The device operates by stacking the plates and allowing a serpentine flow for an even, uniform pressure balance and improved fluid distribution. Stacked, “bridged” plates with small serpentine flow throughways can also be strategically constructed as built-in filters to material passing through the plates. The interchangeability aspects of the plates allows for a variety of configurations to be employed. These variations include, but are not limited to, changing the size of the extrusion, changing the RPM speed of the spinning head/shaft, altering the fiber diameter, altering the volume of the extrusion, varying the pressure of the device, or varying the temperature extrusion. For the purpose of this invention a fiberizer is known by its common term in the art, that being a device which produces fibers.
[0033] The present invention allows a variety of flow patterns/distribution paths. This pattern/path can be easily altered by changing the spinning plate configuration, whereas the prior art die method does not easily allow changes due to the complexities and costs in manufacturing such a setup. Particularly with serpentine flow, stacked plate assemblies, through conventional milling and drilling would be impossible to machine.
[0034] The plates of the device are easily separated to allow cleaning of the extrusion path if clogging occurs during use. As the material moves through the extrusion channel or slots, the plates and/or spacers allow for cleaning by removal of the plates. This cleaning may be required during normal operation, or may be needed during temperature variations if the feed material did not melt/process as expected. Such a method provides a more cost effective and easier clean out method than conventional dies. If a situation exists where wear is high, a disposable plate or module assembly may be a viable alternative. A likely candidate for this type of module would be an extrusion in an abrasive environment. Utilizing a low cost material and a low cost method for creating the module, several spinning plate combinations could be preassembled. As the plates become clogged or wear out, the module is simply discarded; minimizing the amount of time the system is down for turnaround/production.
[0035] Another benefit of the invention is the use of slots or grooves as the passage channel, canal, or distribution path. Such a setup is unique to the field, with no known art employing a spinning device with slots/grooves. The current state of the art involves mechanical stamping, and/or electrical discharged machine (EDM) slots and/or grooves being etched/cut from a laser or other applicable device. One advantage of the plate method over the current state of the art is that the plates of the invention may allow for serpentine flow patterns. Utilizing a series of stacked plates or a series of offset plates allows a user the ability to create varied flow patterns in the distribution channel. Such patterns yield better fluid distribution and pressure balance.
[0036] As stated prior, the spinning method of the invention utilizes stacked plates versus standard milled and/or drilled dies from “start-up” block, steel components. The invention provides a spinning head which is lower in cost and offers much faster delivery of material to the fiber nonwoven web production. The invention also allows more circumferential orifices per linear inch as the stack/height varies and allows for more versatility of orifice sizes, for more interchangeability and the ability to withstand high pressure. With this invention, there is no limitation regarding plate thickness, slot size, groove size or stack height.
[0037] Referring now to the drawings, FIG. 1 a details a drawing of the spinning apparatus and takeaway means. The main part of the apparatus comprising a spinning head 2 , detailed in FIG. 1 a . The head operates by rotating about a cylindrical shaft 4 , as material is gravity fed in a supply means 5 next to the shaft 4 , the material enters the spinning head 2 and is centrifugally forced to the edge, allowing for an extrusion of the material at various diameters of said spinning head 2 . The unit is kept under a constant temperature by a heating device located on the source material storage area 6 , or the extruder 8 , with heat being used to allow for proper flow of the material. The flow of material in this embodiment is typically by gravity feed only as low or atmospheric pressure is used. A driving pulley 11 or similar system, and a rotation motor 12 , detail the rotational means which creates the centrifugal force for the process. The rotational motor 12 can be variable to allow for different flow rates of material. In addition various types of centrifugal device can be utilized.
[0038] FIG. 1 a details the substrate take away means 14 which can be a continuous belt carrier where fiber is sprayed or discharged onto the belt, removed from the belt and wound into a roll, or can be fibers sprayed or discharged onto a substrate carrier and wound, or can be downstream fibers from another source such as meltblown, spunbound or spunlaced acting as a carrier. The substrate take away means 14 in FIG. 1 a does not include the fiber web, as the web is added after passing the spinning head 2 . After passing the spinning head, the substrate take away means 16 carries the final web product.
[0039] FIG. 1 b details the same apparatus as FIG. 1 a , with an alternate configuration for the material supply means. The material can also be fed under pressure from an extruder 3 . The material flows from the extruder 3 , to a rotary flange 10 . The rotary flange 10 attached to the extruder 3 , and the shaft 4 . The rotary flange 10 , being a flow through flange having two flanges combined. One flange being stationary, and attached to the extruder 3 , the other being rotational and attached by a means to the rotational motor 12 . The shaft 4 , in this example having an inner chamber to allow the flow of fluid therein. The rotational motor 12 can be variable to allow for different flow rates of material. The utilization of the gravity feed system of FIG. 1 a and the pressurized extrusion system of FIG. 1 b is dependent on the application. The two embodiments are readily interchangeable means of delivering the material to the spinning plates.
[0040] The spinning head 2 , has at least one circular plate. The spinning head 2 typically consists of a housing device which contains at least one circular plate. The plate(s) being stamped, machined, etched, scored, laser cut, or indented into a path to which material can flow. At the plate edges, openings are created to allow the material to be delivered to the substrate takeaway means 16 and create the fiber web. An opening can be a full plate thickness opening through which the material can pass, or can be a partial plate thickness opening. Such a partial opening can be stamped, machined, etched, scored, laser cut or indented into the surface. The partial opening can be on one or both sides of the plate. The use of the partial or full opening is determined based on the application. The spinning head 2 , contains the plates and also is the area wherein the extrusion occurs. The substrate takeaway 16 allowing for extruded material to be eventually wound into a roll or other storage means. The fibers are centrifugally extruded from the spinning head 2 , onto the substrate takeaway means setup 14 . The substrate takeaway means 16 , is the mode/method onto which the fiber web is blown, extruded, gravity fed or pulled by vacuum onto a takeaway means. In order to adequately move the materials, a forming tube 18 , forms the substrate into a cylinder near the spinning head 2 . The forming tube 18 , forms the substrate and/or the takeaway belt into a cylinder, and from there the fibers are spun onto the belt/substrate 14 .
[0041] FIGS. 2 and 3 detail the internal workings of the spinning apparatus. FIGS. 2 and 3 detail the central location of the plates, and shows material moving through the supply means 5 , along the shaft area 4 , and eventually into the center of the plate. From there centrifugal force 25 , moves the material from the center area through the plate to the outer edge and eventually to an extruder type opening on the outflow edge. The material exits the spinning device via this opening. From the opening, a takeaway means delivers the material to its final location.
[0042] FIG. 2 details the current state of the art for fiber blowing, such a means is used in fiberglass blowing. In FIG. 2 higher velocity gases are blown into the center of the spinning head 2 . The gases approach the spinning head via a gas inlet 20 . This high velocity gas 21 , aids in moving the material thru the device, to the outflow edge and onto the substrate carrier. The fibers 22 , are attenuated as they exit the spinning head 2 and specifically the stacked plates 24 of the spinning head 2 . This high velocity gas 21 action creating a flow pattern which the fibers 22 , follow. The velocity of the gas may vary as needed. In this embodiment the direction of material flow 23 , through the supply means 5 , is in the same direction 21 , as the direction of flow of the attenuated fibers.
[0043] FIG. 3 details an embodiment of the apparatus employing a vacuum/suction device. The device is mounted so as to draw air away from the unit housing the spinning device 2 and plates 24 . The drawing of this air thru the outlets 26 , creates a flow which draws the fibers 22 outward onto the takeaway means 28 . FIG. 3 shows the takeaway means 28 as being a substrate device which carries the fibers 22 to the final storage location. The takeaway means 28 , operating in the opposite direction 27 , of the material flow 23 , from the supply means in this embodiment. Also, FIG. 3 details the tube 30 device which is created by the substrate carrier. Here the tube 30 constricts down in a circular manner around the spinning head 2 . The vacuum from the outlets 26 , causes the material to draw away from the outflow edge of the spinning plates 24 and onto the takeaway means 28 created by the support tube 30 .
[0044] FIG. 4 details the stacked plates 24 used in the spinning apparatus. Two different types of plates are used in this embodiment, a fiber making plate 40 , and a spacer plate 42 . In most embodiments the plates are stacked in an alternating manner with a spacer plate 42 , next to a fiber making plate 40 . This process being repeated as needed. However, another embodiment involves the use of two fiber-making plates with each plate doubling as a spacer plate or the offsetting of two fiber making plates to effect a divergent flow pattern.
[0045] Also detailed in FIG. 4 is the flow pattern involved in one embodiment of the invention. As the material leaves the storage area and extruder the material travels through the supply means 5 , along the shaft 4 , the material entering a central cavity or central opening 32 , located directly adjacent the shaft 4 . The material travels from the central opening 32 and by centrifugal force 25 , is drawn into the spinning plates 24 . The material being drawn from the center of the spinning plates 24 , 40 , 42 to the outer edge. At the outermost edge of the spinning plates 24 is an outflow edge 34 . Such an outflow edge 34 , being an opening through which the material exits and becomes a fiber and/or nanofiber.
[0046] The spinning plates 24 are attached to the shaft 4 by the plate holder device 36 . The plate holder device 36 encasing the spinning plates and rotating with the unit. At the end opposite the rotational shaft 4 is a plate holder end cap housing 38 . The end cap housing being a solid plate which prevents further flow of material and forces the material to exit via the outflow edge 34 . The plate holder device 36 and plate holder end cap housing 38 are also known collectively as a housing unit. Typically the material used in constructing the plate holder device 36 and end cap 38 (or housing unit), is thicker than the spinning plates 24 . This allows for higher pressures in the apparatus.
[0047] The spinning plates 24 are further defined in FIG. 5 as fiber making plates 40 or as spacer plates 42 . The fiber making plates 40 and spacer plates 42 are typically derived from stamped, machined, laser cut, etched, scored, indented or electrical discharged machining methods. In cases where the alteration does not go though the entire thickness of the plate the fiber making plates 40 and spacer plates 42 may be marked or altered on either one or both sides of the plate. The fiber making plate 40 is circular with a center hole or central opening 32 . The center hole 32 allowing for material to be continually fed from the supply means 5 . The fiber making plate 40 , typically has a series of holes or slots 44 radiating from or near the center hole 32 to the outflow edge 34 . These orifices, holes or slots 44 can be slotted, etched, laser cut, scored, indented or electrical discharge machined. The profile of this orifice can be square, rectangular, round, slotted, half round or triangular “V” grooved. The orifices 44 are configured in various manners to allow varied configurations of the fiber web. Variations on the orifices 44 allow for varying qualities, quantities and distribution of fibers in the web. The size of the orifice varies with dimensions as small as 0.0005″ by 0.0005″. The number of the orifices 44 per linear inch varies with each application but can be from 1 to 300 orifices per circumferential inch. In applications where the orifices are small enough and placed close together there can be up to 660 orifices per linear inch. In order to achieve this value the orifices must be as small as 0.0005″ wide by 0.0005″ deep and must be spaced 0.001″ apart. When employed in combination, a variety of plates with differing orifice sizes and orifice numbers can be used. Also the spacing is specific to the application in question.
[0048] As stated previously, the orifices 44 radiate outward to an outflow edge 34 . The outflow edge 34 allows for the escape or extrusion of material from the spinning head 2 and into the take away means 28 . The outflow edge 34 typically employs a concentric tip 46 . Such a concentric tip 46 is made by mechanical, chemical or electrical methods.
[0049] The spacer plate 42 in FIG. 5 typically has less area than the fiber making plate 40 , as the purpose is to effect a diversion in the normal flow path of the material. The material following a distribution path altered by the insertion of varying spacer plates 42 , offset fiber making plates 40 or differently configured fiber making plates 40 . The spacer plates 42 are typically manufactured by stamped, machined, laser cut, etched or electrical discharged machining methods. If fluid passageways or distribution channels 48 are needed in the spacer plates 42 , these channels can be made by slotted, etched, laser cut, scored or indentation methods and can be square, rectangular, slotted, round, half round or triangular “V” grooves.
[0050] The thickness of the fiber making plate 40 , and the spacer plate 42 , will vary, but in one embodiment the thickness was between 0.0005″ and 0.1″. In another embodiment the thickness of these plates varied between 0.001″ and 0.1″. For the purposes of this application, the term “thin” is intended to mean plates having a thickness of between about 0.0005 inch and 0.1 inch. The plates themselves are typically made from ferrous or non-ferrous metals but can also be made from plastic, ceramic, inconel or any other suitable materials. Advantages provided by the use of a ceramic plates involves less wear and the ability to withstand higher temperatures. When combining plates a variety of thicknesses can be used as it is not necessary to use one standard plate thickness. The distribution path created by these plates will vary based on the application but can be as low as 0.010″ long and 0.0005″ deep by 0.0005″ wide.
[0051] The plates, as detailed in FIG. 4 and FIG. 6 are stacked with the shaft 4 , of the apparatus passing thru the central opening 32 , of the spinning plates 24 . The shaft 4 , rotates and creates a centrifugal force 25 , moving the material 7 , from the supply means 5 , into the chamber created by the central opening 32 . The material is transported into the spinning plates 24 , through the plates, through the outflow edge 34 , and then outside the apparatus to the takeaway means 28 . The fiber is aided onto the takeaway means by either a vacuum draw, centrifugal means or a high velocity gas. The high velocity gas introduced into the system via the gas inlet 20 at the side of the apparatus. The high velocity gas in one embodiment encircling the spinning plates in a halo or ring 56 . The gas flowing from the ring 56 attenuating the fibers into a free fall onto the takeaway means. The gas exiting the halo ring 56 via a narrow opening 57 .
[0052] As shown in FIG. 4 the distribution path created by the plates can be, but is not limited to, a serpentine path. Such a path is achieved by the stacking of dissimilar plates 40 , 42 , or by offsetting similar plates. These methods creating a variety of plate, path and flow configurations allowing for variations of the fiber diameter, fiber strength and/or configuration in the fiber web. In a serpentine setup the pressure is more uniform and the plates can also be strategically constructed to act as a filter for material. One goal of plate arrangement involves improved fluid distribution and pressure balance. In one embodiment the plates are held together by a series of bolts, however any suitable fastening means can be used as a securing means. One such fastening means includes a narrow top to bottom strip weld of the stacked plates. The plate arrangement 24 is secured in the plate holder device 36 to the end cap housing plate 38 . The end cap housing plate 38 prohibiting further flow of the material thru the center channel and in essence forcing the material to the outflow edges 34 . The housing unit 36 , 38 thicknesses varying depending upon the temperature and pressure application requirement.
[0053] The mechanism to spin the fibers has a speed which can vary from 50 to 20,000 revolutions per minute. Varying the speed of this device 12 , or a similar device will affect the amount/qualities/diameters of the resultant fiber. Also changing the fluid viscosity, via the heater or by changing chemical/flow properties of the source material will affect the fiber amount/qualities/diameters.
[0054] The basic setup for the spinning plate 24 arrangement is for similar sized plates to be stacked on top of one another, such a configuration is detailed in FIG. 6 a . Another embodiment of the fibermaking plates involves a stacked/stepped configuration, as shown in FIG. 6 b . This embodiment involves changing the size of the inner diameter of the center opening 32 . The center opening 32 of the plates at the material entry end 50 would be wider than the center opening 32 of the plates at the top or end-cap end 52 . Moving from the material entry end 50 , to the end cap end 52 , the central opening 32 of the plates 24 becomes progressively smaller. The largest diameter center opening 32 would be near the opening/entry end 50 , channeling/stepping down to the smallest inner diameter opening 32 at the end cap 38 or end furthest from the entry end 52 . Such a setup would incorporate a blocking plate 54 . The blocking plate 54 being a solid plate of the same diameter of the adjacent plate. The blocking plate 54 prohibits the flow of material through the plate and in essence creates separate zones of extrusion. Such an apparatus would allow better pressure distribution and flow through the fiber making system. For example, one embodiment is a series of plates 24 with an inner diameter for the central opening 32 , of 15″ near the entry end 50 . Immediately adjacent to these plates would be a series of plates 24 with a 14″ inner diameter for the central opening 32 , and immediately adjacent to this would be a series of plates 24 with a 13″ inner diameter for the central opening 32 . Here each level is dedicated to extruding the material, but the pressure distribution and flow improves versus a standard straight flow channel.
[0055] The angle of the spinning plates 24 in the module is typically at a 90 degree angle to the rotational shaft 4 . However, as shown in FIG. 7 , in order to create a variation in the lay down of the fibers 22 , the angle of the spinning plates 24 can be altered from 0.1 to 20 degrees from this typical position, i.e. being at a 70 to 89.9 degree angle to the rotational shaft 4 . Such an alteration creates a wider spread of fibers 22 , and allows the take away system to run at a faster rate than a standard 90 degree angle rotating member take away speed.
[0056] Various types of plates are used to achieve different purposes. FIG. 8 details the various types of plates which can be used to effect the final product. A chamber separator plate, or blocking plate 54 is used to separate zones of flow from one another. Such a plate is solid and allows passage of material only through its central opening 32 . Such a plate is useful in a stepped type system as shown in FIG. 7 . A spacer plate 42 can have a variety of configurations as shown in FIG. 8 such as a plate with support tie bars 60 . Either setup allowing for space to be placed between adjacent plates. Each plate allowing for passage of fluid via the central opening 32 . Finally the plate setup must include plates with an outflow edge 34 . Such an edge can occur on a plate having single-face channel grooves 62 , double faced channel grooves 90 or can be slotted 64 .
[0057] FIG. 9 details another embodiment of the spinning plates 24 . In this configuration two fiber making plates 40 are shown with a spacer plate 42 . The central opening 32 or paths for material flow can be seen in both the top and bottom plates. One embodiment of the invention involves making the spinning plates 24 from a low cost or disposable material. This would allow frequent changes of the spinning plates 24 in areas where the device is prone to clogging and for applications where changing the plate would be quicker or more cost effective than a cleanout. The plates utilize a channel or a slotted configuration as an outflow edge 34 . The plates detailed in this and other embodiments can be aligned or offset as warranted by the application and final product.
[0058] Alternate embodiments of the spinning plate configurations are possible. One option is for openings/orifices to be rectangular, square, triangular, and/or round. Another option allows the user to vary the different number of plates. Another option is to separate the plates by one, two or more spacer plates, the preferred embodiment involving a spacer plate alternating with a fiber making plate. Every embodiment requires an end cap plate 38 . Such a plate being solid and preventing flow of material through. The entire apparatus being secured into a plate holder device 36 which secures the various plates together.
[0059] FIGS. 10 a and 10 b detail an embodiment of the collection system take-away means. The drawing details a belt or conveyor substrate 14 which accepts the fiber material and transports it away 71 , from the spinning head 2 . The fiber 22 is sprayed, vacuum assisted, blown or drawn onto the substrate 14 , 16 . The substrate 14 being passed near the spinning head 2 and then taken away for storage. The speed and tension at which this takeaway occurs is important, as variations can affect the quality and tensile properties of the fiber. A supply roll 70 of substrate material such as a polyester, polypropylene or any suitable carrier material allowing the fiber/nanofiber the ability to form a nonwoven web to bond, or easily release is needed. This supply roll passes near the spinning head 2 , is kept at a constant diameter at the forming tube 18 , which can remain in a tube form or can be mechanically or electrically slit to open and then taken to a rollup or storage roll 72 .
[0060] FIG. 10 b defines the conical nature of the takeaway with the perspective shown in FIG. 10 a being a side view. FIG. 10 b details the takeaway means 16 and substrate carrier 14 , expanding into a flat apparatus allowing the fiber mesh to create a web-like sheet 74 . Such takeaway means 16 , can be, but are not limited to, a method of blowing the fibers or a method that can be pulled under a vacuum.
[0061] Another embodiment involves a continuous belt fiber takeaway. The area described as FIG. 11 details a dual purpose continuous carrier embodiment of the takeaway belts. In such a setup continuous carrier belt 76 , moves with or without a substrate 14 . Fibers are sprayed onto a supply roll 70 , of a material means. The fibers are sprayed onto this means 70 , as the substrate passes near the spinning head 2 . A continuous carrier belt 76 , is powered by a drive motor 78 . The continuous carrier belt operating as a loop, requiring no changes or starting/stopping of this belt 76 . The substrate of the takeaway means 16 , next peels/strips the nonwoven material away 22 , and winds the nonwoven material into a roll 80 , for storage/use.
[0062] The source material used for fiber making can be, but is not limited to glass, polymer or thermoplastic materials. Organic polymer materials made from sugar and corn can be used. In the prototype embodiment, polypropylene was used as the source material. The prototype material was heated and spun under temperature, however it is also possible to cold spin a raw material if the materials chemical properties/makeup allow for flow at room temperature or less than room temperature.
[0063] The typical end product created can be, but is not limited to substrates, nonwoven media, geotextiles, insulation and other areas where fiber is the primary end product.
[0064] The delivery of the material from the raw material source 6 , to the fiber spinning plates 24 , can be gravity fed or can be fed under pressure. Such a pressure can be, but is not limited to, 1 to 500 atmospheres. The pressure in the spinning apparatus distribution path and/or the outflow edge 34 , can also be at atmospheric pressure or from 1 to 500 atmospheres.
[0065] The diameter of spinning head 2 , will vary based on application and method of use. The diameter of spinning head 2 being within the range of 0.1″ to 145″ dia, or within the range of 1.5″ to 50″ dia, or being with the range of 2.5″ to 12″ dia. The takeaway tube 18 , which envelops the device can be from 0.5″ to 200″ inside diameter or can be from 3″ to 54″ inside diameter or can be from 8″ to 24″ inside diameter. The preferred embodiment utilizing a 3.5″ spinning head 2 , with a 12″ takeaway tube 18 . However, many variations are possible on these setups based on the finished product desired. For example for flat goods requiring a 120″ sheet a spinning head utilizing a 35″ diameter (approximate) is required.
[0066] The temperatures of the extrusion will also vary based on application and method of use. The melt and flow point of the material being used will dictate the optimum temperature for extrusion. In one embodiment a temperature of 450 to 500° F. was utilized to properly affect the material flow of polypropylene. As stated previous the heater is used to affect the flow properties of the source materials and is only needed to effect flow, serving no other apparent purpose. Provided the material has the ability to flow at room temperature (or even lower than room temperature) spinning is possible. The only limitation on temperature being the ability of the material to flow in the spinning means.
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The present invention relates to a method for spinning fibers, or fiberizers, using a rotary fiber-making die system made up of thin plates, embodied by a housing fixture, configured and stacked to define slots, channels and/or grooves through which the material used to make the fibers will flow. The die system allows for the production of different size and types of fibers, including nanofibers having a diameter of less than 1 micron, and facilitates a variety of cost effective methods for extrusion. The use of plates means the dies can be manufactured cost effectively, with easier clean-outs, replacements and/or variations.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to vehicle engine control, and more particularly, to a catalytic converter control system for oxygen storage management and control.
BACKGROUND OF THE INVENTION
[0002] Increasingly stringent federal and state motor vehicle emissions standards require that specific emissions-related systems on a motor vehicle be controlled and optimized. These systems must be functioning as intended over the life of the vehicle, and if the systems have deteriorated or lose their functionality, the vehicle operator must be informed and the system repaired. For example, a catalytic converter of a motor vehicle is monitored because of its ability to reduce undesirable emissions in exhaust gases from the engine of the motor vehicle.
[0003] The performance of the catalytic converter depends upon the chemical compositions of the exhaust gases from the engine of the motor vehicle. Maintaining the feed-gas concentration to the catalytic converter close to stoichiometry maximizes catalytic converter efficiency. The oxygen storage capability of the catalytic converter determines the functional performance of the converter, which may also deteriorate over time due to factors such as engine misfire, a faulty oxygen sensor, poisoning or prolonged high-temperature operation. Such deteriorzatioin results in diminished capability to store the oxygen available in the exhaust gases. Active management and control of the amount of oxygen stored in the catalyst during motor vehicle operation helps lower pollutants from motor vehicle emissions.
[0004] Three-way catalytic converters are designed to have oxygen storage capability to improve their conversion efficiency. Oxygen storage/release is carried out by the precious-metal-assisted transition between Ce 3+ and Ce 4+ of Ceria compound added to the washcoat of the catalyst. The major storage/release reactions are shown below.
Ce 2 O 3 + 0.5 O 2 Pt / Pd / Rh 2 CeO 2 ( 1 ) ( Storage ) Ce 2 O 3 + NO Pt / Pd / Rh 2 CeO 2 + 0.5 N 2 ( 2 ) 2 CeO 2 + CO Pt / Pd / Rh Ce 2 O 3 + CO 2 ( 3 ) ( Release ) 2 CeO 2 + H 2 Pt / Pd / Rh Ce 2 O 3 + H 2 O ( 4 )
[0005] Current engines have an on-board control system that applies one or more oxygen sensor outputs to control fuel/air flow rates. Emission control is accomplished by increasing catalyst loading. This results in adding more precious metal particles, thereby increasing the overall volume and cost of the catalytic converter.
[0006] A major drawback of current engine systems are that no known current engines employ active management of oxygen storage amount or oxygen storage capacity. Knowing the instantaneous oxygen storage amount is key to emission control. A further drawback is that catalysts can be saturated when too much oxygen is coming high-temperature exposure and poisoning due to the decreased surface area of the Ceria and the precious metal particles.
[0007] Accordingly, active oxygen storage management and control would improve emission control. An engine capable of predicting instantaneous oxygen storage amount is desired to overcome emission breakthroughs, increase catalytic converter efficiency, and generally reduce the overall size and cost of the catalytic converter.
SUMMARY OF THE INVENTION
[0008] The active oxygen storage management and control method and system according to the invention include sensing oxygen levels upstream and downstream of a catalytic converter for a fuel-injected engine of a motor vehicle. An engine control system predicts an oxygen consumption mass flow rate, and then determines an oxygen storage mass flow rate based on the sensed upstream and downstream oxygen levels and the predicted oxygen consumption mass flow rate. The oxygen storage mass flow rate is used to determine an instantaneous oxygen storage amount.
[0009] To determine the oxygen storage mass flow rate, the upstream and downstream oxygen levels are sensed and used to calculate upstream and downstream oxygen mass fractions, which are then used to determine a converter-in oxygen mass flow rate and a converter-out oxygen mass flow rate. Thus, the oxygen mass flow rate is preferably determined from converter-in mass flow rate, converter-out mass flow rate, and the predicted oxygen consumption mass flow rate.
[0010] Further, the upstream and downstream oxygen levels are preferably used to determine an upstream and downstream oxygen flow rate by determining an upstream and downstream lambda. In this manner, the determination of the upstream and downstream oxygen mass fractions are achieved by using the upstream or downstream lambda, respectively, as well as a set of reaction constants and a reaction fraction.
[0011] The method according to the invention is used to control exhaust emissions from a motor vehicle by predicting an instantaneous oxygen storage amount in the catalytic converter, determining a maximum oxygen storage capacity, and selecting a target percentage of the maximum oxygen storage amount. The motor vehicle engine performance is controlled so that the instantaneous oxygen storage amount is approximately the target percentage of the maximum oxygen storage amount. To accomplish this control, the instantaneous oxygen storage amount and the maximum oxygen storage amount are calculated as discussed above.
[0012] An engine control system according to the invention disposes oxygen sensors upstream and downstream from a catalytic converter. The engine control system monitors engine operating parameters including an output signal on the upstream and downstream oxygen sensors, determines an instantaneous oxygen storage amount based on the monitored sensor output signals, and controls engine operation to maintain the determined instantaneous oxygen storage amount in a predicted oxygen storage capacity. The engine control system monitors a plurality of engine control terms including a target instantaneous oxygen storage amount selected within a range from zero oxygen storage capacity to about a predicted maximum oxygen storage capacity.
[0013] The engine control system controls engine operation to maintain the instantaneous oxygen storage amount at approximately the target instantaneous oxygen storage amount. A plurality of fuel injectors receive a control signal from the engine control system to supply fuel to the engine at a rate where the instantaneous oxygen storage amount is approximately the target instantaneous oxygen storage amount.
[0014] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0016] [0016]FIG. 1 is a schematic diagram of an emission control system according to the present invention for catalytic converter control;
[0017] [0017]FIG. 2 is an algorithm block diagram illustrating a method according to the present invention for catalytic converter control; and
[0018] [0018]FIG. 3 is a graph representing how instantaneous oxygen storage changes over time within the maximum oxygen storage capacity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0020] Referring to FIG. 1, an emission control system 10 for a motor vehicle (not shown) is illustrated. The emission control system 10 includes an engine 12 and an engine controller 14 in communication with the engine 12 . The engine controller 14 includes a microprocessing unit 13 , memory 15 , inputs 16 , outputs 18 , communication lines and other hardware and software (not shown but known in the art) necessary to control the engine 12 and related tasks. The engine controller 14 may control tasks such as maintaining a fuel-to-air ratio, spark timing, exhaust-gas recirculation and onboard diagnostics. The emission control system 10 may also include other sensors, transducers or the like that are in communication with the engine controller 14 through the inputs 16 and outputs 18 to further carry out a method according to the present invention as described below.
[0021] The emission control system 10 also includes at least one fuel injector 20 , and preferably a plurality of fuel injectors 20 , which receive a signal from the engine controller 14 to precisely meter an amount of fuel to the engine 12 . As a result of the combustion process that takes place in the engine 12 , exhaust gasses are created and passed out of the engine 12 . Constituents of the exhaust gas include hydrocarbons, carbon monoxide and oxides of nitrogen, which are generally believed to have a potentially detrimental effect on air quality.
[0022] The emission control system 10 includes a catalytic converter 22 for receiving the exhaust gas from the engine 12 . The catalytic converter 22 contains material that serves as a catalyst to reduce or oxidize the components of the exhaust gas into harmless gasses. The emission control system 10 includes an exhaust pipe 24 connected to the catalytic converter 22 and to the atmosphere.
[0023] The emission control system 10 further includes an upstream oxygen sensor 26 and downstream oxygen sensor 28 , each of which measure the level of oxygen in the exhaust gas. The upstream oxygen sensor 26 is positioned in front or upstream of the catalytic converter 22 . Similarly, the downstream oxygen sensor 28 is positioned after or downstream of the catalytic converter 22 . It should be appreciated that as part of the emission control system 10 , the oxygen sensors 26 , 28 are in communication with the engine controller 14 .
[0024] Referring to FIG. 2, an algorithm block diagram 30 illustrating the computational process of the present invention is described. Input module 32 receives conventional control terms such as engine speed, engine load, and λ values from upstream and downstream O 2 sensors 26 , 28 . Input vector 32 distributes upstream λ, downstream λ, fuel composition, and engine operating condition variables to modules 34 and 40 to calculate converter-in and converter-out O 2 mass fraction and a predicted O 2 consumption mass flow rate respectively. The output of module 34 is then used to calculate converter-in O 2 mass flow rate in module 36 and converter-out O 2 mass flow rate in module 38 . Subtracting the output of modules 38 and 40 from the output of module 36 yields the O 2 storage mass flow rate in module 42 .
[0025] Module 44 represents the integration calculation of the output of module 42 , which is provided to module 46 for calculating the net O 2 storage amount. Modules 48 , 50 , and 52 are control algorithms while module 46 provides an extra control term for the fuel control algorithm module 48 , On Board Diagnostic (OBD) algorithm module 50 , and the fuel cutoff algorithm module 52 . The output of module 48 is fed back into the integrator module 44 to adjust fuel control to meet target operation. The control algorithm outputs of modules 46 , 50 , and 52 are distributed by the output module 54 for incorporation into overall engine control.
[0026] The following equations describe the detailed calculations illustrated in FIG. 2:
{dot over (m)}={dot over (m)} 1 −{dot over (m)} 2 −{dot over (m)} 3 (5)
{dot over (m)} 1 =V 1 *{dot over (m)} 4 (6)
{dot over (m)} 2 =V 2 *{dot over (m)} 4 (7)
{dot over (m)} 3 =f (λ 1 , {dot over (m)} 4 , T 1 , RPM, MAP, i ) (8)
v 1 =[a 1 *(1 +b*y )(λ 1 −x )]/[( a 2 +a 3 *y )+ a 4 *(1 +b*y )λ 1 ] (9)
v 2 =[a 1 *(1 +b*y )(λ 2 −x )]/[( a 2 +a 3 *y )+ a 4 *(1 +b*y )λ 2 ] (10)
x=f(y, RPM, MAP) (11)
y=hydrogen to carbon ratio of the fuel (12)
O 2str =∫mdt =∫( {dot over (m)} 1 −{dot over (m)} 2 − 3 ) dt=( 13)
OSC=f (λ 1 , T 1 , RPM, MAP ) (14)
[0027] where {dot over (m)} is the O 2 storage mass flow rate; {dot over (m)} 1 is the converter-in O 2 mass flow rate; {dot over (m)} 2 is the converter-out O 2 mass flow rate; {dot over (m)} 3 is the O 2 consumption rate inside the converter; {dot over (m)} 4 is the total exhaust mass flow rate; v 1 is the upstream O 2 mass fraction; v 2 is the downstream O 2 mass fraction; λ 1 is upstream λ (defined as (Air Supplied)/(Theoretical Air Requirement)) at the upstream O 2 sensor; λ 2 is downstream λ at the downstream O 2 sensor; x is the reaction fraction of fuel reacted in complete combustion; y is the hydrogen to carbon ratio in the fuel; T 1 is the catalyst temperature; MAP is the engine load; RPM is the engine speed; O 2str is the instantaneous O 2 storage amount, OSC is the maximum O 2 storage capacity, i is the number of emission species; and a 1 , a 2 , a 3 , a 4 , and b are constants. Mass transport delay is considered in the above calculations.
[0028] Referring to equations (9) and (10), O 2 mass fraction is modeled. Constants a 1 , a 2 , a 3 , a 4 , and b are defined as: a1=molecular weight of O 2 ; a 2 =atomic weight of carbon; a 3 =atomic weight of hydrogen; a 4 =molecular weight of O 2 +(N 2 to O 2 ratio in air)*molecular weight of N 2 ; and b=¼ derived from the stoichiometry of the complete combustion reaction. The complete combustion reaction is:
CHy+(1+y/4)O 2 →CO 2 +y/2H 2 O.
[0029] Upstream and downstream λ are represented by λ 1 and λ 2 respectively. At the optimum stoichiometric point, λ=1.0. The O 2 sensor is designed and calibrated to respond to differing levels of O 2 generated during combustion. Using such a sensor, it can be determined whether the air-to-fuel mixture is “rich” (not enough air for the amount of fuel; generally λ<1.0) or “lean” (excess air for the amount of fuel; generally λ>1.0).
[0030] During operation of a vehicle, an output voltage is based on sensor calibration and the level of O 2 detected. One use of the sensor is as an on/off switch. That is, if the output is above some predetermined target voltage, the air-to-fuel mixture is rich and if it is below the target voltage, the mixture is lean. Another use involves processing the actual sensor output through a closed-loop feedback-control system, which compares sensor output to a target value, generates an error, and then develops a correction factor for upcoming combustion cycles. Both applications use O 2 sensor output to adjust the amount of fuel used for subsequent combustion cycles, thereby attempting to achieve a stoichiometric air-to-fuel ratio. The conventional way to adjust the amount of fuel is by lengthening or shortening the time pulse of the fuel injectors.
[0031] The equations listed above correspond to the modules illustrated in FIG. 2:
[0032] Module 32λ 1 , λ 2 , {dot over (m)} 4 , T 1 , RPM, MAP, i, x, y.
[0033] Module 34→equation (9) and (10)
[0034] Module 36→equation (6)
[0035] Module 38→equation (7)
[0036] Module 40→equation (8)
[0037] Module 42→equation (5)
[0038] Module 44→equation (13).
[0039] A preferred embodiment of the present invention includes a method of predicting the instantaneous oxygen storage amount (O 2str ) and the maximum oxygen storage capacity (OSC). With this method, the O 2str can be controlled within a calibratable band to maximize the catalyst conversion efficiency with a minimum volume of the converter, thus preventing any transient NOx, CO, and hydrocarbon (HC) breakthroughs. Furthermore, the O 2str and OSC may also be used as OBD, and provide smarter fuel cutoff. The present invention also provides cost savings in precious metal loading.
[0040] The OSC is determined based on O 2str predictions. When downstream O 2 breakthrough occurs, an algorithm is triggered to determine whether it is caused by catalyst saturation or by a sharp lean spike. The OSC is updated when the downstream breakthrough is the result of catalyst saturation, which is used to determine when an OBD alarm should be triggered.
[0041] Fuel enrichment and lean-out air-to-fuel ratio are triggered based on the estimated O 2str to clean up excess oxygen or replenish oxygen so that the amount of oxygen stored can be controlled within the ideal range to prevent NO x , CO, or HC breakthroughs.
[0042] The OSC, which can be used to monitor catalyst deterioration, is estimated based on λ 1 , T 1 , RPM, and MAP. When the maximum OSC is detected to reach the point at which the catalyst conversion efficiency is below a designated threshold, an OBD alarm will be triggered.
[0043] Referring to FIG. 3, a graph 60 representing how O 2str without active control changes over time within the OSC is illustrated. Time is measured on the horizontal axis and mass of O 2 is measured vertically. Line 62 represents the predicted OSC. The OSC gets smaller over time as the catalyst deteriorates and ages. Target operation 64 is calibrated as a percentage of OSC. Therefore, over time, as the catalyst ages and the OSC decreases, the target value will be adapted, preferably within capacity. Target-hysterisis 66 defines deviation from target amount 64 in which the extra feedback term to the overall engine control is set to zero or is running at optimum condition. Target-hysterisis 66 represents the optimum O 2str range during vehicle operation. The control objective is to maintain the O 2str within target-hysterisis 66 .
[0044] Trace line 72 illustrates the path in which O 2str changes over time of vehicle operation. When the O 2str is above target-hysterisis 66 and below upper control limit 68 , the catalyst has too much O 2 stored and excess O 2 needs to be “cleaned up,” i.e., removed. This is accomplished by adding more fuel, commonly known as “enrichment.” Alternatively, if the O 2str is below target-hysterisis 66 and above lower control limit 70 , the catalyst has too little O 2 stored and O 2 must be replenished in the engine system. This is accomplished by adding more air (which includes O 2 ), commonly known as “lean out.” If O 2str reaches above upper control limit 68 or below lower control limit 70 , the engine control will respond more aggressively through enrichment or lean out. Upon resuming the supply of fuel after deceleration-fuel-cut-off, fuel enrichment will be conducted based on OSC to remove excess O 2 , and thus prevent NO x breakthrough.
[0045] Direct measurements of O 2 flowing into and out of the converter 22 and the prediction of the O 2 consumption rate determine the O 2str . The method and system according to the invention computes a reasonable amount of chemical reaction data and is implemented for instantaneous on-board control purposes. This method and system may be implemented into any on-board vehicle control unit without incorporating any new hardware or adding new parts to the vehicle. The inventive method and system generally adds an additional feedback control term to existing PID control. More particularly, the total O 2str is controlled based on OSC via fueling modifications. Different fueling strategies are used based on the difference between the O 2str and the oxygen storage control target. The feature outputs a number of control terms, which will be added to a conventional O 2 -feedback fuel control.
[0046] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A method and system for controlling exhaust emissions from an engine of a motor vehicle includes sensing oxygen levels upstream and downstream of a catalytic converter, predicting an instantaneous oxygen storage amount in the catalytic converter, determining a maximum oxygen storage capacity, selecting a target percentage of the maximum oxygen storage amount, and controlling the motor vehicle engine performance to a state where the oxygen storage amount is approximately the target percentage of the maximum oxygen storage amount. The instantaneous oxygen storage amount is determined from an oxygen storage mass flow rate, which is determined from a converter-in mass flow rate, converter-out mass flow rate, and a predicted oxygen consumption mass flow rate. The converter-in and converter-out mass flow rates are calculated from an upstream and downstream oxygen mass fraction, respectively, based on the sensed upstream and downstream oxygen levels, respectively.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a substrate of glass, ceramics, plastic, or metal, etc., having a treatment surface, i.e., a water repellent coating or film being formed on an undercoating layer or film thereof, and a treatment method therefor.
2. Description of Related Art
Conventionally, a substrate comprising for example glass or the like, on the surface of which a water repellent coating, layer or film is formed, has been already known, in for example, Japanese Patent Publication No. Hei 4-20781 (1992), Japanese Laid-open Patent No. Hei 5-86353 (1993), Japanese Laid-open Patent No. Hei 5-161844 (1993), Japanese Laid-open Patent No. Hei 2-311332 (1990) and Japanese Patent No. 2,525,536.
In Japanese Patent Publication No. Hei 4-20781 (1992), it is disclosed that on the surface of the substrate there is formed a coating layer or film from a silane compound excluding polyfluoro radicle or synthetic resin, and further thereon is formed a water repellent and oil repellent multi-layer coating or film comprising a silane compound including polyfluoro radicle.
Further, in Japanese Laid-open Patent No. Hei 5-86353 (1993), there is disclosed a method by which a thin film of siloxan radicle is formed on the surface of glass, ceramics, plastic, or metal, etc., by use of a compound including chlorosilyl radicle, such as SiCl 4 , in molecular form thereof, and further thereon is formed a chemical absorption unimolecular accumulation layer or film (a water repellent film or coating).
Also in Japanese Laid-open Patent No. Hei 5-161844 (1993), there is described a method in which, having formed a unimolecular film of siloxan radicle or an absorption film of polysiloxan previously, the chemical absorption unimolecular film (a water repellent film or coating) is formed on the surface of a substrate by a further chemical absorption processing conducted in an atmosphere including a surface-active agent of chlorosilane radicle.
Moreover, Japanese Laid-open Patent No. Hei 2-311332 (1990) describes a water repellent glass obtained through silylating the surface of glass substrate by a silyl compound, such as fluorinated alkylsilane, the surface of which is formed from a metal oxide, such as SiO 2 .
Furthermore, Japanese Patent No. 2,523,536 discloses that an undercoating film or layer of silica is applied on the glass substrate before treating the surface thereof by the fluorine compound, in the same manner as described in Japanese Laid-open Patent No. Hei 2-311332 (1990), and further that weather resistance of the water repellent film is improved by including olefin telomer in the fluorine compound.
With the substrate which can be obtained by the method disclosed in Japanese Patent Publication No. Hei 4-20781 (1992), since the density of the undercoating layer is low, the undercoating layer must be more than 100 nm in thickness thereof and also the temperature for baking must be higehr than 400° C.
In the method disclosed in Japanese Laid-open Patent No. Hei 5-86353 (1993), since the absorbent for the reaction to water in air is unstable, it is necessary to maintain the humidity in the atmosphere low, thereby control of the environment being difficult. Further, there are problems, in that it takes 2-3 hours for the treatment, and the nonaqueous solvent is expensive.
For implementation of the method which is disclosed in Japanese Laid-open Patent No. Hei 5-161844 (1993), equipment for controlling the atmosphere must be large-scaled, and it takes time to form a perfect absorption film.
With the substrate which is obtained by the method disclosed in Japanese Laid-open Patent No. Hei 2-311332 (1990), since baking at 500° C. for instance is necessitated for obtaining the high density metal oxide layer when forming the metal oxide film through a sol-gel method, also large-scaled equipment for baking the substrate at high temperature is necessary, thus raising the production cost. Further, having tried this method, the roughness of the metal oxide film thereby obtained is relatively high, resulting that it is difficult for water drops present on the surface of the water repellent glass to roll freely thereon.
Furthermore, with the substrate which is obtained by the method disclosed in Japanese Patent No. 2,525,536, though being superior with respect to weather resistance, such a result is only obtained through double-checking thereof that the durability of the water repellent film in a friction test is not adequate, and it is also difficult for water drops present on the surface of the water repellent glass to roll freely thereon since the roughness of the surface of the silica undercoating layer or coating is relatively high.
SUMMARY OF THE INVENTION
For resolving the drawbacks in the conventional art mentioned above, according to the present invention, there is provided a substrate having a treatment surface, characterized in that, on a surface of a substrate of glass, ceramics, plastics or metal, an undercoating film layer is formed by drying a liquid for undercoating treatment which is obtained by dissolving and reacting a material having chlorosilyl radicle in molecular form therein within an alcohol group solvent, so that on said undercoating film layer there is formed a water repellent or oil repellent layer, wherein a surface roughness (Ra) of said surface layer is equal to or less than 0.5 nm.
Further, the surface roughness (Ra) of the surface layer is preferably to be as small as possible. However, for example, the surface roughness (Ra) of a fire polished surface of float glass (i.e., upper surface of the float glass floating on molten tin) is about 0.2 nm, and the roughness (Ra) of a glass surface obtained through precise grinding is about 0.1 nm. Therefore, the substantially lowest threshold value of surface roughness (Ra) of the glass surface which can be obtained is about 0.1-0.2 nm.
As mentioned above, the undercoating film or layer formed from the undercoating treatment liquid, which is obtained by dissolving and reacting the material having chlorosilyl radicle in molecular form therein within an alcohol group solvent, has high smoothness, and therefore, the surface layer formed on the undercoating film or layer also comes to have high smoothness (Ra≦0.5 nm), reflecting the smoothness of the undercoating layer, thereby obtaining a superior water repellent property, i.e., a high contact angle and a low critical inclination angle.
Here, it is possible to remove defects in appearance by keeping the surface of the substrate clean when forming the undercoating layer or film on it, and it is also possible to increase adhesive strength between the substrate surface and the undercoating film by activating the surface of the substrate. For example, even in a case where the glass substrate comprises an oxide, it is possible to form an active surface by grinding the surface to within 0.5 nm≦Ra≦3.0 nm using a grinding agent.
However, in the case where the roughness (Ra) of the substrate surface exceeds 3.0 nm, it is difficult to make the roughness (Ra) of the surface layer (the water repellent layer) less than 0.5 nm even if effecting the undercoating treatment thereon. Therefore, it is preferable that the roughness (Ra) of the substrate surface be equal to or less than 3.0 nm. Moreover, when the substrate is made of glass plate, transparency of the substrate can be maintained when the roughness (Ra) is within a range of 0.5 nm=Ra≦3.0 nm.
Further, in the case where hydrophilic radicle is poor in the surface of the substrate, it is preferable to conduct the surface treatment after treatment for hydrophilizing the surface, i.e., by treating the surface with plasma containing oxygen or treating under a corona discharge atmosphere, or alternatively, by irradiating ultraviolet light of a wavelength in the vicinity of from 200 to 300 nm onto the substrate surface in an atmosphere containing oxygen.
Further, according to the present invention, it is appropriate to restrict the concentration of the material having chlorosilyl radicle in molecular form therein within the liquid for the undercoating treatment, this being equal to or greater than 0.01 wt % and equal to or less than 3.0 wt %.
As an example of a material having chlorosilyl radicle radicle in molecular form therein, there can be listed SiCl 4 , SiHCl 3 or SiH 2 Cl 2 , etc., and it is possible to select a single or a plurality of materials from among these as the material. In particular, since it contains the most Cl radicles, SiCl 4 is preferable. The chlorosilyl radicle is very high in reactivity thereof, and it forms a minute or dense undercoating film through a self-condensation reaction or by reaction to the substrate surface. However, it can contain a material in which a part of a hydrogen is replaced by methyl radicle or ethyl radicle.
Further, as the alcohol group sovlent, for example, methanol, ethanol, 1-propanol, and 2-propanol are desirable. The material containing chlorosilyl radicle in molecular form therein and the alcohol group solvent, as is shown by equation (1) below, react to form alkoxide by removing hydrogen chloride:
(—Si—Cl)+(ROH)→(—Si—OR)+(HCl) (1)
Further, the material containing chlorosilyl radicle in molecular form therein and the alcohol group solvent react as shown by equation (2) below:
(—Si—Cl)+(ROH)→(—Si—OH)+(RCl) (2)
In the alcohol solvent, a part of (—Si—OR) reacts as shown by equation (3) below with an acidic catalyst which is formed as shown by equation (1), and forms (—Si—OH).
(—Si—OR)+(H 2 O)→(—Si—OH)+(ROH) (3)
In addition, (—Si—OH) which is produced as shown by the above equations (2) and (3) reacts as shown by equation (4) below, and forms siloxane bonding:
(—Si—Cl)+(—Si—OH)→(—Si—O—Si—)+(HCl) (4)
It is considered that, by means of the above-mentioned siloxane bonding, the bonding between the substrate and the undercoating film, or between the undercoating film and the surface film such as the water repellent film is strengthened. Namely, in the case where a compound including the siloxane bonding is simply used as the liquid for the undercoating treatment as disclosed in the conventional arts, though the siloxane bonding exists within the undercoating film, the siloxane bonding joining between the substrate and the undercoating film, or between the undercoating film and the water repellent film, are not so influential.
According to the present invention, by treating with a liquid for performing an undercoating treatment which is obtained by reacting the material having chlorosilyl radicle radicle in molecular form in the alcohol group solvent within thirty (30) minutes after mixing thereof, an undercoating film being superior in smoothness can be formed, and since a part of the chlorosyl radicle takes part in the siloxane bonding, good bonding between the substrate and the water repellent film can be obtained by the siloxane bonding.
Here, it is preferable that the concentration of the material having chlorosilyl radicle in molecular form therein contained in the undercoating treatment liquid, though depending on the method of coating be equal to or greater than 0.01 wt % and equal to or less than 3.0 wt %. If it is lower than that, no effect by adding the material can be obtained, and if higher than that, the effect of adding the material is not improved. For example, in particular, in the case of coating by using, for example, a curtain flow coating method, judging from the appearance during the coating, it is preferable that the concentration be equal to or greater than 0.3 wt % and equal to or less than 1.0 wt %.
The method for coating the undercoating treatment liquid should not be limited in particular. However, other methods can be listed, such as: a dip coating method, a curtain flow coating method, a spin coating method, a bar coating method, a roll coating method, a hand coating method, a brush painting method, a spray coating method, etc.
Further, as the surface treatment, for instance, a water repellent treatment and an oil repellent treatment can be listed. Though the liquid agents for the water and oil repellent treatments should not be limited in particular, a treating method by using water repellent or oil repellent agents containing silane compound, siloxane compound or silicon compound therein is preferable.
As the silane compound, there can be listed water repellent agents containing:
CF 3 (CF 2 ) 7 (CH 2 ) 2 Si(OCH 3 ) 3 ,
CF 3 (CF 2 ) 6 (CH 2 ) 2 Si(OCH 3 ) 3 ,
CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl 3 ,
CF 3 (CF 2 ) 6 (CH 2 ) 2 SiCl 3 , and the like.
These repellent agents can be used, depending on necessity, by being hydrolyzed using a catalyst such as acid or base. Further, an agent, containing the siloxane compound which can be obtained through hydrolysis or condensation of the silane compound, can be used too.
As the silicon compound there can be used polydimethylsiloxane of straight chain or chain form, or silanol metamorphism, alkoxide metamorphism, hyrogen metamorphism, halogen metamorphism thereof, etc.
For the method for the water repellent or oil repellent treatment, in the same manner as the undercoating treatment, though it should not be limited in particular, methods such as the hand coating method, the brush painting method, etc., can be applied thereto.
Further, as the surface treatment according to the present invention, a hydrophilic treatment or an antifogging treatment can be applied, in addition to the water repellent or oil repellent treatment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, detailed explanation of the embodiments according to the present invention will be given.
Embodiment 1
By adding 0.01 g of chlorosilane (SiCl 4 , produced by Shinnetsu Silicon Co.) to 100 g of ethanol (produced by Nacalai Tesque, Inc.) and mixing thereof, a liquid for the undercoating treatment is obtained. The obtained liquid for the undercoating treatment was coated on a glass plate (300×300 mm) which was ground and cleaned, under a humidity of 40% and at room temperature, and was then dried for about one minute, thereby obtaining the undercoating film.
Then, by dissolving 1.3 g of CF 3 (CF 2 ) 7 (CH 2 ) 2 Si(OCH 3 ) 3 heptadecafluorodecyltrimethoxisilane produced by Toshiba Silicon Co.) into 40.6 g of ethanol and mixing them for an hour, and thereafter by adding 0.808 g of ion-exchanged water and 0.1 g of 0.1 hydrochloric acid and mixing them for a further one hour, an agent A for the water repellent treatment was obtained.
Thereafter, 3 ml of agent A for the water repellent treatment was put onto a cotton applicator and it was coated onto the glass substrate with a film formed by the undercoating treatment, and thereafter any agent for water repellent treatment which was excessively coated is removed by wiping with a fresh cotton applicator soaked in ethanol, thereby obtaining a water repellent glass substrate.
The contacting angle with water drops of 2 mg in size was measured as a static contact angle by using a contact goniometer (CA-DT, produced by Kyowa Kaimen Kagaku Co.).
As a weather resistance test, ultraviolet light was irradiated there onto by using Super UV tester (W-13, produced by Iwasaki Denki Co.), under the conditions of an ultraviolet light strength of 76±2 mW/cm 2 , irradiating for 20 hours with a darkness cycle of 4 hours, and by showering the substrate with ion-exchanged water for 30 seconds every hour.
Further, as an abrasion test, a sand-rubber eraser (product by Lion Co., No. 502) was rubbed on the water repellent glass reciprocally 100 times at a load of 50 g per 15×7 sq. mm.
Moreover, as a measure for indicating the water repellency, the critical inclination angle was measured. For measuring the performance of rolling a water drop on the surface of the water repellent glass (contact angle=100-110°), a water drop of diameter 5 mm (it comes to be approximately semicircular in shape if the contact angle is 100-110°) was disposed on the surface of the water repellent glass which is horizontally positioned. Then, the water repellent glass plate was inclined gradually, and the inclination angle (the critical inclination angle) when the water drop disposed on the surface of the water repellent glass begins rolling was recorded. The smaller the critical inclination angle, the better in dynamic repellent property. For instance, this applies to rain drops landing on the front windshield glass of a moving automobile which must be easily splashed or scattered away so that they do not interrupt the view of the driver.
However, as the smoothness of the obtained water repellent glass, the surface roughness (Ra), is calculated by measuring the surface contour with an atomic force microscope (AFM) (SPI3700, produced by Seiko Instruments Inc.) by a cyclic contact mode.
As shown in TABLE 1, an initial contact angle was 108°, an initial critical inclination angle 13°, and the contact angle after the weather resistance test of 400 hours was 88°, and that after the abrasion test is 84°, serving as a measure of the durability thereof.
Comparison 1
A water repellent glass substrate was obtained in the same manner as in embodiment No. 1, except that 0.005 g (0.005 wt %) of chlorosilane was added in the preparation of the liquid for the undercoating treatment.
As shown in TABLE 1, though an initial contact angle of 107° is indicated, the initial inclination angle is large, at 18°, and the contact angle after the weather resistance test came down to 71°, thereby indicating that the durability is reduced.
Embodiments 2 to 4 and Comparison 2
Water repellent glass substrates were obtained in the same manner as in embodiment No. 1, except that 0.5 g, 1.0 g, 3.0 g and 5.0 g (0.5 wt %, 1.0 wt %, 3.0 wt % and 5.0 wt % in concentration) of chlorosilane were added to the respective preparations of the liquid for the undercoating treatment.
That is to say, in embodiment 2, 0.5 g (0.5 wt % in concentration) of chlorosilane was added. In embodiment 3, 1.0 g (1.0 wt % in concentration) of chlorosilane was added. In embodiment 4, 3.0 g (3.0 wt % in concentration) of chlorosilane was added. And in comparison 1, 5.0 g (5.0 wt % in concentration) of chlorosilane was added.
When the concentration of chlorosilane is high, the thickness of the undercoating becomes thick, and as a result of this, the interference of light is gradually strengthened. When it exceeds 5 wt % in concentration thereof, a remarkable increase in color reflection can be distinguished. When the concentration of chlorosilane rises further so as to increase the thickness of the undercoating layer, a baking process is additionally required.
Embodiment 5
In a 1 liter glass reactor having a thermometer, a mixer and a cooler, 10.0 g of polydimethylsiloxane containing hydrolysis radicle, which is expressed by the chemical equation shown below, was reacted with 10.0 g of CF 3 (CF 2 ) 7 (CH 2 ) 2 Si(OCH 3 ) 3 (heptadecafluorodecyltrimethoxisilane, produced by Toshiba Silicon Co.) together with 360 g of t-buthanol and 1.949 of 0.1 N hydrochloric acid in a co-hydrolysis reaction for 5 hours at a temperature of 80° C., and further 160 wt % of n-hexane was added and mixed for 10 hours at room temperature.
Further, by adding 10.0 g of organopolysiloxane which is expressed by the chemical equation 2 shown below and 5.0 g of methasulfonic acid into the mix and mixing them for 10 minutes, an agent B for the water repellent treatment was obtained.
By coating the agent for water repellent treatment on the undercoated glass substrate which is produced at a 0.5 wt % concentration of SiCl 4 , in the same manner as in embodiment 1, a water repellent glass substrate is obtained.
Also with this repellent glass substrate, as shown in the TABLE 1, superior results can be obtained in the initial contact angle and the durability (i.e., the weather resistance test and the abrasion test).
Comparisons 3 and 4
After the undercoating treatment using tetrachlorotin or tetrachlorozirconium as the agent for the undercoating treatment in place of chlorosilane, the water repellent glass substrate was produced by using the above-mentioned agent B for water repellent treatment thereof.
Though they show 106° for the initial contact angle, however, the initial critical inclination angles thereof became large, such as 18° and 19°, and the contact angles after the weather resistance test were reduced to 65° and 64°, respectively.
Comparison 5
The water repellent glass substrate was produced in the same manner as in embodiment 1 except that as the solvent for the undercoating treatment liquid, chloroform was used in place of ethanol.
Though TABLE 1 shows a large contact angle at 107°, however, the initial critical inclination angle is large, such as 20°, and the contact angle after the weather resistance test was reduced to 63° and the contact angle after the abrasion test was also reduced to 67°.
Comparison 6
Comparison 6 was performed for double-checking embodiment 6 which is disclosed in the specification of Japanese Patent No. 2,525,536.
Namely, the water repellent glass substrate was obtained in the same manner as in embodiment 1 except that as the solvent for the undercoating treatment liquid perfluorocarbon solution (FC-77, produced by 3M Co.) was used in place of ethanol.
The results show a high value for the surface roughness (Ra) at 7.0 nm, and also a high value for the initial critical inclination angle at 25°. Also, though it shows the initial contact angle at 107°, the contact angle thereof after the abrasion test was reduced to 65°.
Comparison 7
Comparison 7 was performed for double-checking embodiment 3 which is disclosed in Japanese Laid-open Patent No. Hei 2-31132 (1990) cited above as the prior art.
Namely, dissolving and mixing 31 g of tetraethylsilicate (produced by Colcoat Co.) into 380 g of ethanol while adding and mixing 6.5 g of water and 1.6 g of 1N hydrochloric acid, and mixing for 24 hours at a temperature of 20° C., the liquid for the undercoating treatment was prepared.
This liquid for the undercoating treatment was painted by the flow coating method in the same manner as in embodiment 1 and was dried in about a minute. After the undercoating treatment, a layer of silicon oxide was formed through a heating process by heating the substrate for an hour at a temperature of 500° C. Thereafter, the water repellent glass substrate was obtained by using the above-mentioned agent A for the water repellent treatment, in the same manner as in embodiment 1.
The surface roughness (Ra) shows a high value at 0.6 nm, and the initial critical inclination angle is also high, at 22°. The contact angle was 107°, however, it went down to 67° after the abrasion test.
Comparison 8
The water repellent glass substrate was obtained in the same manner as in comparison 7 except that the heating process of the undercoating film is not conducted.
The surface roughness (Ra) shows a high value at 0.7 nm, and the initial critical inclination angle was also high at 23°. The contact angle is 108°, however, it went down to 45° after the abrasion test.
Completing the results of the embodiment and comparisons mentioned heretofore, they are arranged and shown in TABLE 1.
TABLE 1
Ingredients
for Under-
Contact Angle
coating
Agent for
Surface
Initial
(°) after
Contact Angle
Treatment
Water
Rough-
Initial
Critical
Weather
(°) after
(Concentration
Repellent
ness
Contact
Inclination
Resistance
Abrasion Test
wt %)
Treatment
Appearance
Ra (nm)
Angle (°)
Angle (°)
Test (400 H)
(100 times)
Embodiment 1
SiCl 4 /0.01
agent A
OK
0.4
108
13
82
84
Comparison 1
SiCl 4 /0.005
agent A
OK
0.9
107
18
71
65
Embodiment 2
SiCl 4 /0.5
agent A
OK
0.2
107
12
86
82
Embodiment 3
SiCl 4 /1.0
agent A
OK
0.3
108
12
87
87
Embodiment 4
SiCl 4 /3.0
agent A
OK
0.2
109
13
86
87
Comparison 2
SiCl 4 /5.0
agent A
remarkable
0.3
107
12
87
84
reflection
color
Embodiment 5
SiCl 4 /0.5
agent B
OK
0.2
108
12
88
86
Comparison 3
SiCl 4 /1.0
agent B
OK
0.7
106
18
65
80
Comparison 4
SiCl 4 /1.0
agent B
OK
0.6
106
19
64
83
Comparison 5
SiCl 4 /1.0*1
agent A
OK
0.8
107
20
63
67
Comparison 6
SiCl 4 /1.0*2
agent A
OK
7.0
107
25
80
65
Comparison 7
TEOS/0.4*3
agent A
OK
0.7
107
22
54
67
Comparison 8
TEOS/0.4*3
agent A
OK
0.7
108
23
50
45
*1 solvent: Chloroform
*2 solvent: perfluorocarbon
*3 solvent: see lines 23-28 of page 15
Ra was measured based on the standard of JIS B 0601-1982
As is fully explained in the above in accordance with the substrate and the treating method of the present invention, since a highly reactive compound including chlorosilyl radicle in molecular form thereof is used as the liquid for the undercoating treatment, there is no necessity for conducting the baking at high temperature after forming the undercoating film layer. As a result, no large-scaled equipment is necessitated, and the production cost can be reduced.
Further, since it is sufficient for the agent for the undercoating treatment to be painted without using a liquid phase absorption or gaseous phase absorption method, the time for the treating can be shortened, and by using a low-cost alcohol solvent, the liquid for the undercoating treatment can painted uniformly and thinly.
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For obtaining a substrate on the surface of which a water repellent film is firmly bonded through an undercoating film, and which shows a low critical inclination angle, superior durability, and high density, a water repellent and/or oil repellent film layer is formed by using a liquid for undercoating treatment. The liquid for undercoating treatment is obtained by dissolving and reacting a material having chlorosilyl radicle radicle in molecular form therein and is dissolved into an alcohol group solvent, so that a surface roughness (Ra) of less than 0.5 nm is obtained, thereby achieving high durability and a low critical inclination angle.
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FIELD OF THE INVENTION
[0001] This invention relates generally to machine vision systems, and more particularly, to visual recognition of objects that consist of several object parts that are allowed to move with respect to each other.
BACKGROUND OF THE INVENTION
[0002] Object recognition is part of many computer vision applications. It is particularly useful for industrial inspection tasks, where often an image of an object must be aligned with a model of the object. The transformation (pose) obtained by the object recognition process can be used for various tasks, e.g., pick and place operations, quality control, or inspection tasks. In most cases, the model of the object is generated from an image of the object. Such pure 2D approaches are frequently used, because it usually is too costly or time consuming to create a more complicated model, e.g., a 3D CAD model. Therefore, in industrial inspection tasks one is typically interested in matching a 2D model of an object to the image. A survey of matching approaches is given in R7 (see attached Reference list). The simplest class of object recognition methods is based on the gray values of the model and the image (R7, R16). A more complex class of object recognition uses the object's edges for matching, e.g., the mean edge distance (R6), the Hausdorff distance (R20), or the generalized Hough transform (GHT) (R4).
[0003] All of the above approaches do not simultaneously meet the high industrial demands: robustness to occlusions, clutter, arbitrary illumination changes, and sensor noise as well as high recognition accuracy and real-time computation. The similarity measure presented in R21, which uses the edge direction as feature, and a modification of the GHT (R24), which eliminates the disadvantages of slow computation, large memory amounts, and the limited accuracy of the GHT, fulfill the industrial demands. Extensive performance evaluations (R25), which also include a comparison to standard recognition methods, showed that these two approaches have considerable advantages.
[0004] All of the above mentioned recognition methods have in common that they require some form of a rigid model representing the object to be found. However, in several applications the assumption of a rigid model is not fulfilled. Elastic or flexible matching approaches (R3, R13, R5) are able to match deformable objects, which appear in medicine when dealing with magnetic resonance imaging or computer tomography, for example. Approaches for recognizing articulated objects are also available especially in the field of robotics (R11).
[0005] Indeed, for industrial applications like quality control or inspection tasks it is less important to find elastic or articulated objects, but to find objects that consist of several parts that show arbitrary mutual movement, i.e., variations in distance, orientation, and scale. These variations potentially occur whenever a process is split into several single procedures that are—by intention or not—insufficiently “aligned” to each other, e.g., when applying a tampon print using several stamps or when equipping a circuit board with transistors or soldering points. In FIG. 1 an example object is shown. FIG. 3 illustrates the mutual movements (variations) of the object parts. Clearly, when taking such kind of objects as rigid it may not be found by conventional object recognition approaches. However, when trying to find the individual parts separately the search becomes computationally expensive since each part must be searched for in the entire image and the relations between the parts are not taken into account. This problem can hardly be solved taking articulated objects into account since there is no true justification for hinges, but the mutual variations can be more general. Because the object may, for example, consist of several rigid parts, obviously, also elastic objects cannot model these movements. One possible solution is to generate several models, where each model represents one configuration of the model parts and to match all of these models to the image. However, for large variations, this is very inefficient and not practical for real-time computation. In U.S. Pat. No. 6,324,299 (R1) a method of locating objects is described where the object has a plurality of portions. In a first step the coarse pose of the object is determined and in a subsequent step the fine poses of the object portions are calculated. Therefore, the variations of the portions must be small enough to find the coarse pose of the object, in contrast to the present invention, where the variations are explicitly modeled and may be of arbitrary form and of arbitrary size. Additionally, in U.S. Pat. No. 6,324,299 the variations are not automatically learned in a training phase as it is done in the present invention. U.S. Pat. No. 6,411,734 (R2) extends the method presented in U.S. Pat. No. 6,324,299 by checking the found object portions whether they fail to satisfy user-specified requirements like limits on the poses of the object portions. The advantage of the present invention is that this check can be omitted since the object parts are only searched over the range of valid poses and therefore, only valid instances are returned.
SUMMARY OF THE INVENTION
[0006] This invention provides a method for automatically learning a hierarchical object recognition model that can be used to recognize objects in an image, where the objects consist of several parts that are allowed to move with respect to each other in an arbitrary way. The invention automatically decomposes the object into its parts using several example images in which the mutual movements (variations) of the object parts are shown and analyzes the variations. In a preferred embodiment, the single object parts are assumed to be rigid, thus showing no deformations. In a further preferred embodiment only rigid transformations (translation and rotation) are taken into account. Thus, the objects can be found if they are at arbitrary position and orientation in the image. Additional pose parameters, e.g., scale, can be taken into account in a straightforward manner.
[0007] The mutual variations of the object parts are analyzed and used to build a hierarchical model that contains representations of all rigid object parts and a hierarchical search strategy, where the parts are searched relatively to each other taking the relations between the parts into account.
[0008] This generation of the hierarchical model will be called offline phase and must be executed only once and therefore is not time-critical. But in the time critical online phase, in which the object is searched in an image, the hierarchical model facilitates a very efficient search.
[0009] The single steps of the hierarchical model computation are shown in the flowchart of FIG. 4. The only input data of the proposed algorithm are a sample image of the object (model image), in which the object is defined by the user, e.g., using a region of interest (ROI), and some additional example images that, at least qualitatively, describe the mutual movements of the single object parts.
[0010] The first step is to decompose the object, which is defined by the ROI within the model image, into small initial components. Note that these components need not coincide with the real object parts. For instance, if the connected components of the image edges are used as criterion for decomposition the following components would result from the example of FIG. 1: 1 hat, 1 face, 2 arms, 2 hands, 2 legs, 2 feet, the outer rectangle of the upper body, the inner rectangle of the upper body and at least 1 component for each letter printed on the upper body. For each initial component a representation is calculated that can be used to search the initial component in the example images. This representation will be called initial component model and can be built using an arbitrary recognition method that is able to find objects under at least rigid transformation (translation and rotation). In a preferred embodiment of the invention a recognition method that is based on the image edges is used. Additionally, if industrial demands are to be fulfilled the similarity measure described in R21 or in “System and method for object recognition”, European patent application 00120269.6, (R22) or the modified Hough transform (R24) should be preferred.
[0011] Each initial component is searched for in all example images using the initial component models. Thus, the pose parameters of each initial component in each example image are obtained. These parameters are analyzed and those initial components that form a rigid object part are clustered, leading to the final decomposition, which corresponds to the object parts. In the example of FIG. 1 and FIG. 3, the hat and the face are clustered into one rigid part since they show the same movement in each image. The same holds for all initial components that form the upper part of the body. They are also clustered into one rigid part. For each of the newly generated (clustered) parts a representation is calculated by applying the same recognition method as for the initial components. This representation will be called object part model. It is used to search the newly generated object parts in the example images. The initial component models that are not clustered are used unchanged as object part models. Therefore, each object part is described by one object part model. The relations (relative movements) between each pair of the rigid object parts are computed by analyzing the pose parameters over the sequence of example images and stored in a fully connected directed graph, where the vertices represent the object parts and the link between vertices i and j describes the overall movement of part j relatively to part i. By computing the shortest arborescence of the graph it is possible to ascertain a hierarchical search tree that incorporates an optimum search strategy in the sense that the search effort is minimized. Finally, the hierarchical model consists of the object part models, the relations between the object parts, and the optimum search strategy.
[0012] In the online phase the hierarchical model can then be used to search the entire object containing the movable object parts in an arbitrary search image. This is performed by searching the object parts in the image using the object part models of the chosen similarity measure. Note that only one object part must be searched within the entire search range, whereas the remaining object parts can be searched in a very limited search space, which is defined by the relations in combination with the search tree. This facilitates an efficient search despite the relative movements of the object parts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will be more fully understood from the following detailed description, in conjunction with the accompanying figures, wherein:
[0014] [0014]FIG. 1 is a model image of an example object and a user defined region of interest for automatic initial decomposition;
[0015] [0015]FIG. 2 is a model image of an example object and several user defined region of interest for manual initial decomposition;
[0016] [0016]FIG. 3 is a sequence of six example images that show the mutual movements of the parts of the object introduced in FIG. 1;
[0017] [0017]FIG. 4 is a flowchart of a preferred embodiment of the invention showing the single steps of the hierarchical model computation;
[0018] [0018]FIG. 5 is an illustration of the elimination and merging of small initial components.
[0019] [0019]FIG. 6 is an image showing the result of the automatic initial decomposition of the object introduced in FIG. 1 when using the connected components of the model image edges as criterion and applying the elimination and merging of small initial components. The initial components are visualized by their image edges. To identify the initial components a number is assigned to each component;
[0020] [0020]FIG. 7 a is a plot showing the development of an image edge in scale space under the existence of a neighboring edge;
[0021] [0021]FIG. 7 b is a plot showing the development of the image edge of FIG. 7 a after eliminating the neighboring edge;
[0022] [0022]FIG. 8 is an illustration of the network used for solving the ambiguities that are due to self-symmetries of the initial components, due to mutual similarities between the initial components, or due to similarities of the initial components to other structures in the example images.
[0023] [0023]FIG. 9 is a graphical representation of the similarity matrix for the initial components of FIG. 6. Each matrix element contains the probability that the corresponding two initial components belong to the same rigid object part. Since this matrix is symmetric only the upper triangular matrix is shown;
[0024] [0024]FIG. 10 illustrates the calculation of the relations between an object pair (rectangle and ellipse) from the relative poses in the model image (bold border) and in three example images (pictures in the upper row). In this example the rectangle is taken as reference and the relative movement of the ellipse is computed by transforming the ellipse into the reference system defined by the rectangle (pictures in the middle row). The overall relative orientation describes the angle variation (dark circle sector in the lower left picture) and the smallest enclosing rectangle of arbitrary orientation of all ellipse reference points is taken as position variation (bold rectangle in the lower right picture);
[0025] [0025]FIG. 11 illustrates the result of the hierarchical model generation. The search tree is visualized together with the relative search ranges for each object part. The position search ranges are visualized by rectangles and the angle search ranges are visualized by circle sectors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Initial Decomposition
[0027] In the first step of the invention, the object is initially broken up into small components. This can be done either automatically or interactively by the user. The condition the initial decomposition must fulfill is that each rigid object part must be represented by at least one initial component; otherwise the algorithm is not able to split this component later on and to find the rigid object parts automatically. Therefore, an over-segmentation should be preferred. However, very small initial components fail the property of being unique, but this can be balanced by the invention at it is shown later.
[0028] If the user chooses to do the initial decomposition automatically he has to define the entire object by a region of interest (ROI). A ROI is an arbitrarily shaped part of an image that restricts the image domain for further processing. In the example of FIG. 1 the ROI is a rectangle that encloses the entire object. The image domain defined by the ROI is then used to perform the initial decomposition. Several grouping methods that can be found in literature are suitable for this task. In a preferred embodiment of the invention, edges are extracted in the model image by applying a threshold on an edge filter amplitude, e.g. of the Sobel filter. The connected components of the edges are treated as individual initial components. In a preferred embodiment initial components that are smaller than a user defined threshold are either eliminated or merged to neighboring components to avoid meaningless initial components that are due to noise or hard to identify in the example images: In a first step the size of the initial components, e.g., the number of edge pixels, is calculated. If the size is below the user defined threshold it must be checked whether it is possible to merge the current initial component to a neighboring component. If a merging is not possible the initial component is eliminated. The check is performed by computing the distances of all edge pixels in the current initial component to all other initial components with a size above the user defined threshold. If the maximum distance of all edge pixels to a compared component is smaller than a threshold, the probability of these two components belonging together is high. Therefore, the current initial component is merged to the compared component. In the upper left picture of FIG. 5 a model image is shown. The upper right picture of FIG. 5 is the result of the edge extraction step under the assumption that no image noise is present in the image. The lower left picture of FIG. 5 illustrates the result of the edge extraction step when dealing with real images containing noise to a certain degree. The first step of the initial decomposition leads to 7 independent components. The size of components 2 , 3 , 4 , 5 , 6 , and 7 is smaller than the user defined threshold. In the lower right picture of FIG. 5 the result of the elimination and merging is shown. The components 2 , 3 , 4 , and 5 are affiliated to component 1 because the maximum distance d 1 is smaller than the predefined threshold. The components 6 and 7 are eliminated because the maximum distance d 2 exceeds the predefined threshold. In FIG. 6 the initial components of the object introduced in FIG. 1 are visualized.
[0029] As mentioned, other grouping methods or combinations of them could also be included in the invention to do the initial decomposition: Gestalt psychology has uncovered a set of principles guiding the grouping process in the visual domain (R26, R15, R28). Computer vision has taken advantage of these principles, e.g., in the field of perceptual organization and grouping (R23, R18, R27, R17).
[0030] If the user chooses to do the initial decomposition manually, not only one ROI must be specified by the user but a separate ROI for each initial component. All extracted edges within a specified ROI are then treated as one initial component. Thus, it is possible to take advantage of previous knowledge of the user. In the example of FIG. 2 a total of 11 ROIs are defined by the user. The selected ROIs imply that the user was sure that the upper body forms one rigid object part and that he was not sure whether the head and the face form one rigid object part.
[0031] Generation of Initial Component Models
[0032] In the next step the initial component models are computed. In a preferred embodiment of the invention the implementation of the similarity measure presented in R21 is used as recognition approach to calculate the initial component models and to search the initial components in the example images. This approach uses a recursive coarse-to-fine strategy to speed up the recognition, like most implementations of conventional object recognition methods. This includes a subsampling of both the model image and the search image in combination with an appropriate image smoothing leading to a scale-space representation of both images. However, one has to take care of unfavorable scale-space effects. In scale-space the edges of the initial components are influenced by neighboring edges. This is uncritical in most cases when dealing with large objects since there are still enough edges of the object left that are not influenced by neighboring edges and therefore still enable a good match. However, some problems occur when dealing with small objects, like the initial components, since the ratio between the number of edge pixels in the initial components and the number of neighboring edge pixels is becoming small, i.e., the influence of the neighboring edges is increasing. In FIG. 7 a and FIG. 7 b , the principle of the scale-space effect is illustrated. In FIG. 7 a a 1D gray value profile, which includes two edges, is shown. Only the left edge belongs to the initial component and therefore should be represented in the initial component model whereas the right edge represents a neighboring edge. In scale-space the disturbance of the model edge caused by the neighboring edge increases with the degree of smoothing (sigma). This problem could be avoided if no scale-space representation is used within the recognition method. However, this would lead to high computation times that are not suitable. Therefore, the gray values at both sides of the initial component edges are artificially continued to the surrounding area to eliminate the disturbing neighboring edges. To eliminate all disturbing edges the size of the surrounding area must be chosen appropriately. If, for example, a scale-space discretization is used in a way that four neighboring pixels are merged into one within two successive discretization steps and the total number of steps is l, then the gray values at both sides of the initial component edges should be continued by at least 2 l pixels to fully eliminate the influence of all neighboring edges. The result is shown in FIG. 7 b . The model edge is no longer disturbed by the neighboring edge. Other, more sophisticated, approaches explicitly model the edges and subsequently reconstruct the gray values in the surrounding of the edges (R10). These could be incorporated easily in the invention.
[0033] After the disturbing edges have been eliminated for each initial component an initial component model is built. Since it is possible that a neighboring initial component belongs to the same rigid object part than the current initial component, the neighboring edges (belonging to the neighboring initial component) will be also present in the example images in the same position relative to the current initial component. Therefore, for each initial component a second initial component model is built without previously eliminating the neighboring edges. This leads to a higher possibility that all matches are found in the example images. The consequence that the search for the initial components leads to duplicate matches is not critical since it is compensated using the algorithm described in the following section. Basically, false positives or double matches are preferred during the offline phase in comparison to missing a match.
[0034] Search of Initial Component Models
[0035] The initial component models are used to search the initial components in each example image using the selected recognition approach. Thus, all poses P i of each component i in each example image are obtained. In a preferred embodiment the position refers to an arbitrary reference point of the initial component model, e.g., the center of gravity of the edge pixels within the initial component. The orientation refers to the orientation of the initial component in the model image, i.e., the orientation of each initial component in the model image is 0°. The poses P i include the poses obtained when searching the initial component model that was built after eliminating the neighboring edges, as well as the poses obtained when searching the initial component model that was built without previously eliminating the neighboring edges.
[0036] Besides the problem of disturbing edges another problem arises when searching for small initial components: The result of the search may not be unique because of self-symmetries of the initial components, mutual similarities between the initial components, or similarities of the initial components to other structures in the example image. Additionally, the number of matches doubles in many cases, since two initial component models are used for the search of each initial component. These two problems can be solved using the same algorithm, which is presented in the following paragraph. To maintain the description of the algorithm as simple as possible the second problem of using two initial component models is neglected. In the example of FIG. 1, the left leg, for instance, is found four times in the first example image (upper left image of FIG. 3): At the true position of the left leg, at the position of the right leg and each at orientation 0° and 180° (cf. FIG. 8). Consequently, it is indispensable to solve these ambiguities to get the most likely pose for each component. Let n be the number of initial components and M i the pose of component i in the model image (i=1, . . . , n). The pose represented by match k of initial component i in an example image is described by E i k , where k=1, . . . , n i and n i is the number of matches (found instances) of component i in the current example image. The ambiguities are solved by minimizing the following equation
∑ i = 1 n argmin k = 1 … n i ( δ i k ) → min ( Equation 1 ) δ i k = ∑ j = 1 n argmin l = 1 … n j ( Ψ ( M i , M j , E i k , E j l ) ) , ( Equation 2 )
[0037] while taking the two constraints into account that each initial component is attributed to at most one physical match and each physical match is attributed to at most one initial component. A physical match is the real or physical mapping of an initial component to an example image, i.e., one physical match may be occupied by several matches returned by the recognition method due to the above mentioned ambiguities. δ i k is a variation measure of match k of component i and Ψ is a cost function that rates the relative pose of match l of component j to match k of component i in the example image by comparing it to the relative pose of the two components in the model image. The more the current relative pose in the example image differs from the relative pose in the model image the higher the cost value. In a preferred embodiment of the invention, Ψ takes the difference in relative position Δpos and relative orientation Δorient into account, where the difference in position is measured in pixels and the difference in orientation is measured in degrees. To be able to combine the two measurements into the cost function Ψ a balance factor w is introduced that balances the relative influences of the two measurements, leading to the following equation:
ψ{square root}{square root over (∥Δpos∥ 2 +( w ·∥Δorient∥) 2 )} (Equation 3)
[0038] Optionally, ψ can be mapped to any other function, which is strictly monotonic increasing. In a preferred embodiment, the logarithm is computed to favor small variations. Note that additional pose parameter (e.g. scale) can be included easily by introducing a separate balance factor for each additional parameter.
[0039] The minimization of Equation 1 follows the principle of human perception where the correspondence problem of apparent motion is solved by minimizing the overall variation (R23). To solve Equation 1 while taking the two constraints into account the problem is formulated as a bipartite graph matching problem, which can be solved applying linear programming techniques, for example: The nodes in the one set N comp of the bipartite graph represent the initial components, the nodes in the other set N phys represent the physical matches as it is illustrated in FIG. 8. Each match is represented by one link in the graph. To check whether the matches refer to the same physical match in the example image, information about the self-symmetries of the initial components and about the mutual similarities between the initial components must be considered. This information can be obtained by matching each initial component to itself and to all other components in a preliminary stage using the similarity measure of the chosen recognition method. The poses of these matches can be used to decide whether two matches in the example image refer to the same physical match. Each edge within the bipartite graph corresponds to one separate match and is assigned the value of the corresponding δ i k . Now the objective function z that must be maximized (optimized) can be set up:
z = ∑ i = 1 n ∑ k = 1 n i ( δ max - δ i k ) x i k ( Equation 4 )
[0040] x i k are the unknowns in the optimization, where x i k is 1, if the match k of initial component i is included in the solution, and 0 otherwise. Since the number of matches should be maximized, the variations δ i k (which should be minimal) must be converted into weights δ max −δ i k (which should be maximal), where δ max is a constant value such that δ max >δ i k ∀{i,k|1≦i≦n,1≦k≦n i }. Additionally, several constraints must be stated and introduced into the optimization:
x i k ≧0 ∀{i,k|1≦i≦n,1≦k≦n i } (Equation 5)
x i k ≦1 ∀{i,k|1≦i≦n,1≦k≦n i } (Equation 6) ∑ k = 1 n i x i k ≤ 1 ∀ { i , n i i ≤ 1 ≤ n , n i ≥ 2 } ( Equation 7 ) ∑ x i k ≤ 1 ∀ physical matches , where at least two x i k are assigned to the current physical match ( Equation 8 )
[0041] The first two constraints (Equations 5 and 6) ensure that all x i k either have a value of 1 or a value of 0 in the solution, i.e., either match k of initial component i is part of the solution or it is not. The third constraint (Equation 7) ensures that each initial component is assigned to at most one match. The fourth constraint (Equation 8) ensures that each physical match is assigned to at most one initial component. This linear programming problem can be solved by different algorithms, which are available in literature, e.g., by the simplex method (R9, R19). The ambiguities are solved for each example image individually.
[0042] Clustering of Initial Components
[0043] Since the initial decomposition led to an over-segmentation, the initial components belonging to the same rigid object part must be merged to larger clusters by analyzing the pose parameters obtained in the previous step. Initial components that show similar apparent movement over all example images are clustered together.
[0044] First, the pairwise probability of two initial components belonging to the same rigid object part is calculated. Let M 1 =(x 1 M , y 1 M , φ 1 M ), M 2 =(x 2 M , y 2 M , φ 2 M ), E 1 =(x 1 E , y 1 E , φ 1 E ), and E 2 =(x 2 E , y 2 M , φ 2 E ) be the poses of two initial components in the model image and in an example image. Without loss of generality φ 1 M and φ 2 M are set to 0, since the orientations in the model image are taken as reference. The relative position of the two initial components in the model image is expressed by Δx M =x 2 M −x 1 M and Δy M =y 2 M −y 1 M . The same holds for the relative position Δx E and Δy E in the example image. To be able to compare the relative position in the model and in the example image, the relative position in the example image must be rotated back to the reference orientation:
[ Δ x ~ E Δ y ~ E ] = [ cos ϕ 1 E sin ϕ 1 E - sin ϕ 1 E cos ϕ 1 E ] [ Δ x E Δ y E ] ( Equation 9 )
[0045] If the used recognition method additionally returns accuracy information of the pose parameters, the accuracy of the relative position is calculated with the law of error propagation. Otherwise the accuracy must be specified empirically. Then, the following hypothesis can be stated:
Δ{tilde over (x)} E =Δx M
Δ{tilde over (y)} E =Δy M
φ 1 E =φ 2 E (Equations 10)
[0046] The probability of the correctness of this hypothesis corresponds to the probability that both initial components belong to the same rigid object part. It can be calculated using the equations for hypothesis tests, e.g., as given in R14. This is done for all object pairs and for all example images yielding a symmetric similarity matrix, in which at row i and column j the probability that the initial components i and j belong to the same rigid object part is stored. In a preferred embodiment the entries in the matrix correspond to the minimum value of the probabilities in all example images. To get a higher robustness to mismatches the mean or other statistical values can be used instead of the minimum value. In FIG. 9 the similarity matrix for the example given in FIG. 1 and FIG. 3 is displayed. One can see the high probability that hat and face belong together and that the initial components of the upper part of the body form a rigid object part.
[0047] Based on this similarity matrix the initial components are clustered, e.g., using a pairwise clustering strategy that successively merges the two entities with the highest similarity until the maximum of the remaining similarities is smaller than a predefined threshold. Other clustering techniques can be incorporated easily in the invention.
[0048] Generation of Object Part Models and Search
[0049] Models for the recognition approach for the newly clustered components are created and searched in all example images, as described above. This avoids errors that are introduced when taking the average of the single initial poses of each initial component within the cluster as pose for the newly clustered component. However, this information can be exploited to reduce the search space by calculating approximate values for the reference point and the orientation angle of the new clustered component in the example images. After this step for each rigid object part an object part model is available and the pose parameters for each object part in each image are computed.
[0050] Computation of the Relations Between Object Parts
[0051] The pose parameters of the clustered components, i.e., rigid object parts, are analyzed and the pairwise relations between part i and j are derived (where i=1, . . . , n p and j=1, . . . , n p and n p is the number of object parts). For this purpose, in each image, the pose of object part i defines a local coordinate system in which the pose of object part j is calculated. In a preferred embodiment the angle range that encloses all orientations of object part j in the local coordinate systems of all example images describes the angle variation of object part j with respect to object part i. In a preferred embodiment, the corresponding position variation is described by the smallest enclosing rectangle of arbitrary orientation of the reference points of object part j in the local coordinate systems of all example images. Other descriptions beside the smallest enclosing rectangle of arbitrary orientation can be used instead, e.g., the smallest enclosing axis aligned rectangle, the convex hull, the smallest enclosing circle or other arbitrary descriptions of a set of points in the 2D plane. The principle is exemplified in FIG. 10.
[0052] Apart from the angle variation and the position variation the relation information additionally can include statistical values like the mean and the standard deviation of the relative angle and of the relative position. This information is calculated for each ordered object pair. In order to find an optimum search strategy that minimizes the entire search effort one has to define a measure that quantifies the search effort Ω ij that must be expended to search object part j if the pose of object part i is known. In the preferred embodiment the search effort is defined as
Ω ij =l ij ·h ij ·Δφ ij , (Equation 11)
[0053] where l ij and h ij is the length and the height of the smallest enclosing rectangle, respectively, describing the position variation of part j relative to part i, and Δφ ij specifies the corresponding angle variation. The calculation of the search effort strongly depends on the chosen object recognition method and should be adapted individually. Please note that Ω is not symmetric, i.e., Ω ij is not necessarily equal to Ω ji . Since it cannot be expected that the example images cover the variations completely but only qualitatively, the values for l ij , h ij , and Ωφ ij can be adapted by applying a user selected tolerance.
[0054] Computation of the Hierarchical Search Tree
[0055] The strategy of the invention during the online phase is to search a selected root object part within the entire search range and then successively search the remaining parts only relatively to the object parts already found. To do so, the search region of the current object part's reference point is transformed regarding to the pose of the already found object part from which the current part is searched relatively. The equation for calculating the search effort Ω should be constructed in a way that the computation time of the chosen recognition methods increases linearly with Ω. Therefore, the sum of the Ωs that are accumulated during the search in the online phase must be minimized to find an optimum search strategy.
[0056] In a preferred embodiment of the invention the optimum search strategy that minimizes the overall recognition time can be computed by applying graph theory algorithms. The object parts are interpreted as vertices in a graph where the directed arc between the vertices i and j is weighted with the corresponding search effort Ω ij . Thus, a fully connected directed graph D=(V,A) is obtained, where V denotes the set of vertices of size |V|=n p and A the set of arcs of size |A|=n p (n p −1). With each arc a ij εA the weight Ω ij is associated. An arborescence of D is a subtree of D such that there is a particular vertex called the root, which is not the terminal vertex of any arc, and that for any other vertex v i , there is exactly one arc, whose terminal vertex is v i . A spanning arborescence of D is an arborescence that contains all vertices of D. Thus, the problem of finding an optimum search strategy is equivalent to finding a spanning arborescence H=(V,B) of D, such that
∑ ( v i , v j ) ∈ V b ij → min ( Equation 12 )
[0057] An algorithm for finding the spanning arborescence of minimum weight in a graph is given in R8.
[0058] The root vertex can be chosen using different criteria. Since the root vertex corresponds to the only object part that is searched not relatively to another object part in the online phase but in the entire search range of the search image, the recognition time of the online phase strongly depends on the recognition time of the root part. Therefore, when using the recognition method presented in R21 large object parts should be preferred to be the root part since more discretization steps can be used to speed up the search. Furthermore, the root part should not be self-symmetric or similar to another object part to avoid ambiguities during the online phase, which slow down the search in the online phase. These two criteria can be evaluated automatically by the invention. In a preferred embodiment, the root part plays another decisive role: it should be ensured that the root part is always found during the search in the online phase, since the whole object cannot be found if the root part is missing or occluded to a high degree. Therefore, in practice, the third criterion must be evaluated by the user. In an alternative embodiment several root parts can be selected, which are subsequently searched. The number of root parts to select depends on the user defined maximum level of occlusion under which the object should be found during online phase as well as on the user defined maximum number of object instances that should be found. However, the computation time increases with the number of selected root parts.
[0059] [0059]FIG. 11 illustrates the result of the optimum search strategy. Here, the upper part of the body was selected to be the root part. Thus, the upper body is searched for in the entire search image, the left arm is searched relatively to the upper body taking the relations into account, the left hand is searched relatively to the left arm, etc.
[0060] Finally, the hierarchical model consists of the object part models, the relations between the parts, and the optimum search strategy.
[0061] Search of the Hierarchical Model
[0062] After the hierarchical model has been built in the offline phase following the steps described in the invention so far, it can be used to search the object in an arbitrary search image during the online phase. In a preferred embodiment of the invention the similarity measure presented in (Steger, 2001) is used to search the object part models of the hierarchical model in the search image in order to take advantage of the properties of this similarity measure like robustness to occlusions, clutter, arbitrary illumination changes, and sensor noise as well as high recognition accuracy and real-time computation. The poses of all found model parts belonging to the same found instance of a hierarchical model are stored in the hierarchical match.
[0063] In the first step, the root object part is searched in the search image. In a preferred embodiment each found instance of the root object part represents one potential candidate of a hierarchical match. In an alternative embodiment several root object parts are searched for to ensure a higher robustness of missing or occluded root object parts. Hence, each found instance of each root object part represents one potential candidate of a hierarchical match.
[0064] In the second step, for each candidate the remaining object parts are searched in the order of the search tree while limiting the search space of each object part according to the relations between the object parts as mentioned above.
[0065] In case that one object part could not be found, several strategies can be applied: In a preferred embodiment the object parts that in the search hierarchy reside directly below the missing object part are searched relative to the object part that in the search hierarchy resides closest above the missing object part and has been already found. In the worst case the root object part is selected to start the relative search. In an alternative embodiment of the invention the object parts that in the search hierarchy reside directly below the missing object part are searched relatively to the already found object part from which the search effort is minimal. In a further alternative embodiment of the invention all object parts that in the search hierarchy reside below the missing object part are not searched and are also treaded as missing.
[0066] In case that one object part is found more than once, in a preferred embodiment the current hierarchical match candidate is cloned according to the number of found object part matches and each match of the object part is assigned to one hierarchical match candidate. The search is continued for each hierarchical match. To avoid that parts are searched relative to the same object part instance several times in different hierarchical match candidates, the object part matches are stored in a separate list independently of the hierarchical match candidates. Additionally, the object part relative to which each object part in the list has been searched, is stored in the list. Each hierarchical match candidate just references the respective object part matches in the list by using pointers. If a match of an object part that is searched has already been stored in the list and has been searched relative to the same object part instance as the current match is searched, the current object part is not searched but only a pointer to the respective existing match in the list is added to the hierarchical match candidate.
[0067] To speed up the recognition not all object parts of each potential candidate match are searched: Like the preferred recognition method (R21), most recognition methods return a score value sε[0;1] that rates the quality of the returned matches. Additionally, the user can specify the minimum score value s min a match must at least have to be returned. In a preferred embodiment of the invention a score value s H for each hierarchical match is computed:
s H = ∑ i = 1 n p s i f i F , where ( Equation 13 ) F = ∑ i = 1 n p f i . ( Equation 14 )
[0068] s i denotes the score of object part i that is returned by the recognition method (s i is set to 0 if the object part was not found, i.e., s i <s min ), and f i is a weighting factor that balances the contributions of the score values of the single object parts. In a preferred embodiment f i is proportional to the size of object part i. In an alternative embodiment, the user specifies the values f i for each object part. In a preferred embodiment the user specifies a minimum score value s min H for the hierarchical match. Thus, the search for the current potential hierarchical candidate match can be aborted after j of the n p object parts have been searched, whenever the following condition is fulfilled:
∑ i = 1 j s i f i F + ∑ i = j + 1 n p f i F < s min H . ( Equation 15 )
[0069] Additionally, the found instances of the hierarchical match candidates are checked if they overlap too much with other hierarchical match candidates. In a preferred embodiment of the invention the overlap between two hierarchical match candidates is checked by determining the smallest enclosing axis aligned rectangle of all smallest enclosing axis aligned rectangles of the object part instances for both hierarchical match candidates. If these two rectangles overlap a more precise overlap fraction is computed: First, for both hierarchical match candidates the smallest enclosing rectangles of arbitrary orientation are determined for each object part instance. The rectangles are united obtaining two regions, one for each hierarchical match candidate. The overlap fraction is calculated as the ratio of the area of the intersection of the two united regions and the smaller of the two united regions. If the overlap exceeds a user-supplied fraction, the hierarchical match candidate with the lower score value is deleted. The information of the smallest enclosing rectangles of arbitrary orientation for each object part can be computed in the offline phase. For the overlap check in the online phase they only have to be transformed according to the pose parameters of the object part matches, which facilitates an efficient computation of the overlap fraction.
[0070] The hierarchical match candidates with a score exceeding s min H are interpreted as hierarchical matches and are returned to the user as the result of the search. In a preferred embodiment the returned matches include for each found instance of the hierarchical model the score value s H , and for each found object part within each hierarchical model the subpixel precise row and column coordinates, the orientation angle, and the score value s i .
[0071] While several particular embodiments of the invention have been described in detail, various modifications to the preferred embodiments can be made without departing from the spirit and scope of the invention. Accordingly, the above description is not intended to limit the invention except as indicated in the following claims.
Reference List
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The present invention provides a method for the recognition of objects in an image, where the objects may consist of an arbitrary number of parts that are allowed to move with respect to each other. In the offline phase the invention automatically learns the relative movements of the single object parts from a sequence of example images and builds a hierarchical model that incorporates a description of the single object parts, the relations between the parts, and an efficient search strategy. This is done by analyzing the pose variations (e.g., variations in position, orientation, and scale) of the single object parts in the example images. The poses can be obtained by an arbitrary similarity measure for object recognition, e.g., normalized cross correlation, Hausdorff distance, generalized Hough transform, the modification of the generalized Hough transform, or the similarity measure. In the online phase the invention uses the hierarchical model to efficiently find the entire object in the search image. During the online phase only valid instances of the object are found, i.e., the object parts are not searched for in the entire image but only in a restricted portion of parameter space that is defined by the relations between the object parts within the hierarchical model, what facilitates an efficient search and makes a subsequent validation step unnecessary.
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BACKGROUND OF INVENTION
1. Field of Invention
The present invention relates to dispensers generally, and more specifically, to aerosol dispensers that are pressurized by mechanical energy instead of chemical energy.
2. Description of the Related Art
Aerosol dispensers have been in use for more than fifty years, and continue to gain in popularity because of the convenience of their use. However, many of those dispensers rely upon chemical propellants, including chloro-fluorocarbons and hydrocarbon compounds to pressurize the product. The use of chemical pressurizing agents creates special problems, including safety concerns in filling, shipping, handling, storing, using and disposing the pressurized, and often flammable containers. Another set of concerns involves questions relating to the effect of certain pressurizing chemical agents upon the earth's ecosystem, including particular questions concerning their effect on the ozone layer, and questions concerning the effect of the release of volatile organic compounds into the atmosphere. Accordingly, there has been great interest in the development of aerosol dispensers that do not use chemical propellants, but which also retain the conveniences of use associated with the chemically charged dispensers.
Among the alternatives to chemically pressurized aerosol dispensers are various mechanically pressurized models using finger pumps and triggers. These typically require a continued vigorous pumping to produce a continuous spray, and, as a result, are inconvenient to use. Further, the duration of the spray is in most instances limited by (1) the length of the stroke of the pump or trigger, (2) the fact that the pressure of the spray in most instances does not remain constant during a discharge cycle but decreases rapidly near the end of the cycle with the spray becoming a wet stream or dribble, and (3) the fact that the device must generally be operated in an upright position. In addition, many of the finger-operated pumps are not capable of producing a fine mist or suitably atomized spray for use with such products as cosmetics and hair sprays. As a result, such devices only partially solve the problem of providing a convenient, yet safe alternative to chemically pressurized aerosol dispensers.
Other alternatives to chemically pressurized dispensers include various mechanically pressurized models that obtain prolonged spray time by storing a charge without the use of chemical propellants. Such “stored charge” dispensers include types that are mechanically pressurized at the point of assembly, as well as types that may be mechanically pressurized by an operator at the time of use.
Stored charge dispensers that are pressurized at the point of assembly often include a bladder that is pumped up with product. Examples include those described in U.S. Pat. Nos. 4,387,833 and 4,423,829.
Stored charge dispensers that are pressurized by an operator at the time of use typically include charging chambers that are charged by way of screw threads, cams, levers, ratchets, gears, and other constructions providing a mechanical advantage for pressurizing a product contained within a chamber. This type of dispenser will be referred to as a “charging chamber dispenser.” Many ingenious charging dispensers have been produced. Examples include those described in U.S. Pat. No. 4,872,595 of Hammett et al., U.S. Pat. No. 4,222,500 of Capra et al., U.S. Pat. No. 4,174,052 of Capra et al., U.S. Pat. No. 4,167,941 of Capra et al., and U.S. Pat. No. 5,183,185 of Hutcheson et al., which is expressly incorporated by reference herein.
While some of the prior stored charge dispensers avoid some or all of the difficulties of the finger pump or trigger dispensers, the stored charge dispensers tend to have drawbacks of their own. In the devices pressurized at the point of assembly, the charging chamber is often an elastic bladder that remains charged during the life of the product, degrading over time, and these devices typically cannot be refilled with product. In the devices pressurized by an operator at the time of use, the charging chamber devices have been relatively difficult to manufacture due the large number of interrelated working parts required, and/or the fact that they are composed of parts not readily suited to high quantity, high yield injection molding production techniques, and/or the fact that they are required to be used with specially designed containers.
These drawbacks have tended to make the charging chamber dispensers expensive and not commercially feasible for mass market applications, and have tended to make other stored charge dispensers less than completely satisfactory substitutes for chemically pressurized dispensers. Accordingly, existing stored charge and charging chamber dispensers have only partially solved the problem of providing a convenient, yet safe alternative to chemically pressurized aerosol dispensers.
The current invention is a charging chamber dispenser that possesses specific improvements so that it combines convenience of use with commercial feasibility. It is believed that this is, finally, a non-chemical aerosol dispenser that retains the desirable features commonly associated with chemical aerosols, and is, therefore, a non-chemical aerosol dispenser that can attain widespread vendor and customer acceptance.
SUMMARY OF THE INVENTION
Accordingly, the mechanically pressurized aerosol dispensing system of this invention in one of the preferred embodiments consists essentially of: (a) a cap which houses a piston; (b) an actuator moveably attached to the cap, forming together with the cap a dispensing head assembly; and (c) an expandable elastic reservoir. The system is fitted over a standard container holding a liquid product, and includes a dip tube assembly to draw liquid into the dispensing head assembly, including an aerosol nozzle and valve, to release the contents out of the dispensing head assembly.
Complementary screw threads on the cap and actuator are selectively pitched so that a short twist of the threaded cap raises the piston, opening a charging chamber within the dispensing head assembly. This creates a vacuum with the resulting suction pulling the product up through the dip tube to fill the charging chamber. Twisting the cap in the opposite direction lowers the piston in a downstroke which closes the charging chamber, forcing the product into the expandable elastic reservoir. The reservoir expands under pressure, holding the product for subsequent discharge. Pushing a button, which is part of the standard valve assembly in the cap, releases the product through the nozzle.
The general working of the system briefly summarized above is enhanced by several specific improvements, including: (a) use of a snap-in piston so that the piston and the cap may be separately molded, allowing different materials for each and easier mold forms; (b) use of a container which is a separate piece from the dispensing head assembly, permitting easy filling of the container, and taking advantage of ordinary bottles and standard bottling technology; (c) use of a reservoir, piston and actuator in such a way as to realize the additional advantages of establishing a one-way valve mechanism for sealing the dip tube on the downstroke cycle, and also establishing a drain back mechanism for discharging undispensed product back into the container without the need of extra parts for either function, (d) use of a piston sealing mechanism which produces a tight seal while maintaining a low coefficient of friction so as to make the mechanical twisting motions of the cap and actuator easy, and (e) use of a flexible face fitment two-way valve mechanism for providing a positive shut off to reduce dribbling or seeping, while also preventing product build up behind the nozzle.
These and other specific improvements (and other embodiments) will be described in more detail later, and their significance will be explained. In summary, it is the cooperation of such elements as these in the system of this invention which results in a non-chemical aerosol that works from any position/orientation, even upside down, that does not require a finger pump to actuate, and that can be fitted to a wide variety of standard disposable or reusable containers. Further, the system of this invention produces a longer duration spray which does not become a wet stream or dribble near the end of the cycle, and a finely atomized high pressure spray which does not take inordinate mechanical force to charge. The system of this invention is simple and uses relatively few parts, all of which can be easily fabricated from existing materials and can be injection molded with existing mold techniques.
It is a specific objective of the system of this invention to solve substantially all of the problems that have, until now, prevented non-chemical aerosol dispensers from being widely accepted as the replacement for chemically pressurized aerosol dispensers.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in, and form a part of the specification, illustrate the preferred embodiments of the present invention, and together with the descriptions serve to better explain the principles of the invention.
In the Drawings
FIG. 1 is an offset front view of this invention particularly featuring the actuator, the acuator housing, and the collar cap.
FIG. 2 is a front view of the actuator assembly of this invention shown here without a mechanical break-up unit (MBU).
FIG. 3 is a sectional side view of the actuator assembly of FIG. 2, again shown without an MBU.
FIG. 4 is a side view of this invention showing the overcap, the actuator housing, the collar cap, and the container.
FIG. 5 is a sectional side view of one embodiment of the dispenser invention shown in FIG. 4, specifically the double helix action (DHA) model, which is shown here with the piston in the down position.
FIG. 6 is a sectional side view of the DHA model of FIG. 5, but is shown here with the piston in the up position.
FIG. 7 is an exploded view of the individual components that together comprise the DHA model of FIGS. 5 and 6.
FIG. 8 is a sectional side view of a second embodiment of the dispenser invention shown in FIG. 4, specifically the basic single helix action (SHA) model, which is shown with the piston in the down position.
FIG. 9 is an exploded view of the individual components that together comprise the basic SHA model of FIG. 8 .
FIG. 10 is a blown-up representation of the two-part valve mechanism that is integral to each of the embodiments of this invention.
FIG. 11 is an exploded view of the individual components that together comprise a third embodiment of the dispenser invention shown in FIG. 4, the simplified single helix action (SHA) model, specifically showing the elimination of several parts as compared to the embodiments shown in FIGS. 7 and 9.
FIG. 12 is a sectional side view showing the embodiment of FIG. 11 with the piston in the down position.
FIG. 13 is a sectional side view showing the embodiment of FIG. 11 with the piston in the up position.
FIG. 14 is a sectional side view showing the embodiment of FIG. 11, as a sectional side view in 90 degree rotation from the cross-section of FIG. 12, particularly pointing out the vent holes, open to the atmosphere when the piston is fully extended, which allow the system to re-establish equilibrium.
DETAILED DESCRIPTION OF THE INVENTION
With the above summary in mind, it may now be helpful in fully understanding the inventive features of the present invention to provide in the following description a thorough and detailed discussion of a number of specific embodiments of the invention.
Most generally, and referring to FIGS. 1, 4 , 7 , 9 and 11 for purposes of illustration, it may be seen in overview that the non-chemical aerosol dispenser system 10 generally comprises an actuator assembly 20 (shown in FIGS. 2 and 3 without an actuator housing 22 ), a collar cap assembly 40 , shown in FIG. 9 to include a threaded collar cap 42 housing a piston 44 in combination with a spindle 46 , and interconnected with a cylindrical housing 50 by a piston collar 48 , and an expandable elastic reservoir 60 . As shown in FIGS. 7, 9 and 11 , the dispenser system 10 fits onto the collar of a standard container 70 . In all of the disclosed embodiments discussed below, the container 70 may be any standard container, and it does not need to be specially made to withstand a minimum gas pressure. Since the container 70 is not pressurized, it also does not need to be cylindrical or round in shape, nor does it need to be constructed with heavy or thick material. In fact, there are no apparent geometrical limitations placed on the container 70 , thus enabling the dispenser system 10 to have a virtually unlimited range of possible consumer uses, including the possibility of its use with food products. Moreover, the container 70 can be disposable or reusable, and it can be filled and refilled readily with ordinary techniques known to those persons skilled in the art. In summary, unlike chemically propelled aerosols, the current invention is readily adaptable to a wide variety of products characterized by a wide variety of viscosities, surface tensions, formulations, etc., and it can further be configured in a wide variety of product-specific or consumer-specific packaging options. Such container interchangeability is well known by persons skilled in the art and is not further described herein.
The expandable elastic reservoir 60 as illustrated in all of the disclosed embodiments discussed below, is shown in FIGS. 7, 9 and 11 , and is described as an elastomeric bladder, but it may be any kind of reservoir which can expand under pressure, thus storing a force. Accordingly, the reservoir 60 should be understood to represent, not only the elastomeric bladder of these embodiments, but more generally, a means for resistably expanding a reservoir under hydraulic pressure, including not only elastic reservoir containers, but also structures consisting of spring-loaded pistons and equivalent devices mounted within rigid and semi-rigid reservoir containers, including containers having springs embedded within, or affixed to, flexible materials. In fact, a spring-loaded reservoir would represent a viable alternative that would also represent a less expensive component. Such structures, however, are well known by those skilled in the art and are not further described herein.
Several embodiments of this invention are now disclosed, each comprising a core group of interconnected components, and each further comprising a standard container 70 , an elastomeric bladder 60 , and an actuator assembly 20 using a flexible face fitment 24 in combination with a compression fitment 26 as seen in FIGS. 5-9 and 11 - 13 and as described above.
One embodiment, referred to as the double helix action (DHA) model, is illustrated in FIGS. 5-7. A second embodiment, referred to as the basic single helix action (basic SHA) model, is illustrated in FIGS. 8 and 9. Both models are comprised of essentially the same components, with minor variances in the geometries of the individual components. Both models specifically incorporate a piston head 57 and cylindrical housing 50 , as illustrated generally in FIGS. 7 and 9, that are each smaller in their respective diameters then those disclosed in previously patented dispensers, which allow the DHA and the basic SHA models to generate longer upward and downward bore strokes than those generated by previously patented dispensers. The longer bore strokes are critical to the efficiency of this invention. The longer strokes allow additional product initially to be hydraulically drawn into the cylindrical housing 50 , and subsequently forced into the elastomeric bladder 60 , thus ultimately allowing the product to be dispensed with a longer duration spray that that generated by previously patented dispensers. Further, the DHA and basic SHA models featuring piston heads 57 and cylindrical housings 50 with smaller diameters respectively, require the application of less force to overcome the frictional forces working against the downstroke of the piston 44 , thus making it easier for the user to operate the DHA and basic SHA models, and thus accommodating a wider range of users with otherwise limiting physical conditions, i.e., arthritis.
A third embodiment, illustrated in FIGS. 11-13 and referred to as a simplified SHA model, is manufactured using fewer components than basic SHA model, and it features a piston head 257 and cylindrical housing 250 with slightly larger diameters respectively than either the DHA model or the basic SHA model. In the simplified SHA model, the piston head 257 and cylindrical housing 250 have diameters of approximately 1.0 inch as compared to the piston head 57 and the piston housing 50 of the previous two models that have diameters measuring approximately 0.782 inches. This increase in diameter of each component 250 , 257 , while simultaneously leaving the size and space of the threads of the spindle 46 , 146 and the grooves of the piston collar cap 48 , 148 unchanged, leaves the length of the piston 44 and the length of the cylindrical housing 50 unchanged. By making this slight modification, the simplified SHA model is able to increase the amount of product ultimately charged in the elastomeric reservoir 60 , thus increasing the duration of the product spray upon activation.
Further, while the increase in the size of the piston head 257 requires a user to apply more force to overcome the frictional forces working against the downstroke of the piston 244 , the simplified SHA model only requires one turn of its actuator housing 222 to fully charge the elastomeric reservoir 60 versus the 1¾ turns required of the actuator housings 22 , 122 for both of the smaller head 57 models illustrated in FIGS. 7 and 9. In all three embodiments, the disclosed diameters of the respective pistons heads 57 , 257 and cylindrical housings 50 , 250 are exemplary for purposes of illustration. Those persons skilled in the art will appreciate that by simply changing the relative diameter sizes of the piston heads 57 , 257 and the cylindrical housings 50 , 250 , the amount of product hydraulically withdrawn from the container 70 and forced into the elastomeric reservoir 60 will be varied accordingly. Alternately, changes in the relative pitch of the threads of the spindle 46 , 146 and the grooves of the piston collar cap 48 , 148 and/or changes in the relative length of the piston 44 or the cylindrical housing 50 , will likewise vary the ultimate product output as those persons skilled in the art will appreciate and as will be discussed in more detail below.
Both the DHA model shown in FIGS. 5-7 and the SHA model shown in FIGS. 8 and 9 are comprised of the following common components: an actuator housing 22 , a flexible face fitment 24 , a compression fitment 26 , a turbo-actuator 28 (otherwise referred to as a MBU), a valve stem seal 30 , a spring valve retainer 32 , a collar cap 42 , 142 , a piston 44 , a spindle 46 , 146 , a piston collar 48 , 148 , a cylindrical housing 50 , a reservoir bladder 60 , and an overcap 80 . The actuator assembly 20 , 120 as shown in the embodiments illustrated in FIGS. 7 and 9, generally comprises the actuator housing 22 , 122 , the flexible face fitment 24 , the compression fitment 26 , the turbo-actuator 28 , the valve stem seal 30 , and the spring valve retainer 32 . For a detailed summary of the structural composition of, and the mechanical operation of the actuator assembly, U.S. patent application Ser. No. 09/748,730, filed on Dec. 26, 2000, is attached hereto in its entirety and is incorporated expressly herein by reference. The actuator assembly therein disclosed by Blake is representative of the actuator assemblies incorporated in each of the disclosed embodiments of the present invention. Such an actuator assembly creates a discharge pathway through which product is dispensed, such that the flexible face fitment flexes away from two shutoff mating surfaces at a predetermined minimum pressure and then flexes back into sealing contact with the two shutoff mating surfaces when the product pressure drops below this minimum pressure. This results in a product that is dispensed in a fairly constant pattern that then shuts off abruptly, allowing negligible product dribbling as the pressure decreases and minimal product build-up behind the valve.
Referring to FIG. 9 for general purposes of illustration and FIG. 10 specifically, one novel feature of this invention that is common to all three models is the introduction of a valving mechanism 34 , comprised of the valve stem seal 30 and the spring valve retainer 32 , upon which the atomizing turbo actuator 28 sits. Once the reservoir bladder 60 has been charged up to the desired capacity, the valving mechanism 34 stands ready to be activated, which occurs when the button 29 on the turbo actuator 28 is depressed, thus allowing the contents of the reservoir 60 to discharge. The two components 30 , 32 of the new valving mechanism 34 essentially replace five components that have been standard in most other previously disclosed aerosol valves. Common to the prior designs, stem valves just rested within the spring valve retainers while the actuators were locked or retained into position to inhibit the valve action via two wings at the base edge, which retained the assembly by snapping into windows molded into the upper body structure. The new valving mechanism 34 eliminates these unnecessary retention means by virtue of the geometry of the valve stem seal 30 , which has a bulbous contoured tip 33 that flexes into a pocket within the spring valve retainer 32 , thus seating itself so as to be permanently retained. Further assisting with the retention of the valve stem seal 30 within the spring valve retainer 32 is the leaf spring 35 that flexes upon the downward pressure of, and engages the outer lip 37 of, the valve stem seal 30 .
Referring to FIGS. 7, 9 and 11 , the actuator housings 22 , 122 , 222 and the collar caps 42 , 142 , 242 of the three disclosed models form the pressurizing mechanism of this dispenser system 10 . Components 22 , 122 , 222 , and 42 , 142 , 242 are each essentially circular in shape, and along with the rest of the components of the dispenser system 10 (with the exceptions of the flexible face fitment 24 and the compression fitment 26 ), are positioned symmetrically around a common vertical axis. Actuator housings 22 , 122 , 222 and the collar caps 42 , 142 , 242 also each feature an alternating grooved surface upon their respective circular outer walls 21 , 121 , 221 , and 41 , 141 , 241 so as to facilitate a non-slipping grip by the consumer. The pressurizing mechanism is activated when a system user grips the outer wall 21 , 121 , 221 of the actuator housing 22 , 122 , 222 with one hand, grips the outer wall 41 , 141 , 241 of the collar cap 42 , 142 , 242 or alternatively, the container 70 with the other hand, and proceeds to twist the actuator housing 22 , 122 , 222 counter-clockwise while simultaneously holding the collar cap 42 , 142 , 242 or the container 70 motionless. In each of the three disclosed models, the twisting steps are the same, i.e., the actuator housing 22 , 122 , 222 action is reversed, that is, it is twisted clockwise while the collar cap 42 , 142 , 242 or the container 70 is held stationary in order to complete the pressurizing or priming of the dispenser system 10 .
In each of the three disclosed models, and illustrated in FIGS. 7, 9 and 11 , an inset upper lip 81 of the actuator housing 22 , 122 , 222 creates an engaging means by which overcap 80 is seated to protect the activating button 29 from accidental discharge while the system 10 is in storage or while it is in transit. Such engaging means can be any of a wide variety of mechanical features that allows the overcap 80 to be securely fastened to the actuator housing 22 , 122 , 222 and yet also easily removed for operation of the dispenser system 10 . Such engaging means are well known to those persons skilled in the arts and will not be further discussed herein.
Referring specifically to FIGS. 5-7, the actuator housing 122 of the DHA model has an inner circular wall 123 that defines a space within its circumference through which the spring valve retainer 32 portion of the actuator assembly 120 is seated. The space within the circumference of the inner circular wall 123 is defined by the diameter that is slightly larger than the diameter of the spring valve retainer 32 , such that there is minimal clearance between the two components 123 , 32 that creates a minimal frictional force between the two components 123 , 32 upon operation of the system 10 . Between the grooved outer circular wall 121 and the inner circular wall 123 of the actuator housing 122 , there is an intermediate circular wall 125 , extending below the outer wall 121 in length, but not extending below the length of the inner wall 123 . The intermediate wall 125 is threaded, a feature which gives rise to the “double” helix action observed during the enactment of the pressurizing mechanism as will be further described below.
In each of the three models disclosed, the pressurizing mechanism is engaged initially by a first action generated by the upstroke of the piston 44 , as shown generally in FIG. 6 . As particularly shown in the figures, the first action occurs when a user applies an external rotating force that twists the actuator housing 122 , engaging grooves 124 of inner circular wall 123 with ribs 147 of spindle 146 , thereby providing rotation of spindle 146 . Correspondingly, when a user applies an external rotating force that twists the actuator housing 122 , threads 126 of intermediate wall 125 engage lugs 58 of outer circular wall 51 of housing 50 . In some embodiments, lugs 58 may comprise bayonet lugs, ramp lugs, or the like. The engagement and configuration of the threads 126 and the lugs 58 provide for an upward motion of the actuator housing 122 when the actuator housing 122 is twisted or rotated in a direction. Further, lugs 127 of piston collar 148 engage with one or more elements of cylindrical housing 50 , such as windows, and the lugs 128 of piston collar 148 engage with threads 145 of spindle 146 , providing an upward motion of spindle 146 and linear travel of piston 44 upon twisting the actuator housing in a direction. Therefore, piston 44 , which is connected to the spindle 146 , will linearly travel during the upstroke of the piston 44 and spindle 146 . As the spindle 146 and piston 44 withdraw from the cylindrical housing 50 during the course of the first action, product is pulled out of the container 70 through the dip tube acceptor port 54 and is deposited within the cylindrical housing 50 . The second action commences with the counter-directional twisting of the actuator housing 122 and a corresponding rotation of inner circular wall 123 and spindle 146 , a downward motion of actuator housing 122 , and a downward motion and linear travel of spindle 146 and piston 44 , provided by the mechanical relationships described above. As the spindle 146 and the attached piston 44 travel downward, the product is forced out of the cylindrical housing 50 and into the elastomeric bladder 60 , thus priming the dispenser system 10 prior to the activating button 29 being depressed. As will be recognized by persons skilled in the art, the quantity and type of product dispensed by such a system 10 can be varied by changing either the spacing between and/or pitch of the threads of the spindle 146 and the lugs of the interfacing piston collar 148 .
Continuing to refer generally to FIG. 7, similar changes can also be made with respect to the distance between and the pitch of the threads on the intermediate wall 125 of the actuator housing 122 . Further, by altering the spacing and pitch of the threads of the spindle 146 and the lugs of the interfacing piston collar 148 , as well as the internal threads of the actuator housing 122 and lugs 58 of outer circular wall 51 , products of various viscosities, surface tensions, formulations, etc. can be selected for a variety of specific applications. These variations will be discussed in greater detail below in reference to SHA embodiments. In this particular embodiment, the double helix action described above results in the deposition of the maximum amount of product within the elastomeric reservoir 60 as well as the maximum amount of product ultimately dispensed.
By contrast, FIG. 9 shows that the intermediate wall 25 of the basic SHA model is essentially smooth and is shaped such that it accepts the upper inner wall 43 of the collar cap 42 so as to more effectively facilitate the counter-directional twisting of the actuator housing 22 and the collar cap 42 during the pressurizing step, while also providing a significant degree of registration between the two components 22 , 42 . In both the DHA model and the basic SHA model, the twisting of the actuator housing 122 , 22 forces the spindle 146 , 46 which is attached to the piston 44 , to travel via its threads either upward or downward along the grooves of the piston collar 148 , 48 and/or along the grooves of the intermediate circular wall 125 , thus mechanically providing the force necessary to withdraw product from the container 70 , deposit it first within the cylindrical housing 50 and then ultimately within the elastomeric reservoir 60 to complete the charging of the dispenser system 10 . The mechanical advantage to these embodiments, referred to generally as a floating track and rail system design is that, with minimal effort, a single twist of the two components of DHA model (or 1¾ turns of basic SHA model, which would require the application of even less force by the user) generates a substantially long bore stroke, which translates into the acquisition of a large volume of product, which is then ready to be dispensed. This large volume of product is then capable of being sprayed consistently for a long period of time, i.e., 12-15 seconds, before the mechanical charge built up in the system 10 dissipates. In combination with the non-clogging flexible face actuator assembly's precise shut-off capability, this translates into a mechanical aerosol dispenser that has dispensing qualities comparable to those historically only found in chemical aerosol dispensers.
Referring again to FIG. 9, the upper inner wall 43 of the collar cap 42 of the basic SHA model is essentially smooth and further includes an inner circular rim 45 formed within the interior of the cap 42 that provides the structure against which the cylindrical housing 50 seats. The collar cap 42 also provides a lower inner circular wall 47 , slightly outset from the upper inner wall 43 that has threads upon its interior surface such that the collar cap 42 can be threadably connected with the standard container 70 housing the desired product.
Continuing to view FIG. 9, the outer circular wall 51 of the cylindrical housing 50 of the basic SHA model defines an annular space at its top that has a diameter large enough to accept the piston 44 , the piston collar 42 , and the spindle 46 . The circular bottom 53 of the cylindrical housing 50 extends radially inward from the outer circular wall 51 . It is not a solid bottom, however, and the inner circular edge 55 of the bottom 53 defines an inner space through which the reservoir bladder 60 protrudes and upon which the piston 44 comes to a final resting position. The cylindrical housing 50 includes several windows 52 that allow for a snap fit connection to the several corresponding lugs 49 of the piston collar 48 , provided in some embodiments as wing lugs, so that the piston 44 and spindle 46 are able to move securely up and down within the cylindrical housing 50 along the lugs 128 of the piston collar 48 , similar to the travel means described for the DNA model above.
The cylindrical housing 50 illustrated in FIG. 9, further includes a dip tube acceptor port 54 protruding from its bottom as well as a bleed back feature 56 , located in this embodiment, approximately 180° away, i.e., substantially opposite from the dip tube acceptor port 54 . The acceptor port 54 allows a dip tube (not shown) to be attached that provides a product pathway from the standard container 70 up into the cylindrical housing 50 , from where it then travels up through the actuator assembly 20 during the dispensing cycle. The bleed back feature 56 allows an overcharged reservoir bulb 60 to release some product back into the standard container 70 , thus reducing the pressure during the storage of the charge. In this embodiment, the bleed back feature 56 is conical in shape with the apex of the cone consisting of a webbing that, when pierced in the manufacturing process, forms the pathway for fluid to travel from the bulb 60 to the container 70 . Those persons skilled in the art will recognize that the geometry of the bleed back feature 56 controls the fluid's drop size and the rate at which the drops travel back to the container 70 . A wide range of geometrical shapes and sizes of bleed back features 56 can be selected depending on the objectives of each system and the type (i.e., viscosity, formulation, etc.) of product utilized.
FIG. 9 further illustrates the piston 44 itself as a narrow tube seated upon a circular head 57 that is raised up along with the spindle 46 within the cylindrical housing 50 upon the initial counter-directional twisting of the actuator housing 22 and the collar cap 42 , and forced back down into the cylindrical housing 50 until it rests upon the cylindrical housing bottom 53 upon the reverse counter-directional twisting of the two components 22 , 42 . The up and down motion of the piston 44 within the cylindrical housing 50 provides the mechanical force needed to pull product from the standard container 70 up into the cylindrical housing 50 as described above. From the cylindrical housing 50 , the product is forced into the elastomeric bladder 60 upon the downstroke of the piston 44 . When the activating button 29 is depressed, the product is dispensed up through the actuator assembly 20 . As described above, the piston 44 , connected to the spindle 46 , travels up and down within the cylindrical housing 50 due to the twisting of the collar cap 42 which engages the threaded outer wall of the spindle 46 , that is connectedly joined to the collar cap 42 through the snap fitting of the piston collar 48 . This action provides for an upward motion of the piston 44 and spindle 46 in the first directional instance, and a downward motion of the piston 44 and spindle 46 in the second, reversible directional instance.
Continuing to refer to FIGS. 8 and 9, the lip 61 of the reservoir bladder of the basic SHA model is seated within an upstanding wall 57 extending radially upward from the bottom 53 of the cylindrical housing 50 while the rest of the reservoir bladder 60 protrudes through the inner annular space defined by the inner circular edge 55 of the bottom 53 of the cylindrical housing 50 extending down into the standard container 70 . As described above, upon the downward motion of the piston 44 and spindle 46 , the reservoir bladder 60 becomes charged with a hydraulic pressure differential created within the cylindrical housing 50 . Upon the release of the pressure through the depressing of the activating button 29 , the reservoir bladder 60 is discharged and the equilization of the hydraulic pressure differential within the cylindrical housing 50 allows any excess product to be dispensed within the standard container 70 . On the upward stroke of the piston 44 , product travels through the port acceptor 54 and into the cylindrical housing 50 where it awaits dispensing. The overcap 80 , which seats itself over an inset outer retaining wall 81 extending above the actuator housing 22 , serves solely to protect the actuator housing 22 from accidental discharge prior to use.
Thus with the exception of the geometries of the respective actuator housings 22 , 122 , the piston collars 48 , 148 , and the spline patterns on the spindles 46 , 146 , the basic SHA model and the DHA model, as illustrated in FIGS. 5-7 and 8 - 9 , generally comprise the same components in combinations that are described above. The advantages created by the two embodiments include the abilities of both to obtain long bore strokes versus the strokes of previously disclosed dispensers. Further, the DHA model, as shown in FIGS. 5-7, exhibits an additional mechanical advantage due to the spline-to-rib engagement via two modes that simultaneously move the mechanism down with one twist/turn on the actuator housing 122 , utilizing a back and forth radial motion that produces twice the travel of the piston 44 and spindle 146 within the cylindrical housing 50 , thus more readily facilitating the hydraulic charging of the reservoir bladder 60 . While the stroke takes place, the actuator housing 122 moves upwards by one-half of the entire stroke.
By contrast, the basic SHA model, shown in FIGS. 8-9, features the same diameter piston 44 and spindle 46 combination that are used in the DHA model, but is differentiated by the reduction by one-half stroke when the upper mode of travel is removed, thereby forcing the lower mode to provide the remaining travel for the other half of the required stroke. Regarding other geometrical and functional aspects, however, the two embodiments are essentially similar.
A third embodiment, referred to as the simplified SHA model, features a slightly larger diameter piston 244 , is illustrated in FIGS. 11, 12 and 13 . One difference between this embodiment and the DHA model and the basic SHA model, is that it features less components and thus creates a simpler product to manufacture. In the simplified SHA model, the piston head 257 as shown has an approximately 1.0 inch diameter versus the approximately 0.782 inch diameter represented by the piston head 57 in the previous two embodiments. Again, it is important to note that the diameter specified is not intended to be limiting in any way; rather, the relative proportionality of the piston head 57 , 257 and cylindrical housing 50 , 250 and/or the relative proportionality of the threads of the spindle or piston 46 , 146 , 244 and the grooves of the piston collar cap 48 , 148 , 245 and/or the length of the piston 44 , 144 , 244 and the length of the cylindrical housing 50 , 250 are more important, as the proportional increasing or decreasing of the sizing of these components will accommodate a variety of product applications as will be readily appreciated by those persons skilled in the art.
In particular, the simplified SHA model features combining several of the individual components from the previously described embodiments during the manufacturing process, while retaining the primary function and the beneficial features of the general dispenser system 10 . Referring to FIG. 11, the piston 44 and spindle 146 , 46 of both the DHA model and basic SHA model are replaced by a single component referred to as a threaded piston 224 . Similarly, the piston collar 148 , 48 and the collar cap 142 , 42 of the DHA model and of the basic SHA model have been replaced by a single component referred to as the threaded collar cap 242 .
Continuing to view FIG. 11, although both threaded collar cap 242 and actuator housing 222 have been geometrically modified relative to their DHA model and basic SHA model counterparts, there are many similarities between the three models. The threaded collar cap 242 and the actuator housing 222 of simplified SHA model still feature the alternating grooved surfaces of their respective circular outer walls to facilitate a non-slipping grip by the user. Thus, the pressurizing mechanism remains the same as in the two previously disclosed embodiments. Further, the threaded collar cap 242 retains the internal threading required to threadably connect with the standard container 70 housing the desired product.
FIG. 11 also illustrates that one of the few geometrical differences between the three models is that the newly constructed actuator housing 222 features only an outer circular wall 221 and an inner circular wall 223 . The space defined within the inner circular wall 223 still accepts the spring valve retainer 32 as it does in the DHA model and the basic SHA model, which itself accepts the valve stem seal 30 (comparable to the other two models as seen in FIGS. 7 and 9 ). The threaded piston 244 travels up the internal threading of the lower inner circular wall 245 of the threaded collar cap 242 . The lower inner circular wall 245 of the threaded collar cap 242 acts essentially as the threaded collar cap 48 , 148 of the basic SHA model and the DHA model respectively, extending beneath the outer circular wall 241 . Further, the threaded collar cap 242 features an upper inner circular wall 243 , similar to the upper inner circular wall 43 of the basic SHA model, that seats within the annular space formed between the outer circular wall 221 and the inner circular wall 223 of the actuator housing 222 . Finally, the geometry of the cylindrical housing 250 of the simplified SHA model is different from the cylindrical housing 50 of both the basic SHA model and the DHA model. Instead of comprising windows 52 with which to engage the lugs 49 of the threaded collar 48 of the basic SHA model, it features an essentially smooth outer circular wall 251 with a retaining lip 259 encircling its upper end that provides a registration means by which to attach to the threaded collar cap 242 .
In respect of several components of the SHA model, the dispenser system 10 may be considered to be more simple both in operation and in manufacture. Futhermore, a venting means is disclosed. While all three embodiments include a venting system—it is required because the dispensing system 10 is considered open, wherein ambient air needs to be replaced when product is dispensed during the replenishing cycle of the dispensing sequence in order to offset the vacuum conditions created during the hydraulic priming. The venting system incorporated in the simplified SHA model is the most efficient. Referring to FIGS. 12, 13 and 14 , the venting means include a pair of vent holes 290 , located approximately 180° apart, and a pair of helix chambers, an upper helix chamber 292 and a lower helix chamber 294 . Functionally, when the vent holes 290 are open, i.e., when the threaded piston is at the apex of its downstroke, ambient air is allowed to enter the dispenser system 10 thus establishing an offset to the vacuum conditions created by the hydraulic priming and recreate an equilibrium condition within the system 10 . The ambient air enters the upper helix chambers 292 and carries through the window-to-latch configuration interface between the threaded collar cap 242 and the cylindrical housing 250 . Ambient air is also exchanged between the helix threads 296 of the interface between the cylindrical housing 250 and the lower circular inner wall 245 of the threaded collar cap 242 as the threads of the threaded piston 244 travel up and down the internal threads of the lower inner circular wall 245 of the threaded collar cap 242 . This telescoping action of the helix threads 296 with the air exchange feature, facilitates the system's functioning attributes to aid in maintaining a pressure equilibrium within the container 70 relative to the ambient environment outside, and at the same time, allows air exchange throughout the dispensing stroke as well as the replenishing stroke.
Continuing to refer to FIGS. 12, 13 and 14 , the two above-discussed situations occur only through the opening of the vent holes 290 , which occurs within every approximate 90° rotation during the telescoping action described above. In each cycle, there is only a full turn forward and backward that delivers approximately 15 seconds duration of spray with the vents holes 290 being open or closed throughout this cycle. Thus, the system 10 remains in a sealed “vents closed” position during the period in which the threaded piston 244 is fully retracted. For this reason, the system 10 will be assembled to the container 70 in a mode where the piston is fully extended and shipped to the user as a sealed container in this same configuration.
The foregoing description is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those persons skilled in the art, it is not desired to limit the invention to the exact construction and process shown as described above. Accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention as defined by the claims which follow.
The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
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A mechanically pressurized aerosol dispensing system comprising a cap which houses a piston, an actuator moveably attached to the cap, forming together with the cap a dispensing head assembly, and an expandable elastic reservoir. The system is fitted over a standard container holding a liquid product, and includes a dip tube assembly to draw liquid into the dispensing head assembly, where the contents are released through the dispensing head assembly, via the aerosol nozzle and valve. A twist of the threaded cap raises a piston, thereby opening a charging chamber within the dispensing head assembly. This creates a vacuum with the resulting suction pulling the product up through the dip tube to fill the charging chamber. Twisting the cap in the opposite direction lowers the piston in a downstroke which closes the charging chamber, forcing the product into the expandable elastic reservoir where it is then discharged through the nozzle.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of pending U.S. application Ser. No. 13/280,032, filed Oct. 24, 2011; which is a continuation of U.S. application Ser. No. 09/637,923, filed Aug. 14, 2000, now U.S. Pat. No. 8,073,550; which is a divisional of U.S. application Ser. No. 08/904,175, filed Jul. 31, 1997, now U.S. Pat. No. 6,104,959; all of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to effecting pathological changes in subcutaneous histological features so as to eliminate unsightly or potentially harmful vascular and cellular conditions, without side effects and with fewer steps and less discomfort than has heretofore been possible.
BACKGROUND OF THE INVENTION
[0003] Radiation therapy is an accepted treatment for a wide variety of medical conditions. High intensity radiant energy sources in the visible band, such as lasers, are now being widely used for both internal and extracorporeal procedures. While the microwave band, between 300 MHz and 30 GHz affords the capability of penetrating deeper than visible light while interacting differently with body tissue it has heretofore been employed primarily only in a variety of dissimilar medical procedures.
[0004] Microwave energy exerts its effect on tissue through controlled regional heating (hyperthermia) of affected features through interaction between the wave energy and magnetically polarizable tissue matter. By using microwaves to establish a regional hyperthermia, it is possible to preferentially increase the temperature of diseased or unwanted histological features to levels which are pathologically effective. At the same time, a necessary objective is to maintain adjacent tissue at acceptable temperatures, i.e., below the temperature at which irreversible tissue destruction occurs. Such microwave induced hyperthermia is well known in the field of radiology where it is used in the treatment of individuals with cancerous tumors.
[0005] A number of specific methods for treating histological features by the application of microwave radiation are described in the medical literature. For example, a technique for treating brain tumors by microwave energy is disclosed in an article entitled “Resection of Meningiomas with Implantable Microwave Coagulation” in Bioelectromagnetics, 17 (1996), 85-88. In this technique, a hole is drilled into the skull and a catheter is invasively inserted into the hole to support a coaxial radiator or antenna. Microwave energy is then applied to the antenna to cause the brain tumor to be heated to the point where the center of the tumor shows coagulative necrosis, an effect which allows the meningioma to be removed with minimal blood loss. Another technique in which microwave energy is utilized to treat prostate conditions is disclosed by Hascoet et al. in U.S. Pat. No. 5,234,004. In this technique, a microwave antenna in a urethral probe connected to an external microwave generating device generates microwaves at a frequency and power effective to heat the tissues to a predetermined temperature for a period of time sufficient to induce localized necrosis. In a related technique disclosed by Langberg in U.S. Pat. No. 4,945,912, microwave energy is used to effect cardiac ablation as a means of treating ventricular tachycardia. Here, a radiofrequency heating applicator located at the distal end of a coaxial line catheter hyperthermically ablates the cardiac tissue responsible for ventricular tachycardia. As with the described methods of tumor treatment, this method of cardiac ablation operates by preferentially heating and destroying a specifically targeted area of tissue while leaving surrounding tissue intact.
[0006] While the general principle of propagating microwave energy into tissue for some therapeutic effect is thus known, such applications are usually based on omnidirectional broadcasting of energy with substantial power levels. The potential of microwave energy for use with subcutaneous venous conditions and skin disorders has not been addressed in similar detail, probably because of a number of conflicting requirements as to efficacy, safety, ease of administration and side effects.
[0007] As a significant number of individuals suffer from some type of subcutaneous but visible abnormality, therapeutic techniques which effectively address these conditions can be of great value. Such features which are potentially treatable by microwave energy include conditions such as excessive hair growth, telangiectasia (spider veins) and pigmented lesions such as cafe-au-lait spots and port wine stains (capillary hemangiomas). Of these conditions, excessive hair growth and spider veins are by far the most common, affecting a large percentage of the adult population.
[0008] Unwanted hair growth may be caused by a number of factors including a genetic predisposition in the individual, endrocrinologic diseases such as hypertrichosis and androgen-influenced hirsuitism as well as certain types of malignancies. Individuals suffering from facial hirsuitism can be burdened to an extent that interferes with both social and professional activities and causes a great amount of distress. Consequently, methods and devices for treating unwanted hair and other subcutaneous histological features in a manner that effects a permanent pathological change are very desirable.
[0009] Traditional treatments for excessive hair growth such as depilatory solutions, waxing and electrolysis suffer from a number of drawbacks. Depilatory solutions are impermanent, requiring repeated applications that may not be appropriate for sensitive skin. Although wax epilation is a generally safe technique, it too is impermanent and requires repetitive, often painful repeat treatments. In addition, wax epilation has been reported to result in severe folliculitis, followed by permanent keloid scars. While electrolysis satisfactorily removes hair from individuals with static hair growth, this method of targeting individual hairs is both painful and time consuming. In addition, proper electrolysis techniques are demanding, requiring both accurate needle insertion and appropriate intensities and duration. As with wax epilation, if electrolysis techniques are not performed properly, folliculitis and scarring may result.
[0010] Recently developed depilatory techniques, utilizing high intensity broad band lights, lasers or photochemical expedients, also suffer from a number of shortcomings. In most of these procedures, the skin is illuminated with light at sufficient intensity and duration to kill the follicles or the skin tissue feeding the hair. The impinging light targets the skin as well as the hair follicles, and can burn the skin, causing discomfort and the potential for scarring. Further, laser and other treatments are not necessarily permanent and may require repeated applications to effect a lasting depilation.
[0011] Like hair follicles, spider veins are subcutaneous features. They exist as small capillary flow paths, largely lateral to the skin surface, which have been somewhat engorged by excessive pressure, producing the characteristic venous patterns visible at the skin surface. Apart from the unsightly cosmetic aspect, telangiecstasia can further have more serious medical implications. Therefore, methods and devices for treating spider veins and other subcutaneous histological features in a manner that effects a permanent pathological change to the appropriate tissues are highly desirable.
[0012] The classical treatment for spider veins is sclerotherapy, wherein an injection needle is used to infuse at least a part of the vessel with a sclerotic solution that causes blood coagulation, and blockage of the blood path. With time, the spider veins disappear as the blood flow finds other capillary paths. Since there can be a multitude of spider veins to be treated over a substantial area, this procedure is time-consuming, tedious, and often painful. It also is of uncertain effectiveness in any given application and requires a substantial delay before results can be observed.
[0013] Another procedure for the treatment of shallow visible veins, which is similar to techniques used in depilation, involves the application of intense light energy for a brief interval. This technique exposes the skin surface and underlying tissue to concentrated wave energy, heating the vein structure to a level at which thermocoagulation occurs. In particular, these energy levels are so high that they cause discomfort to some patients, and they can also be dangerous to those in the vicinity, unless special precautions are taken. In addition, some patients can be singed or burned, even though the exposure lasts only a fraction of a second.
[0014] Due to the serious problems that the subcutaneous abnormalities can create in individuals, there is a general need to be able to treat such features in a manner that effects beneficial pathological change without adverse side effects or discomfort. An optimal therapeutic technique should effect a permanent pathological change without requiring repeated applications to reach the desired effect. Moreover, these procedures should be noninvasive, should cover a substantial target area that is not limited to a single hair follicle or spider vein, and should make optimum use of the energy available. Finally, pathological changes should occur only in the targeted feature, and not in intervening or underlying layers.
SUMMARY OF THE INVENTION
[0015] The present invention overcomes the deficiencies in previously described methods for treating subcutaneous features by delivering a dosage of microwave energy that is maintained for only a short duration but at an energy level and at a wavelength chosen to penetrate to the depth of a chosen histological feature. The subcutaneous features are destroyed or pathologically altered in a permanent fashion by the hyperthermic effect of the wave energy while the surrounding tissue is left intact.
[0016] In accordance with the invention, the effective delivery of microwave energy into the subcutaneous feature can be maximized in terms of both the percentage of energy transmitted into the body and a preferential interaction with the target feature itself. The microwave energy is specifically targeted to the chosen depth and the targeted feature is heated internally to in excess of about 55° C., to a level which thromboses blood vessels and destroys hair follicles. The ability to target a wide area containing a number of features simultaneously enables a single procedure to supplant or reduce the need for repetitive applications.
[0017] Methods in accordance with the invention utilize certain realizations and discoveries that have not heretofore been appreciated in relation to wave energy-tissue interactions at a substantial depth (up to 5 mm below the skin surface). The wavelengths that are selected are preferentially absorbed by a targeted feature such as a blood vessel more readily than by skin surface and tissue. Thus, a chosen frequency, such as 14 GHz, penetrates through surface tissue to the chosen depth of the target feature, but not significantly beyond, and the energy heats the target more than adjacent tissue. Dynamic thermal characteristics are also taken into account, because transfer of thermal energy from small target features such as minute heated blood vessels to the surrounding tissue (the “thermal relaxation time”) is much faster than that for larger vessels. The duration of a dosage, typically in the range of 100 milliseconds, is varied to adjust for this size factor.
[0018] Immediately prior to, concurrently with, or after the application of penetrating microwave energy, the skin surface is advantageously cooled. This cooling may be effected in a number of ways such as through the delivery, as rapidly expanding gas, of known coolants into a small space between the microwave emitter and the skin surface. The use of coolant enables the surgeon not only to minimize patient discomfort and irritation, but also to adjust energy dosages in terms of intensity and duration, because heat extraction at the surface also affects heating to some depth below the surface. The surgeon can also employ air cooling to minimize irritation while assuring results over a larger subcutaneous area and with fewer applications.
[0019] While it is advantageous to cool the skin surface with a separate medium in the target area immediately prior to or during wave energy application, it is also shown that the wave energy emitting device itself can be used to draw thermal energy off the skin surface. Again, the skin is heated minimally, giving the patient little, if any discomfort, and avoiding skin irritation. Comfort may be ensured for sensitive patients by a topical anesthetic, or by a conductive gel or other wave energy complementary substance introduced between the applicator and the skin surface.
[0020] The energy applied is generally in excess of about 10 Joules, and the duration is typically in the range of 10 to 1,000 milliseconds, with about 100 milliseconds being most used. The total energy delivered is typically in the range of 10-30 Joules, although the energy delivered as well as frequency may be changed in accordance with the nature of the targeted features, the target volume and depth. In a depilation process, for example, 10 to 20 Joules will usually suffice when a compact applicator is used, while a higher input level, such as 20 to 30 Joules, is used for a telangiectasia treatment.
[0021] A system in accordance with the invention for use in such procedures may employ a tunable power generator, such as a tunable power source operable in the microwave range from 2.45 GHz to 18 GHz, and means for gating or otherwise controlling the power output to provide selected pulse durations and energy outputs. The system also can incorporate power measurement sensors for both forward power and reflected power or circuits for measuring impedance directly. Thereby, tuning adjustments can be made to minimize reflection. Power is delivered through a manipulatable line, such as a flexible waveguide or coaxial line, to a small and conveniently positionable applicator head which serves as the microwave launcher or emitter. The applicator head may advantageously include, in the wave launching section, a dielectric insert configured to reduce the applicator cross-section, and to provide a better match to the impedance of the skin surface. Furthermore, the dielectric insert is chosen so as to distribute the microwave energy with more uniform intensity across the entire cross section, thus eliminating hot spots and covering a larger area.
[0022] If the dielectric is of a material, such as boron nitride or beryllium, oxide, which is a good thermal conductor, it can be placed in contact with the skin and thermal energy can be conducted away from the skin as microwave energy is transferred. Different clinical needs can be met by making available a number of different dielectric element geometries fitting within an interchangeable mount. The applicator head may further include a pressure limiting mechanism to insure that the head does not compress vessels as the procedure is being carried out.
[0023] In addition to the range of capabilities thus afforded, the surgeon can use ultrasound or other inspection techniques to identify the locations of the subcutaneous features for the precise mapping of target sites. Using an indexing or aiming device or element on the applicator head, energy can be applied a minimum number of times at precise locations to encompass a maximum number of targets. Because skin and tissue characteristics vary, pretesting target characteristics and varying the frequency or phase applied can increase efficiency and reduce the possibility of side effects.
[0024] In another application in accordance with the invention, the skin target area may be more readily visualized by using a microwave launcher positionable within an end unit in one of two alternate positions. In one position, the target area can be viewed and the launcher indexed for movement into precise proximity to the target area. In yet another example, a rectangular waveguide of standard size and therefore larger cross-section is used, with air cooling of the skin surface. For depilation, a peel-off, attachable label locating a number of delineated contiguous target areas can be placed on the skin. When the applicator has been energized at each target area, the label sheet can be peeled off, removing hair residue with it.
[0025] The applications of the process and method are not limited to conditions such as spider veins and unwanted hair, but further encompass pigmented lesions and related abnormalities, as well as other temporary and permanent skin disorders.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] A better understanding of the invention may be had by reference to the following specification, taken in conjunction with the accompanying drawings, in which:
[0027] FIG. 1 is a combined block diagram and perspective view of a system in accordance with the invention;
[0028] FIG. 2 is a side view, partially in section, of a microwave applicator for use in the system of FIG. 1 ;
[0029] FIG. 3 is a fragmentary view of the beam launching end of a microwave applicator in relation to a graphical representation of electric field strength across the applicator;
[0030] FIG. 4 is a simplified, perspective view of a section of subcutaneous structure, depicting different layers therein in relation to blood vessels and hair follicles;
[0031] FIG. 5 is an enlarged sectional view of a hair structure from root to shaft;
[0032] FIG. 6 is a simplified depiction of method steps in accordance with the invention;
[0033] FIG. 7 is a graphical depiction of loss factor curves showing the comparative absorption of microwaves in blood and tissue at different frequencies;
[0034] FIG. 8 is a graphical depiction of the temperature changes at and below the skin surface during practice of methods in accordance with the invention;
[0035] FIG. 9 is a graphical depiction of the variation in thermal relaxation time for different blood vessel diameters;
[0036] FIG. 10 is a simplified perspective view of a different microwave applicator used in conjunction with a removable positioning sheet; and
[0037] FIG. 11 is a perspective, partially broken away, view of an alternative applicator head including internal cooling and a viewing system.
DETAILED DESCRIPTION OF THE INVENTION
[0038] A system in accordance with the invention; referring now to FIG. 1 , is depicted in an example intended for use in hair removal, the treatment of spider veins and other skin disorders. This configuration includes a hand-held applicator that is suitable for potential use at any frequency within a suitable range, as well as for measurement of skin or tissue properties. Such a system can be used for treating any of a variety of skin disorders, including hirsuitism, telangiectasia, pigmented lesions and the like. It will be apparent to those skilled in the art that where such degrees of versatility and usage in different possible applications are not required, a simpler and less expensive system will often suffice. In addition, if a manually moveable applicator head is not required, the system can be simplified in this respect as well. In the most rudimentary example, a monofrequency unit with means for adjusting dosage driving a fixed applicator head may be adequate.
[0039] Referring to FIG. 1 , in a system 10 in accordance with the invention microwave energy of a selected frequency can be generated by any one of a number of conventional devices, such as a variable frequency synthesizer 14 that covers a range from about 2 GHz to about 20 GHz. A number of other conventional microwave generators are tunable in the range of 2.45 GHz to 18 GHz, for example, but here a suitable combination includes the frequency synthesizer 14 and a traveling wave tube system 12 having internal power and a high power output amplifier. Where operating conditions are well-defined and wide tunability is not needed, a conventional low cost source such as a magnetron may be used. The output of the traveling wave tube system 12 is gated open for selected intervals by control pulse circuits 16 , which can be set, in this example, for any interval from 10 to 1000 milliseconds. Thus, the selected frequency is delivered as a pulse burst to provide from 50 W to as much as 4 KW output, the power level most often being of the order of a few hundred watts. In transmission to the operative site, the power bursts are directed through a power sensor 18 , which diverts both forward and reverse propagated energy samples to a power meter 20 . Readings at the power meter 20 enable the surgeon to fine tune power, phase or frequency settings to improve impedance matching and energy efficiency.
[0040] Preinspection of the target site is dependent on the nature of the target. Although visual inspection is sometimes alone sufficient for target area selection, as with hirsuitism, target veins at depth below the surface can often better be identified, located, and dimensioned by conventional analytical instruments, such as those using ultrasound imaging. As is described hereafter, the power, duration and frequency applied can also be adjusted in relation to the thermal relaxation characteristics of a target blood vessel, which in turn is dependent on size and location.
[0041] A microwave transmission line 24 , here including a flexible rectangular waveguide or a flexible coaxial section 26 that may be manually manipulated, supplies the microwave energy through a phase shifter or other kind of tuner 27 to a hand applicator 30 shown here as positioned against a limb 32 exposed within a surgical drape 34 . The handpiece 30 , shown in greater detail in FIGS. 2 and 3 , is essentially a rectangular waveguide device having a stepped or other impedance matching section 36 coupled to the flexible coaxial line 26 . The handpiece 30 includes a converging tapered body 38 having an open aperture end 40 serving as the wave launching terminus. Internal to the tapered waveguide section 38 is a dielectric insert 44 here formed of two high dielectric (K=16) tapered strips 46 , 47 held in place between low dielectric constant (K=2.5) spacers 48 of a virtually microwave transparent material such as “Rexolite”. This configuration of dielectrics, as seen in FIG. 3 , spreads the electric field distribution toward the sidewalls, enlarging the target area that is effectively acted upon by the wave energy and eliminating any hot spot tendency within the target area. In addition, the dielectric insert 44 provides a better impedance match to the skin, reducing reflective losses, which can further be minimized by adjustments at the tuner 27 . The dielectric 44 also reduces the cross-sectional area and size of the waveguide, thereby making the handpiece 30 easier to handle. In addition, the internal taper matches the waveguide impedance to the different impedance of the dielectric loaded section, so as to minimize reflection.
[0042] The flexible coaxial line 26 allows a surgeon to move the applicator 30 to place its open end manually wherever desired on the body surface 32 . At the frequency range of 12-18 GHz, a standard WR 62 waveguide section with 0.622″×0.311″ orthogonal dimensions can be employed at the output end of the impedance matching section 36 . The tapered section 38 , loaded by the dielectric 44 in this example, reduces the waveguide dimension to 0.250″×0.150″ at the output terminal face 40 . The end face 40 , however, is set off from the limb or other body surface 32 against which it is juxtaposed by an encompassing and intervening spacer element 54 , best seen in FIGS. 2 and 3 . The spacer element 54 includes an interior shoulder 56 extending around the periphery of the end 40 of the tapered section 38 , defining a standoff volume of a height of about 0.020″ (0.5 mm). A coolant can thus be injected via a side conduit 58 from a pressurized coolant gas source 60 ( FIG. 1 ), via a coupling conduit 62 extending through a solenoid controlled valve 64 . The pulse control 16 opens the valve 64 in timed relation to the microwave pulse to be delivered from the traveling wave tube system 12 . This timing relation can be controlled, so that the target skin area can be precooled prior to delivery of the microwave pulse, cooled concurrently with the delivery or cooled after the start of the delivery of the microwave pulse. Furthermore, a temperature sensor 68 , shown only generally in FIG. 1 , may be disposed within the standoff volume, in contact with the skin or otherwise, to sense the lowering of temperature at the target surface. In this example, the coolant is a pressured gas, such as 1,1,1,2 tetrafluoroethane, held under high pressure in liquefied or gaseous phase. When injected by actuation of the valve 64 , the gas expands vigorously within the standoff volume, rapidly lowering the temperature because of the expansion effect. Since the boiling point of the tetrafluoroethane is approximately −26° C. at 1 atm, it is extremely effective in extracting thermal energy from the target area, even for the short bursts of the order of a fraction of a second that are involved in the present procedure. The temperature sensor 68 may be a Luxtron fiber optic device for measuring temperature, or it may be a thermistor which is coupled in a circuit that triggers the microwave pulse when the coolant has adequately lowered the temperature at the skin surface or in the standoff volume. Other coolants, including air, can alternatively be used to reduce the skin surface temperature within the standoff volume during the procedure.
[0043] Other alternative approaches may be utilized to minimize discomfort and, separately or additionally, provide improved efficiency. A compound that is complementary to the delivery of the microwave energy, in the sense of neither being reflective or absorptive, and therefore not appreciably heated, can be placed on the skin prior to microwave pulse application. For example, a topical anesthetic having short term effectivity may be all that is needed to reduce the discomfort of some patients to an acceptable level. Other patients may require no coolant or topical anesthetic whatsoever. Another alternative is to employ a surface gel or other substance that improves impedance matching between the microwave pulse launching device and the surface tissues.
[0044] The microwave delivery system provided by the applicator 30 delivers microwave energy over an advantageously broad field distribution into a subcutaneous surface area as best understood by reference to FIG. 3 . The dielectric loading introduced by the spaced apart dielectric elements 46 , 47 , which diverge toward the output end as the sidewalls converge in the tapered section 38 , alters the normal horizontal electric field distribution from its normal half sine wave characteristic so that there is substantial field strength at the two sidewalls and no high central energy peak. A single, appropriately shaped, dielectric element can be used to modify the field distribution to like effect. By thus spreading the energy across the target area, there is both elimination of localized energy concentrations (and therefore localized heating) and a larger effective treatment area. As seen in the graphical portion of FIG. 3 , in the solid line, the calculated electric field at the skin surface when the outlet end 40 of the microwave launcher is 0.5 mm off the surface, is more than twice that at the edges. This differential is reduced when the field distribution is modeled at a depth of 0.5 mm below the skin surface. In both instances, there is a degree of dispersion outside the perimeter of the applicator face 40 because of the setoff spacing, but this aids in equalizing the power distribution and poses no radiation danger.
[0045] In accordance with the present invention, advantage is taken of the results of an analysis of the interaction of microwaves with biological tissues at different frequencies. The complex permittivity ε* of any given matter, including biological matter, in a steady state field is conventionally analyzed using the following equation:
[0000] ε*=ε 0 (ε′−jε″),
[0000] in which ε 0 is the dielectric constant of free space and the real component, ε′, is the dielectric constant, while the imaginary component, ε″ is the loss factor. As seen in FIG. 7 , the loss factor (ε″) of blood, in the range of 2 to 20 GHz, shown by tests to be substantially higher than that of skin tissue. Further analysis has ascertained that by considering both relative and absolute factors, the most advantageous conditions exist at about 14 GHz. From published work, the dielectric constant of skin is known to be about 22 at 10 GHz and to decrease with increasing frequency to a value of 12 at 18 GHz. The loss factor for skin reaches a peak of 18 at 9 GHz and decreases with increasing frequency to a value of 12 at 14 GHz. The loss factor ε″ for skin is approximately one-half that for blood in the frequency range between 14 GHz and 20 GHz, and above 10 GHz the loss factor for blood increases somewhat more than for skin, as seen in FIG. 7 . Therefore, the heat generated per unit volume in blood and to some extent in differentiable cellular structures other than skin, can be expected to be twice that of skin. Consequently, differential heating results when microwave energy penetrates subcutaneous regions. Because these subcutaneous regions are of depths up to 5 mm, they are directly within the range of interest that includes hair follicles and roots, telangiectasia, pigmented lesions, and other histological features that are visible through the epidermis and/or dermis, or actually protrude at the skin.
[0046] The structure of skin is somewhat idealistically and simplistically depicted in FIG. 4 , in order to show the physical relation and relative proportions (although not to scale) between the epidermis and dermis layers that lie above subcutaneous tissue, and to further represent histological features of interest in the structure. Sweat glands, nerve endings, corpuscular structures and sebaceous glands are not included for clarity. The hair shafts, most deeply embedded at their roots at 4 to 5 mm depth in the dermis, extend outwardly through the dermis and the relatively more robust epidermal layer. Relatively large arteries and veins branch into the arteriole and venule vessels which feed and derive blood, respectively, as the smallest capillaries that normally are invisible from the skin surface, and that form the termini of the blood paths. When these capillaries, either or both arterioles and venules, become engorged for some reason, as in the telangiectasia condition, they form the lateral and visible pattern, known collectively as spider veins, at a depth of 0.1 to 1.0 mm below the surface of the epidermis. Typically of the order of 0.2 mm in diameter, the spider veins can actually sometimes protrude at the surface, and be larger in diameter as well. Reticular or feeder veins can lie as much as 5 mm in depth below the surface, and are substantially larger, of the order of 1.0 to 2.0 mm in diameter, being large enough to be identified by a non-invasive inspection technique, such as imaging with ultrasound. The reticular or feeder veins sometimes create the overpressure condition causing engorgement of the spider veins.
[0047] FIG. 5 shows further details, again somewhat idealized, of an enlarged hair shaft, extending outwardly from a root into the growing cellular structure of the follicle and the follicle casing that transforms into the hair shaft body that passes through the epidermis. The hair follicle is nourished by at least one artery that feeds the papillae structure at the root and is encompassed in a crown of associated matrix cells. Attack on the cellular follicle structure or on the papillae or the arterioles or venules to and from the papillae can result in permanent destruction of the hair shaft.
[0048] With these considerations in mind, appreciation of the operation of the system of FIG. 1 can more readily be gained. The surgeon can use a suitable frequency for a chosen histological feature within the range of the frequency synthesizer 14 . It is assumed here that the frequency chosen is about 14 GHz. The traveling wave tube system 12 is set to generate approximately 100 to 300 watts, the control pulse circuits 16 being set to open the solenoid valve 64 prior to getting a short pulse from the microwave system 12 . It has been found that a 100 millisecond pulse is satisfactory for both efficacy and safety, although other durations can be used with wattage adjustments to compensate. The output from the traveling wave tube system 12 is directed through the power sensor 18 , the transmission line 24 , the flexible section 26 , through the tuner 27 and to the applicator 30 . If the operator desires, short test pulses of low amplitude can first be sent to obtain readings of the reflected power at the power meter 20 , and fine tuning adjustments can be made at the tuner 27 , in a conventional manner. In addition, the operator can use ultrasound or another non-invasive diagnostic system to analyze the substructure to identify the position of target features, such as reticular veins and arteries, both as to size and location. The procedure initially to be described, however, pertains to depilation, so that the target area is not only readily visible, but is also substantially uniform in depth and structure, as per FIG. 5 .
[0049] When the control pulse circuits 16 operate, they first provide a control impulse to open the solenoid valve 64 , in this example, and then turn on the traveling wave tube system 12 for the selected interval. Because the valve requires a few milliseconds (e.g., 20 to 35) to operate and a few milliseconds are also needed for the pressurized coolant from the source 60 to pass through the outer conduit 62 and the side conduit 58 in the spacer 54 , it is preferred to delay the microwave pulse until cooling has actually begun or is contemporaneously begun. Alternatively, as previously noted, a temperature sensor 68 that detects a temperature drop at the skin surface may be used to either trigger the microwave pulse or to preclude its operation until after the coolant has become effective.
[0050] For depilation, pulses in the range of 10 to 20 Joules in terms of total work output have been shown to effect permanent depilation without significant discomfort or significant adverse side effects. Tests were run using the dielectric loaded applicator 30 having a 0.250″×0.150″ output area (5 mm×3 mm, or 15 mm 2 ), and employing a pulse duration of 100 milliseconds in all instances. A substantial number of experiments were run on test rabbits with this applicator, varying only the power applied so as to change the total energy in Joules. The results were examined by a pathologist and the accompanying Tables 1 and 2, appended following the specification, show the results of his examination.
[0051] The system of FIG. 1 was also employed in a number of tests on rabbits to determine the changes occurring in veins and arteries under different pathological changes, and side effects on tissues and vessels with a protocol using cooling as well as no cooling to determine if pigmentation has an effect are shown in appended Table 3. These tests showed no significant difference in pigmentation versus non-pigmentation; indicating that coloration, and/or the presence of melanin, is not a significant factor in absorption of microwave energy. A different protocol was followed in amassing results shown in appended Table 4, which represents an analysis by a pathologist blinded to the dosages used. Cooling was not used in this example. These results with test rabbits show that pigmentation is not a significant factor and that at 16 Joules dosage and above, there is effective occlusion of target veins and arteries with minimal changes or only mild induration of tissues. The indication of dermal fibrosis again is not indicative of scar development.
[0052] Pathological examination of these animal studies consistently demonstrated destruction of hair follicles over a wide range of microwave energy levels. The destruction extended to the base of the follicle, which is significant to permanent hair removal. The amount of hair destruction within the target area varies in accordance with the total amount of energy, but destruction is substantially complete at 14 Joules and higher. Furthermore, until the energy delivered is in excess of 20 Joules, the appearance of the skin is normal in all cases and the epidermis is histologically intact. Minor indications of dermal fibrosis are not indicative of clinical scar formation. Minor vascular changes, such as intimal fibrosis of small arteries, constitute neither damaging nor permanent conditions. Consequently, a dosage in the range of 14 to 20 Joules is found both to be effective and to be free of deleterious side effects.
[0053] The effects of delivery of microwave energy, with surface cooling, are illustrated graphically in FIG. 8 , which indicates temperature changes at both the surface of animal skin tissue (0.75 mm thick) and 1.5 mm below the surface, in water, under conditions of delivery of up to 12 Joules total energy level over 100 milliseconds duration, accompanied by cooling using expanded tetrafluorethane gas. As shown, the baseline temperature for the test animal skin is approximately 32° C., and that for the body at a depth of 1.5 mm is approximately 37° C. Applying the microwave energy with cooling, the skin surface temperature rose very slightly, but was essentially unchanged. Beneath the skin surface, however, the temperature rise at 1.5 mm depth was at a substantially higher rate, reaching approximately 60° C. at 100 milliseconds. Higher temperatures would of course be reached with the application of higher energy levels. It is posited that even such a temperature is sufficient to cause cellular degradation of the hair follicles near the root, and it may well also thermocoagulate blood in the feeder artery, in the papillae at the hair root, or in the cell matrix surrounding the papillae. Although the hair follicles are not conductive, they may be particularly susceptible to the impinging microwave energy because they are thin dielectric elements which can cause energy concentration and therefore greater heating. Whether one or more effects are observable, permanent destruction has been shown by pathological examination, as in the annexed tables.
[0054] The microwave energy does not significantly penetrate beyond the depth of the targeted histological features because of attenuation, the limitation on total energy delivered and the lower loss factor in tissue.
[0055] Where the histological defects are benign vascular lesions, as with the telangiectasia condition, different tests and operating conditions may be employed, as shown in the steps of FIG. 6 , to which reference is now made. While spider veins can cover a substantial area, and visual targeting may be sufficient, it is often desirable to analyze the target area in greater detail. Thus, ultrasound examination may be utilized to identify and estimate the size of reticular veins feeding a substantial area of spider veins, as an optional first step 80 , which can precede marking of the target surface 82 in any appropriate way. Again, the dielectric constant, skin impedance or other characteristics may be tested in a preliminary step 84 , prior to choosing operative frequency in step 86 . Fine tuning, phase adjustment or another impedance matching option 88 may be employed to reduce reflective losses and increase efficiency. Given the size and location of the target vascular feature, thereafter, the power level and pulse duration may be selected in a step 90 .
[0056] The pulse duration is a significant parameter in relation to the vessel diameter, since the smaller the vessel diameter, the shorter is the thermal relaxation time. Even though the loss factor of blood is higher than that of the tissue, dissipation of heat to surrounding tissue is much faster with a small blood vessel and consequently shorter term heating is needed. As seen in FIG. 9 , thermal relaxation time increases monotonically with vessel diameter, and thus a longer duration pulse is needed, perhaps at the same or a greater power, if the vessel diameter is of a larger size. Given the power level and pulse duration, the operator can select one of the cooling options, which also includes no cooling whatsoever, in step 92 . Typical anesthetics or other anesthetics may be employed at the same time, as shown by optional step 94 .
[0057] Consequently, when the microwave pulse is delivered, the subcutaneous target is heated to the range of 55° C. to 70° C., sufficient to thrombose the vascular structure and terminate flow permanently. The specific nature contributing factors to disappearance of the vessels with time may be one or more factors, including thermocoagulation of the blood itself, heating of the blood to a level which causes thrombosis of the vessel or some other effect. The net result, however, is that a fibrous structure forms in the vessel which clogs and terminates flow, so that the resultant fibrous structure is reabsorbed with time, as new capillary flow paths are found. In any event, heating in the 55° C. to 70° C. is sufficient to effect (step 96 ) the permanent pathological change that is desired (step 98 ).
[0058] An alternative applicator that covers a larger area and is employed with a peelable indicia label as shown in FIG. 10 . The standard WR 62 waveguide for transmission of microwave energy at 14 GHz has, as previously mentioned, interior dimensions of 0.622″×0.311″. An applicator 100 employing such a waveguide section 101 is used directly, without internal dielectric loading, to cover a substantially larger target area while employing air cooling. The waveguide section 101 , coupled via a flexible waveguide and an impedance matching transition (not shown), if necessary, to a microwave feed system 102 has side wall ports 104 coupled to an external coolant source 105 which may deliver coolant through a control device 106 triggered, in relation to the microwave pulse, as previously described. Under some circumstances, when air is used as the coolant, it may simply be delivered continuously into the waveguide, the end of which can be blocked off by a microwave transmission window so that only the launching end and the skin surface are cooled. For use in a depilation procedure, the skin surface of a patient to be treated is covered with a sheet 108 having numbered guide indicia 109 for marking successive applicator 100 positions. These positions overlap because of the fact that the energy concentration is in the central region of the waveguide 101 , at the normal maximum amplitude of the electric field in the TE 10 mode. The peel off label sheet 108 is covered on its skin-adhering side by a separable adhesive. Consequently, when the applicator 100 is moved between successive overlapping index positions marked 1,1,2,2 etc. at the side and corner of each position, the internal areas that are pathologically affected within each location are essentially contiguous, until the entire applicator 100 has been moved through all positions on the sheet 108 , with dosages applied to all of the areas. Hair follicles having been destroyed in those areas, the procedure is terminated and the sheet 108 is peeled off, with the destroyed hair follicles and shafts adhering to it.
[0059] With the arrangement of FIG. 10 , a longer microwave pulse duration or more wattage is needed for increasing the number of Joules because of the broader beam distribution, which means that, heating is at a slower rate (e.g., in the approximate proportion of 0.7° C. rise in skin temperature per joule for the large applicator versus 2.4° C. per joule for the dielectric filled smaller applicator). The skin temperature rise was reduced by a factor of 2 when using air at a temperature of between 0° C. and −5° C.
[0060] It should be noted, furthermore, that a standard open rectangular waveguide can be loaded with dielectric elements in a manner which enables size to be reduced without restricting coolant flow.
[0061] Another alternative that may be used, but is not shown in the figures, relates to a modification of the spacer element that is employed in the example of FIGS. 2 and 3 . One can configure the spacer element with two alternative but adjacent positions for the applicator open (emitter) end, and arrange the applicator so that the emitter end can be shifted between the two positions. In a first or reserve position of the applicator, the target surface can be viewed through the spacer element, and positional adjustments can be made. This part of the spacer element is then used as a frame for visualizing the operative target on the skin surface when the applicator is in the reserve position. As soon as the target area is properly framed, the applicator is simply shifted from the reserve position to the operative position, in proper alignment with the target area, and the procedure can begin.
[0062] A different approach to a useful applicator is shown in FIG. 11 , to which reference is now made. This also illustrates a different means for cooling the skin surface, as well as for viewing the target area. In this example, the applicator 120 comprises an open-ended wave propagation segment 122 fed via a transition section 124 from a coaxial line 126 . The unit may be physically manipulated by an attached handle 128 . The open end of the waveguide 122 is filled by a dielectric element 130 which is not only of suitable electrical dielectric properties but a good heat conductor as well, such as boron nitride or beryllium oxide. The dielectric insert 130 extends beyond the open end of the waveguide, into contact with a skin surface that is to be exposed to microwave radiation. The interior end of the dielectric 130 is urged in the direction toward the skin surface by a non-conductive, non-absorptive microwave leaf spring 134 of selected force and compliance. Thus, the dielectric insert 130 presses on the skin surface with a yieldable force, selected to assure that contact is maintained but that any protruding veins or arteries are not closed simply by the force of the applicator 120 . This applicator 120 and dielectric insert 130 are externally cooled by an encompassing sleeve 136 through which coolant is passed via internal conduits 137 , 138 that communicate with an external supply (not shown) via external conduits 141 , 142 . Consequently, heat is extracted from the surface of the skin via the contacting dielectric 130 itself.
[0063] In addition, a target mark placed on the skin surface by the surgeon may be viewed by a system including a fiber optic line 145 that extends through the dielectric 130 and leads via a flexible fiber optic line 147 to an image viewing system 149 .
[0064] In use, this applicator 120 of FIG. 11 covers a substantial chosen area, with the viewing and cooling features that simplify placement and minimize discomfort. The movable dielectric insert 130 can be a replaceable element, with different shapes of dielectrics being submitted where different conditions apply. It will be appreciated that other expedients may be utilized for shaping the microwave beam, including lens and diffuser systems.
[0065] Although a number of forms and modifications in accordance with the invention have been described, it will be appreciated that the invention is not limited thereto, but encompasses all forms and expedients in accordance with the appended claims.
[0000]
TABLE 1
ANIMAL STUDY PROTOCOL NP970305
Applicator Tip: 0.250″ × 0.150″; Cooling
Dose
Description
Histologic Description
Rabbit
(Joules)
of Skin
Tissue
Hair Follicles
Vasculature
B9
13
skin intact;
some
few hair follicles
vessels patent
decreased
fibrosis;
density of
mild edema
hair
B10
15.2
skin intact;
dermal
relative absence
vessels patent
decreased
fibrosis
of hair follicles
density of
hair
B11
19.6
skin intact;
normal
paucity of hair
vessels patent
decreased
follicles
density of
hair
[0000]
TABLE 2
ANIMAL STUDY PROTOCOL NP970505
Applicator Tip: 0.250″ × 0.150″; Cooling
Dose
Description
Histologic Description
Rabbit
(Joules)
of Skin
Tissue
Hair Follicles
Vasculature
B1/R
22.4
skin intact;
tissue
absent,
veins patent;
hairless
viable,
squamous
arteries
dermal
metaplasia
patent;
fibrosis
increased
intimal
fibroblasts
B1/L
22.4
skin intact;
tissue
hair follicle
veins patent,
hairless
viable,
destruction
arteries
dermal
patent,
fibrosis
intimal
fibrosis
B2/R
20.0
skin shiny;
tissue
hair follicle
possible
hairless
viable,
destruction
fibrous cord
dermal
in small vein;
fibrosis
arteries not
seen in these
sections
B2/L
20.0
skin intact,
tissue
hair follicle
veins patent;
shiny and
viable,
destruction
arteries
hairless
dermal
patent,
fibrosis
increased
intimal
fibroblasts,
mild edema
B3/R
24.1
skin shiny
tissue
hair follicle
veins patent;
and
viable,
destruction;
arteries not
hairless,
dermal
squamous
seen in these
fine
fibrosis,
metaplasia
sections
granularity
small area
of necrosis
on opposite
side of ear
(no cooling)
B3/L
23.6
three
subacute
absence of hair
vessels not
indurated
granulation
follicles
seen in these
areas,
tissue
sections
crusting of
epidermis,
hairless
single
punched
out area
B4/R
23.7
skin shiny
tissue
absence of hair
fibrous cord
and
viable,
follicles
in small vein;
hairless;
dermal
arteries not
fine
fibrosis
seen in these
granularity
sections
B4/L
23.6
four
tissue
hair follicle
congestion of
indurated
viable,
destruction
small caliber
areas
dermal
veins; intimal
fibrosis
fibrosis,
narrowing of
small arteries
B5/R
20.7
skin intact;
tissue
absence of hair
vein possibly
hairless
viable,
follicles,
narrowed;
dermal
squamous
arteries
fibrosis
metaplasia
patent,
intimal
fibrosis
B5/L
21.4
skin intact,
tissue
absence of hair
veins patent;
hairless,
viable,
follicles
arteries
tiny hole
dermal
patent,
fibrosis
intimal
fibrosis
B6/R
22.0
skin intact,
tissue
absence of hair
veins patent;
hairless,
viable,
follicles,
narrowed
fine
dermal
squamous
small artery
granularity
fibrosis
metaplasia
with intimal
fibrosis
B6/L
22.0
punched
dermal
hair follicle
arteries and
out area
fibrosis
destruction,
veins patent
squamous
metaplasia
B7/R
19.2
skin intact,
minimally
focal area of hair
veins patent;
hairless
affected
follicle
partial
destruction
thrombois of
small artery
B7/L
20.5
skin intact,
dermal
focal paucity of
veins patent;
hairless
fibrosis
hair follicles,
arteries
squamous
patent,
metaplasia
minimal
intimal
fibrosis
B8/R
19.0
skin intact,
focal areas
focal destruction
veins patent;
hairless
of dermal
of hair follicles
occlusion of
fibrosis
small artery
with fibrous
cord
B8/L
21.4
skin intact,
dermal
destruction of
veins patent;
hairless
fibrosis,
hair follicles
arteries not
small zone
seen in these
of nodular
sections
fibrosis
B9/R
23.0
skin intact,
small zone
relative absence
veins patent;
hairless
of dermal
of hair follicles,
arteries patent
fibrosis
squamous
metaplasia
B9/L
23.0
skin intact,
dermal
destruction of
veins patent;
hairless
fibrosis
hair follicles,
arteries patent
squamous
with mild
metaplasia
intimal
fibrosis
B10/R
24.6
skin intact,
mild
destruction of
veins patent;
hairless
fibrosis
hair follicles
arteries patent
with mild
intimal
fibrosis
B10/L
24.7
skin intact,
dermal
destruction of
veins patent;
hairless
fibrosis
hair follicles
partial
thrombosis of
small artery
B11/R
22.4
skin intact,
minimal
minimal changes
veins patent;
hairless
changes
arteries patent
B11/L
21.5
skin intact,
dermal
destruction of
veins patent;
hairless
fibrosis
hair follicles,
arteries patent
squamous
metaplasia
B12/R
20.6
skin intact,
dermal
destruction of
veins patent;
hairless
fibrosis
hair follicles,
arteries patent
squamous
metaplasia,
remnants of
follicles seen
B12/L
19.6
skin intact,
zone of
destruction of
veins patent;
hairless
dermal
hair follicles
arteries patent
fibrosis
[0000]
TABLE 3
ANIMAL STUDY PROTOCOL NP970603
Applicator Tip: 0.250″ × 0.150″
Dose
Rabbit
Pigmented
(Joules)
Cooling
Appearance of Skin
A1
No
5.3
No
skin intact - back and ear
Yes
skin intact - back and ear
A2
Yes
5.6
No
skin intact - back and ear
Yes
skin intact - back; tiny dot
left ear
B1
No
9.4
No
back - minimal pallor 2/3
sites; skin on ear intact
Yes
skin intact - back and ears
B2
Yes
9.3
No
skin on back obscured by hair
growth; skin on ear intact
Yes
skin on back obscured by hair
growth; skin on ear intact
C1
No
14.3
No
back - slight abrasion 2/3
sites, small scab 3; skin on
ear intact
Yes
skin intact - back and ear
C2
Yes
14.8
No
skin on back obscured by hair
growth; skin on ear intact
Yes
skin on back obscured by hair
growth; skin on ear intact
D1
No
18.4
No
back - scabs all 3 sites;
ear - tiny scab
Yes
back - slight pallor 2/3
sites, minimal change at site
3; ear - minimal change
D2
Yes
18.6
No
back - small, raised areas at
all 3 sites; ear - small
raised area
Yes
skin intact - back and ear
[0000]
TABLE 4
ANIMAL STUDY PROTOCOL NP970208
No Cooling
Histology-
Histology-
Histology-
Clinical-
Clinical-
Rabbit
Joules
Tissue
Vein
Artery
Tissue
Vessels
D1/R
10.4
Viable,
Patent
Narrowed
Intact
Vein sl.
dermal
Purple
fibrosis
D1/L
10.4
Viable,
Partial
> occlusion
Intact
Narrowing
dermal
occlusion
than vein
edema
D2/R
10.4
Viable,
Sl. altered,
Sl. altered,
Small area
Patent, sl.
dermal
but patent
but patent
of
darkening
fibrosis
blanching
D2/L
10.4
Viable,
Patent
Tiny, vessel
Small area
Patent, sl.
dermal
collapsed
of
darkening
fibrosis
blanching
C1/R
12.0
Viable,
Micro-
Patent
Sl.
Vein segmentally
dermal
thrombosis
blanching
narrowed
fibrosis
C1/L
12.0
Viable,
Ghosted,
Narrowed
Sl.
Vein
dermal
without
and focally
blanching
narrowed
fibrosis
endothelium,
thrombosed
segmentally
but
patent.
Venular
congestion
C2/R
12.0
Viable,
Organization
Not
Mild
Vein
dermal
with
described
blanching
narrowed
fibrosis
evidence of
segmentally
recanalization
C2/L
11.6
Viable,
Thrombosis
Not
Mild
Vein
dermal
with
described
blanching
narrowed
fibrosis
organization
segmentally
B1/R
14.0
Viable,
Patent; not
Not well
Mild
Vessel seen
dermal
well seen in
visualized
blanching
fibrosis
areas of
fibrosis
B1/L
13.7
Viable,
Ghosted,
Patent
Mild
Vessel seen
dermal
necrotic,
blanching
fibrosis
contains
blood
B2/R
14.0
Viable,
Patent
Lumina
Mild
Vessel seen
dermal
narrowed by
blanching
fibrosis
intimal
hyperplasia
B2/L
13.6
Viable,
Occlusion
Not
Minimal
Vein
dermal
focally
described
changes
narrowed
fibrosis
segmentally
A7/R
16.0
Viable,
Focally
Focally
Minimal
Mild
dermal
occluded
occluded
changes
blushing
fibrosis
around
vein
A7/L
16.3
Viable,
Partial
> occlusion
Mild
Blushing
dermal
occlusion,
than vein
induration
around
fibrosis
congestion
vein
of venules
A6/R
15.5
Viable,
Patent
Focal
Minimal
Veins seen
dermal
occlusion
changes
fibrosis
A6/L
15.5
Viable,
Focally
Focally
Mild
Vein segmentally
dermal
absent
absent
blanching
narrowed
fibrosis
A5/R
17.4
Viable,
Thrombosis
Thrombosis
Mild
Vein
dermal
with
with
blanching
narrowed
fibrosis
organization
organization
A5/L
17.5
Viable,
Occlusion
Not
Mild to
Vein
scale crust
(organzation)
described
moderate
narrowed
present,
induration
dermal
fibrosis
|
A system and method for treating subcutaneous histological features without affecting adjacent tissues adversely employs microwave energy of selected power, frequency and duration to penetrate subcutaneous tissue and heat target areas with optimum doses to permanently affect the undesirable features. The frequency chosen preferentially interacts with the target as opposed to adjacent tissue, and the microwave energy is delivered as a short pulse causing minimal discomfort and side effects. By distributing microwave energy at the skin over an area and adjusting power and frequency, different conditions, such as hirsuitism and telangiectasia, can be effectively treated.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefits of the filing of U.S. Provisional Application No. 61/255,935 filed Oct. 29, 2009. The complete disclosures of the aforementioned related patent applications are hereby incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
[0002] This invention relates to heteroaryl substituted arylindenopyrimidines and their therapeutic and prophylactic uses. Disorders treated and/or prevented include neurodegenerative and movement disorders ameliorated by antagonizing Adenosine A 2A receptors. The present application is directed to a subset of a pending genus of compounds, disclosed in US 2009/0054429 A1.
BACKGROUND OF THE INVENTION
[0003] Adenosine is a purine nucleotide produced by all metabolically active cells within the body. Adenosine exerts its effects via four subtypes of cell surface receptors (A 1 , A 2A , A2b and A3), which belong to the G protein coupled receptor superfamily. A1 and A3 couple to inhibitory G protein, while A 2A and A2b couple to stimulatory G protein. A 2A receptors are mainly found in the brain, both in neurons and glial cells (highest level in the striatum and nucleus accumbens, moderate to high level in olfactory tubercle, hypothalamus, and hippocampus etc. regions).
[0004] In peripheral tissues, A 2A receptors are found in platelets, neutrophils, vascular smooth muscle and endothelium. The striatum is the main brain region for the regulation of motor activity, particularly through its innervation from dopaminergic neurons originating in the substantial nigra. The striatum is the major target of the dopaminergic neuron degeneration in patients with Parkinson's Disease (PD). Within the striatum, A 2A receptors are co-localized with dopamine D2 receptors, suggesting an important site for the integration of adenosine and dopamine signaling in the brain.
[0005] Adenosine A 2A receptor blockers may provide a new class of antiparkinsonian agents (Impagnatiello, F.; Bastia, E.; Ongini, E.; Monopoli, A. Emerging Therapeutic Targets, 2000, 4, 635).
[0006] Antagonists of the A 2A receptor are potentially useful therapies for the treatment of addiction. Major drugs of abuse (opiates, cocaine, ethanol, and the like) either directly or indirectly modulate dopamine signaling in neurons particularly those found in the nucleus accumbens, which contain high levels of A 2A adenosine receptors. Dependence has been shown to be augmented by the adenosine signaling pathway, and it has been shown that administration of an A 2A receptor antagonist redues the craving for addictive substances (“The Critical Role of Adenosine A 2A Receptors and Gi βγ Subunits in Alcoholism and Addiction: From Cell Biology to Behavior”, by Ivan Diamond and Lina Yao, (The Cell Biology of Addiction, 2006, pp 291-316) and “Adaptations in Adenosine Signaling in Drug Dependence: Therapeutic Implications”, by Stephen P. Hack and Macdonald J. Christie, Critical Review in Neurobiology, Vol. 15, 235-274 (2003)). See also Alcoholism: Clinical and Experimental Research (2007), 31(8), 1302-1307.
[0007] A selective A 2A antagonist could be used to treat migraine both acutely and prophylactically. Selective adenosine antagonists have shown activity in both acute and prophylactic animal models for migraine (“Effects of K-056, a novel selective adenosine A 2A antagonist in animal models of migraine,” by Kurokawa M. et. al., Abstract from Neuroscience 2009).
[0008] An A 2A receptor antagonist could be used to treat attention deficit hyperactivity disorder (ADHD) since caffeine (a non selective adenosine antagonist) can be useful for treating ADHD, and there are many interactions between dopamine and adenosine neurons. Clinical Genetics (2000), 58(1), 31-40 and references therein. Antagonists of the A 2A receptor are potentially useful therapies for the treatment of depression. A 2A antagonists are known to induce activity in various models of depression including the forced swim and tail suspension tests. The positive response is mediated by dopaminergic transmission and is caused by a prolongation of escape-directed behavior rather than by a motor stimulant effect. Neurology (2003), 61(suppl 6) S82-S87.
[0009] Antagonists of the A 2A receptor are potentially useful therapies for the treatment of anxiety. A 2A antagonist have been shown to prevent emotional/anxious responses in vivo. Neurobiology of Disease (2007), 28(2) 197-205.
[0010] A 2A antagonists have been described in U.S. Pat. No. 7,468,373 B2, US 2009/0054429 A1, and references therein.
SUMMARY OF THE INVENTION
[0011] Selected heterocyclyl substituted arylindenopyrimidines of Formula A display unusually high selectivity for A 2A over A1 receptor antagonism.
[0000]
[0000] wherein:
X is C═O;
[0012] R 2 is phenyl;
R 4 is NH 2 ; and
[0013] R 3 is heteroaryl;
said arylindenopyrimidines of Formula A are selected form the group consisting of:
[0000]
[0000] and solvates, hydrates, tautomers, and pharmaceutically acceptable salts thereof;
DETAILED DESCRIPTION OF THE INVENTION
[0014] The genus of compounds disclosed in US 2009/0054429 A1 have mixed A 2A and A1 receptor antagonism activity. For many disorders for which A 2A receptor antagonism is therapeutically useful, the A1 receptor activity is unwanted and may contribute to side effects or even oppose the beneficial effect of the compound primary A 2A activity. This invention provides a small group of compounds covered by the genus described in the parent case but that have been found to have surprising and unexpected selectivity for the A 2A receptor. The selected group of compounds of the present invention have A 2A /A1 activity ratios of at least 50/1, whereas the average member of the genus has an A 2A /A1 activity ratio of 1/1. Thus, compounds of the present invention are expected to have much greater therapeutic efficacy and/or fewer side effects.
[0015] The invention provides compounds of Formula A.
[0000]
[0000] wherein:
X is C═O;
[0016] R 2 is phenyl;
R 4 is NH 2 ; and
[0017] R 3 is heteroaryl;
said compounds of Formula A are selected form the group consisting of:
[0000]
[0000] and solvates, hydrates, tautomers, and pharmaceutically acceptable salts thereof;
[0018] This invention further provides a method of treating a subject having a disorder ameliorated by antagonizing Adenosine A 2A receptors, which comprises administering to the subject a therapeutically effective dose of a compound of claim 1 .
[0019] This invention further provides a method of preventing a disorder ameliorated by antagonizing Adenosine A 2A receptors in a subject, comprising of administering to the subject a prophylactically effective dose of a compound of claim 1 either preceding or subsequent to an event anticipated to cause a disorder ameliorated by antagonizing Adenosine A 2A receptors in the subject.
[0020] The instant compounds can be isolated and used as free bases. They can also be isolated and used as pharmaceutically acceptable salts.
[0021] Examples of such salts include hydrobromic, hydroiodic, hydrochloric, perchloric, sulfuric, maleic, fumaric, malic, tartaric, citric, adipic, benzoic, mandelic, methanesulfonic, hydroethanesulfonic, benzenesulfonic, oxalic, palmoic, 2 naphthalenesulfonic, p-toluenesulfonic, cyclohexanesulfamic and saccharic.
[0022] This invention also provides a pharmaceutical composition comprising a compound of Claim 1 and a pharmaceutically acceptable carrier.
[0023] Pharmaceutically acceptable carriers are well known to those skilled in the art and include, but are not limited to, from about 0.01 to about 0.1 M and preferably 0.05 M phosphate buyer or 0.8% saline. Such pharmaceutically acceptable carriers can be aqueous or non-aqueous solutions, suspensions and emulsions. Examples of non-aqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and injectable organic esters such as ethyl oleate. Aqueous carriers include water, ethanol, alcoholic/aqueous solutions, glycerol, emulsions or suspensions, including saline and buffered media. Oral carriers can be elixirs, syrups, capsules, tablets and the like. The typical solid carrier is an inert substance such as lactose, starch, glucose, methyl-cellulose, magnesium stearate, dicalcium phosphate, mannitol and the like. Parenteral carriers include sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride, lactated Ringer's and fixed oils. Intravenous carriers include fluid and nutrient replenishers, electrolyte replenishers such as those based on Ringer's dextrose and the like.
[0024] Preservatives and other additives can also be present, such as, for example, antimicrobials, antioxidants, chelating agents, inert gases and the like. All carriers can be mixed as needed with disintegrants, diluents, granulating agents, lubricants, binders and the like using conventional techniques known in the art.
[0025] This invention further provides a method of treating a subject having a condition ameliorated by antagonizing Adenosine A 2A receptors, which comprises administering to the subject a therapeutically effective dose of a compound of Claim 1 .
[0026] In one embodiment, the disorder is a neurodegenerative or movement disorder. Examples of disorders treatable by the instant pharmaceutical composition include, without limitation, Parkinson's Disease, Huntington's Disease, Multiple System Atrophy, Corticobasal Degeneration, Alzheimer's Disease, and Senile Dementia.
[0027] In one preferred embodiment, the disorder is Parkinson's disease.
[0028] As used herein, the term “subject” includes, without limitation, any animal or artificially modified animal having a disorder ameliorated by antagonizing adenosine A 2A receptors. In a preferred embodiment, the subject is a human.
[0029] Administering a compound of claim 1 can be effected or performed using any of the various methods known to those skilled in the art. The compounds of claim 1 can be administered, for example, intravenously, intramuscularly, orally and subcutaneously.
[0030] In the preferred embodiment, compounds of claim 1 are administered orally. Additionally, administration can comprise giving the subject a plurality of dosages over a suitable period of time. Such administration regimens can be determined according to routine methods.
[0031] As used herein, a “therapeutically effective dose” of a pharmaceutical composition is an amount sufficient to stop, reverse or reduce the progression of a disorder. A “prophylactically effective dose” of a pharmaceutical composition is an amount sufficient to prevent a disorder, i.e., eliminate, ameliorate and/or delay the disorder's onset. Methods are known in the art for determining therapeutically and prophylactically effective doses for compounds of Claim 1 . The effective dose for administering the pharmaceutical composition to a human, for example, can be determined mathematically from the results of animal studies.
[0032] In one embodiment, the therapeutically and/or prophylactically effective dose is a dose sufficient to deliver from about 0.001 mg/kg of body weight to about 200 mg/kg of body weight of a compound of Claim 1 . In another embodiment, the therapeutically and/or prophylactically effective dose is a dose sufficient to deliver from about 0.05 mg/kg of body weight to about 50 mg/kg of body weight. More specifically, in one embodiment, oral doses range from about 0.05 mg/kg to about 100 mg/kg daily. In another embodiment, oral doses range from about 0.05 mg/kg to about 50 mg/kg daily, and in a further embodiment, from about 0.05 mg/kg to about 20 mg/kg daily. In yet another embodiment, infusion doses range from about 1.0 μg/kg/min to about 10 mg/kg/min of inhibitor, admixed with a pharmaceutical carrier over a period ranging from about several minutes to about several days. In a further embodiment, for topical administration, the instant compound can be combined with a pharmaceutical carrier at a drug/carrier ratio of from about 0.001 to about 0.1.
[0033] The invention also provides a method of treating addiction in a mammal, comprising administering a therapeutically effective dose of a compound of Claim 1 .
[0034] The invention also provides a method of treating ADHD in a mammal, comprising administering a therapeutically effective dose of a compound of Claim 1 .
[0035] The invention also provides a method of treating depression in a mammal, comprising administering a therapeutically effective dose of a compound of Claim 1 .
[0036] The invention also provides a method of treating anxiety in a mammal, comprising administering a therapeutically effective dose of a compound of Claim 1 .
[0037] The invention also provides a method of treating migraine in a mammal, comprising administering a therapeutically effective dose of a compound of Claim 1 .
DEFINITIONS AND NOMENCLATURE
[0038] Unless otherwise noted, under standard nomenclature used throughout this disclosure the terminal portion of the designated side chain is described first, followed by the adjacent functionality toward the point of attachment.
[0039] As used herein, the following chemical terms shall have the meanings as set forth in the following paragraphs: “independently”, when in reference to chemical substituents, shall mean that when more than one substituent exists, the substituents may be the same or different.
[0040] “Alkyl” shall mean straight, cyclic and branched-chain alkyl. Unless otherwise stated, the alkyl group will contain 1-20 carbon atoms. Unless otherwise stated, the alkyl group may be optionally substituted with one or more groups such as halogen, OH, CN, mercapto, nitro, amino, C 1 -C 8 -alkyl, C 1 -C 8 -alkoxyl, C 1 -C 8 -alkylthio, C 1 -C 8 -alkyl-amino, di(C 1 -C 8 -alkyl)amino, (mono-, di-, tri-, and per-) halo-alkyl, formyl, carboxy, alkoxycarbonyl, C 1 -C 8 -alkyl-CO—O—, C 1 -C 8 -alkyl-CO—NH—, carboxamide, hydroxamic acid, sulfonamide, sulfonyl, thiol, aryl, aryl(C 1 -C 8 )alkyl, heterocyclyl, and heteroaryl.
[0041] “Alkoxy” shall mean —O-alkyl and unless otherwise stated, it will have 1-8 carbon atoms.
[0042] “Halogen” shall mean fluorine, chlorine, bromine or iodine; “PH” or “Ph” shall mean phenyl; “Ac” shall mean acyl; “Bn” shall mean benzyl.
[0043] The term “acyl” as used herein, whether used alone or as part of a substituent group, means an organic radical having 2 to 6 carbon atoms (branched or straight chain) derived from an organic acid by removal of the hydroxyl group. The term “Ac” as used herein, whether used alone or as part of a substituent group, means acetyl.
[0044] “Aryl” or “Ar,” whether used alone or as part of a substituent group, is a carbocyclic aromatic radical including, but not limited to, phenyl, 1- or 2-naphthyl and the like. The carbocyclic aromatic radical may be substituted by independent replacement of 1 to 5 of the hydrogen atoms thereon with halogen, OH, CN, mercapto, nitro, amino, C 1 -C 8 -alkyl, C 1 -C 8 -alkoxyl, C 1 -C 8 -alkylthio, C 1 -C 8 -alkyl-amino, di(C 1 -C 8 -alkyl)amino, (mono-, di-, tri-, and per-) halo-alkyl, formyl, carboxy, alkoxycarbonyl, C 1 -C 8 -alkyl-CO—O—, C 1 -C 8 -alkyl-CO—NH—, or carboxamide. Illustrative aryl radicals include, for example, phenyl, naphthyl, biphenyl, fluorophenyl, difluorophenyl, benzyl, benzoyloxyphenyl, carboethoxyphenyl, acetylphenyl, ethoxyphenyl, phenoxyphenyl, hydroxyphenyl, carboxyphenyl, trifluoromethylphenyl, methoxyethylphenyl, acetamidophenyl, tolyl, xylyl, dimethylcarbamylphenyl and the like. “Ph” or “PH” denotes phenyl.
[0045] Whether used alone or as part of a substituent group, “heteroaryl” refers to a cyclic, fully unsaturated radical having from five to ten ring atoms of which one ring atom is selected from S, O, and N; 0-2 ring atoms are additional heteroatoms independently selected from S, O, and N; and the remaining ring atoms are carbon. The radical may be joined to the rest of the molecule via any of the ring atoms. Exemplary heteroaryl groups include, for example, pyridinyl, pyrazinyl, pyrimidinyl, pyridazinyl, pyrroyl, pyrazolyl, imidazolyl, thiazolyl, oxazolyl, isoxazolyl, thiadiazolyl, triazolyl, triazinyl, oxadiazolyl, thienyl, furanyl, quinolinyl, isoquinolinyl, indolyl, isothiazolyl, 2-oxazepinyl, azepinyl, N-oxo-pyridyl, 1-dioxothienyl, benzothiazolyl, benzoxazolyl, benzothienyl, quinolinyl-N-oxide, benzimidazolyl, benzopyranyl, benzisothiazolyl, benzisoxazolyl, benzodiazinyl, benzofurazanyl, benzothiopyranyl, indazolyl, indolizinyl, benzofuryl, chromonyl, coumarinyl, cinnolinyl, quinoxalinyl, indazolyl, pyrrolopyridinyl, furopyridinyl (such as furo[2,3-c]pyridinyl, furo[3,2-b]pyridinyl, or furo[2,3-b]pyridinyl), imidazopyridinyl (such as imidazo[4,5-b]pyridinyl or imidazo[4,5-c]pyridinyl), naphthyridinyl, phthalazinyl, purinyl, pyridopyridyl, quinazolinyl, thienofuryl, thienopyridyl, thienothienyl, and furyl. The heteroaryl group may be substituted by independent replacement of 1 to 5 of the hydrogen atoms thereon with halogen, OH, CN, mercapto, nitro, amino, C 1 -C 8 -alkyl, C 1 -C 8 -alkoxyl, C 1 -C 8 -alkylthio, C 1 -C 8 -alkyl-amino, di(C 1 -C 8 -alkyl)amino, (mono-, di-, tri-, and per-) halo-alkyl, formyl, carboxy, alkoxycarbonyl, C 1 -C 8 -alkyl-CO—O—, C 1 -C 8 -alkyl-CO—NH—, or carboxamide. Heteroaryl may be substituted with a mono-oxo to give for example a 4-oxo-1H-quinoline.
[0046] The terms “heterocycle,” “heterocyclic,” and “heterocyclo” refer to an optionally substituted, fully or partially saturated cyclic group which is, for example, a 4- to 7-membered monocyclic, 7- to 1′-membered bicyclic, or 10- to 15-membered tricyclic ring system, which has at least one heteroatom in at least one carbon atom containing ring. Each ring of the heterocyclic group containing a heteroatom may have 1, 2, or 3 heteroatoms selected from nitrogen atoms, oxygen atoms, and sulfur atoms, where the nitrogen and sulfur heteroatoms may also optionally be oxidized. The nitrogen atoms may optionally be quaternized. The heterocyclic group may be attached at any heteroatom or carbon atom.
[0047] Exemplary monocyclic heterocyclic groups include pyrrolidinyl; oxetanyl; pyrazolinyl; imidazolinyl; imidazolidinyl; oxazolyl; oxazolidinyl; isoxazolinyl; thiazolidinyl; isothiazolidinyl; tetrahydrofuryl; piperidinyl; piperazinyl; 2-oxopiperazinyl; 2-oxopiperidinyl; 2-oxopyrrolidinyl; 4-piperidonyl; tetrahydropyranyl; tetrahydrothiopyranyl; tetrahydrothiopyranyl sulfone; morpholinyl; thiomorpholinyl; thiomorpholinyl sulfoxide; thiomorpholinyl sulfone; 1,3-dioxolane; dioxanyl; thietanyl; thiiranyl; and the like. Exemplary bicyclic heterocyclic groups include quinuclidinyl; tetrahydroisoquinolinyl; dihydroisoindolyl; dihydroquinazolinyl (such as 3,4-dihydro-4-oxo-quinazolinyl); dihydrobenzofuryl; dihydrobenzothienyl; dihydrobenzothiopyranyl; dihydrobenzothiopyranyl sulfone; dihydrobenzopyranyl; indolinyl; isochromanyl; isoindolinyl; piperonyl; tetrahydroquinolinyl; and the like.
[0048] Substituted aryl, substituted heteroaryl, and substituted heterocycle may also be substituted with a second substituted-aryl, a second substituted-heteroaryl, or a second substituted-heterocycle to give, for example, a 4-pyrazol-1-yl-phenyl or 4-pyridin-2-yl-phenyl.
[0049] Designated numbers of carbon atoms (e.g., C 1-8 ) shall refer independently to the number of carbon atoms in an alkyl or cycloalkyl moiety or to the alkyl portion of a larger substituent in which alkyl appears as its prefix root.
EXAMPLES
[0050] Compounds of Formula A can be prepared by methods known to those who are skilled in the art. The following reaction scheme is only meant to represent an example of the invention and is in no way meant to limit the invention.
[0000]
[0051] Scheme 1 illustrates the synthetic route leading to compound A. Starting with 7-methoxy indanone I and following the path indicated by the arrows, condensation under basic conditions with arylaldehydes affords the benzylidene II. The benzylidene II is then reacted with guanidine (free base) that gives the intermediate amino pyrimidine III and is directly oxidized to the corresponding ketone IV by bubbling air through the basic N-methylpyrrolidinone (NMP) solution. Demethylation can be accomplished by heating IV in NMP in the presence of LiCl to give the corresponding phenol V. The phenol V can be converted to corresponding triflate VI by treatment with N-phenyltriflimide under basic conditions in dimethylformamide (DMF). Finally, the triflate VI is reacted with boronic esters of formula R 2 B(OR) 2 to afford compounds of Formula A.
[0000]
[0052] Scheme 2 illustrates the synthetic route leading to compounds of Formula A, where R 3 is alkylpiperidinyl substituted heteroaryl. Starting from piperazine I, prepared according to scheme 1, is alkylated with alkyl halides in N-methylpyrrolidinone (NMP) to afford compounds of Formula A.
[0000]
[0053] Scheme 3 illustrates an alternative synthetic route leading to compounds of Formula A, where R 3 is piperidinyl substituted heteroaryl, and said piperidinyl is further substituted. Starting from I, prepared according to scheme 1, is heated in the microwave with excess piperazines in NMP to give compounds of Formula A.
Example 1
2-Amino-9-(4-methyl-2-phenyl-thiazol-5-yl)-4-phenyl-indeno[1,2-d]pyrimidin-5-one
Example 1
Step a
7-4-Methoxy-benzyloxy)-indan-1-one
[0054]
[0055] Neat 1-bromomethyl-4-methoxy-benzene (12.3 mL, 84.6 mmol) was added to an acetone slurry (300 mL) of 7-hydroxy-indan-1-one (11.9 g, 80.5 mmol) and K 2 CO 3 (22.3 g, 161.0 mmol) and the resulting mixture was heated to reflux. After 6 h (hours) the mixture was cooled, filtered, and washed with acetone. The filtrate was concentrated in vacuo to afford the title compound that was used without further purification.
Example 1
Step b
2-Benzylidene-7-(4-methoxy-benzyloxy)-indan-1-one
[0056]
[0057] An aqueous solution (10 mL) of NaOH (3.1 g, 77.2 mmol) was added dropwise to an ethanol (EtOH) solution (400 mL) of 7-4-methoxy-benzyloxy)-indan-1-one (5.0 g, 30.8 mmol) and benzaldehyde (8.2 mL, 81.1 mmol). A precipitate formed immediately. The resulting slurry was stirred vigorously for 1.5 h. The slurry was cooled in an ice bath, filtered, and washed with cold EtOH. The collected solid was dried in vacuo to give the title compound that was used without further purification.
Example 1
Step c
9-(4-Methoxy-benzyloxy)-4-phenyl-5H-indeno [1,2-d]pyrimidin-2-ylamine
[0058]
[0059] Powdered NaOH (15.4 g, 386.0 mmol) was added to an EtOH solution (300 mL) of guanidine hydrochloride (36.9 g, 386.0 mmol). After 30 min the sodium chloride was filtered off and the filtrate was added to an EtOH suspension (200 mL) of 2-benzylidene-7-(4-methoxy-benzyloxy)-indan-1-one (27.4 g, 77.2 mmol). The resulting mixture was heated to reflux overnight. The homogeneous solution was cooled in ice for 30 minutes and filtered to give the title compound which was used without further purification.
Example 1
Step d
2-Amino-9-(4-methoxy-benzyloxy)-4-phenyl-indeno[1,2-d]pyrimidin-5-one
[0060]
[0061] Powdered NaOH (860 mg, 21.5 mmol) was added to a NMP solution (20 mL) of 9-(4-methoxy-benzyloxy)-4-phenyl-5H-indeno[1,2-d]pyrimidin-2-ylamine (8.5 g, 21.5 mmol). The resulting mixture was heated to 80° C. and air was bubbled through the solution. After 16 h the mixture was cooled to rt (room temperature), water was added and the resulting precipitate was filtered and washed with water and cold EtOH. The solid was dried in vacuo to give the title compound.
Example 1
Step e
2-Amino-9-hydroxy-4-phenyl-indeno [1,2-d]pyrimidin-5-one
[0062]
[0063] Neat trifluoroacetic acid (TFA) (37 mL) was added to a CH 2 Cl 2 solution (50 mL) of 2-amino-9-(4-methoxy-benzyloxy)-4-phenyl-indeno[1,2-d]pyrimidin-5-one (6.8 g, 16.6 mmol). After 2 h the mixture was concentrated in vacuo. The resulting material was suspended in water and saturated aqueous NaHCO 3 was added. The resulting precipitate was filtered off and dried in vacuo to give the title compound.
Example 1
Step f
[0064] Trifluoro-methanesulfonic acid 2-amino-5-oxo-4-phenyl-5H-indeno[1,2-d]pyrimidin-9-yl ester
[0000]
[0065] Solid t-BuOK (potassium tert-butoxide, 965 mg, 8.6 mmol) was added to a DMF solution (30 mL) of 2-amino-9-hydroxy-4-phenyl-indeno[1,2-d]pyrimidin-5-one (2.1 g, 7.2 mmol). After 20 min, solid PhN(Tf) 2 (phenyl bis(trifluoromethane)sulfonamide, 2.7 g, 7.6 mmol) was added. After 4 h water was added and the resulting precipitate was filtered off and washed with water. The solid was dissolved in THF and dry packed onto silica gel. Column chromatography gave the title compound.
Example 1
Step g
2-Amino-9-(4-methyl-2-phenyl-thiazol-5-yl)-4-phenyl-indeno [1,2-d]pyrimidin-5-one
[0066]
[0067] A solution of trifluoro-methanesulfonic acid 2-amino-5-oxo-4-phenyl-5H-indeno[1,2-d]pyrimidin-9-yl ester (150 mg, 0.36 mmol), 4-methyl-2-phenyl-5-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-thiazole (162 mg, 0.54 mmol), (PPh 3 ) 4 Pd (tetrakis(triphenylphosphine)palladium(0), 20 mg, 0.02 mmol), and K 2 CO 3 (99 mg, 0.72 mmol) in dioxane (1 mL) and toluene (1 mL) was heated to 180° C. by microwave irradiation. After 40 min the mixture was cooled to rt, and purified via column chromatography to give the coupled product. This material was then JNJ-40803932 dissolved in THF and added to 1 mL of 1 N HCl in ether, concentrated, and dried in vacuo to give the title compound JNJ-40803932 as the HCl salt. 1 H NMR (DMSO-d 6 ,400 MHz): δ=7.86-8.14 (m, 5H), 7.65-7.83 (m, 4H), 7.40-7.65 (m, 6 H), 2.33 ppm (s, 3H) MS m/e 447 (M+H).
Example 2
2-Amino-4-(4-fluoro-phenyl)-9-[1-(2-morpholin-4-yl-ethyl)-1H-pyrazol-4-yl]-indeno[1,2-d]pyrimidin-5-one
Example 2
Step a
Trifluoro-methanesulfonic acid 2-amino-4-(4-fluoro-phenyl)-5-oxo-5H-indeno[1,2-d]pyrimidin-9-yl ester
[0068]
[0069] The title compound was prepared using 4-fluoro-benzaldehyde in place of benzaldehyde as described in Example 1.
Example 2
Step b
2-Amino-4-(4-fluoro-phenyl)-9-[1-(2-morpholin-4-yl-ethyl)-1H-pyrazol-4-yl]-indeno[1,2-d]pyrimidin-5-one
[0070]
[0071] The title compound was prepared using 4-{2-[4-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-pyrazol-1-yl]-ethyl}-morpholine and trifluoro-methanesulfonic acid 2-amino-4-(4-fluoro-phenyl)-5-oxo-5H-indeno[1,2-d]pyrimidin-9-yl ester in place of 4-methyl-2-phenyl-5-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-thiazole and trifluoro-methanesulfonic acid 2-amino-5-oxo-4-phenyl-5H-indeno[1,2-d]pyrimidin-9-yl ester, respectively, as described in Example 1. 1 H NMR (DMSO-d 6 ,300 MHz): δ=8.96 (s, 1H), 8.23 (s, 1H), 8.03 (br. s., 2H), 7.88 (s, 1H), 7.51-7.74 (m, 2H), 7.33 (t, J=8.6 Hz, 2H), 4.72-4.86 (m, 2H), 3.89-4.05 (m, 2 H), 3.64-3.82 (m, 4H), 3.41 (br. s., 2H), 3.17 ppm (br. s., 2H)
Example 3
2-Amino-4-(4-fluoro-phenyl)-9-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-yl]-indeno[1,2-d]pyrimidin-5-one
[0072]
[0073] The title compound was prepared using 4-methyl-5-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-2-(4-trifluoromethyl-phenyl)-thiazole in place of 4-{2-[4-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-pyrazol-1-yl]-ethyl}-morpholine as described in Example 2. 1 H NMR (DMSO-d 6 ,400 MHz): δ=8.16 (d, J=8.1 Hz, 2H), 8.00-8.09 (m, 2H), 7.86 (d, J=8.6 Hz, 2H), 7.64-7.78 (m, 3H), 7.29-7.40 (m, 2 H), 2.31 ppm (s, 3H); MS m/e 533 (M+H).
Example 4
5-(2-Amino-5-oxo-4-phenyl-5H-indeno[1,2-d]pyrimidin-9-yl)-thiophene-2-carbonitrile
[0074]
[0075] The title compound was prepared using 5-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-thiophene-2-carbonitrile in place of 4-methyl-2-phenyl-5-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-thiazole as described in Example 1. 1 H NMR (DMSO-d 6 , 400 MHz): δ=7.91-8.00 (m, 3H), 7.84 (d, J=4.2 Hz, 1H), 7.81 (dd, J=7.0, 2.1 Hz, 1H), 7.67-7.76 (m, 2H), 7.47-7.61 ppm (m, 3H); MS m/e 381 (M+H).
Example 5
2-Amino-4-(4-fluoro-phenyl)-9-(4-methyl-2-phenyl-thiazol-5-yl)-indeno[1,2-d]pyrimidin-5-one
[0076]
[0077] The title compound was prepared using 4-methyl-2-phenyl-5-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-thiazole in place of 4-{2-[4-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-pyrazol-1-yl]-ethyl}-morpholine as described in Example 2. 1 H NMR (DMSO-d 6 ,400 MHz): δ=8.02-8.11 (m, 2H), 7.99 (dd, J=7.8, 1.7 Hz, 2H), 7.66-7.79 (m, 3H), 7.47-7.58 (m, 3H), 7.30-7.41 (m, 2H), 2.31 ppm (s, 3H); MS m/e 430 (M+H).
Example 6
{4-[2-Amino-4-(4-fluoro-phenyl)-5-oxo-5H-indeno[1,2-d]pyrimidin-9-yl]-pyrazol-1-yl}-acetic acid ethyl ester
[0078]
[0079] The title compound was prepared using [4-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-pyrazol-1-yl]-acetic acid ethyl ester in place of 4-{2-[4-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-pyrazol-1-yl]-ethyl}-morpholine as described in Example 2. 1 H NMR (DMSO-d 6 ,400 MHz): δ=9.06 (s, 1H), 8.17 (s, 1H), 8.00-8.10 (m, 2H), 7.94 (d, J=7.8 Hz, 1H), 7.51-7.66 (m, 2H), 7.28-7.38 (m, 2H), 5.26 (s, 2H), 4.19 (q, J=7.1 Hz, 2H), 1.15-1.32 ppm (m, 3H); MS m/e 444 (M+H).
Example 7
2-Amino-9-(5-methyl-1-phenyl-1H-pyrazol-4-yl)-4-phenyl-indeno [1,2-d]pyrimidin-5-one
[0080]
[0081] The title compound was prepared using 5-methyl-1-phenyl-4-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-1H-pyrazole in place of 4-methyl-2-phenyl-5-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-thiazole as described in Example 1. 1 H NMR (DMSO-d 6 ,400 MHz): δ=7.89-8.00 (m, 2H), 7.64-7.76 (m, 3H), 7.40-7.64 (m, 8H), 7.32-7.38 (m, 1H), 7.25-7.30 (m, 1H), 2.18-2.27 ppm (m, 3H); MS m/e 430 (M+H).
Example 8
2-Amino-9-[6-(4-benzyl-piperazin-1-yl)-pyridin-3-yl]-4-phenyl-indeno [1,2-d]pyrimidin-5-one
Example 8
Step a
2-Amino-9-(6-fluoro-pyridin-3-yl)-4-phenyl-indeno [1,2-d]pyrimidin-5-one
[0082]
[0083] Solid Pd(dppf)Cl 2 (dichloro[1,1′-ferrocenylbis(diphenyl-phosphine)]palladium(II), 47 mg, 0.06 mmol) was added to a dioxane/water solution (4 mL/1 mL) of 2-fluoro-5-pyridylboronic acid (105 mg, 0.75 mmol), trifluoro-methanesulfonic acid 2-amino-4-(4-fluoro-phenyl)-5-oxo-5H-indeno[1,2-d]pyrimidin-9-yl ester (250 mg, 0.57 mmol), and K 2 CO 3 (158 mg, 1.14 mmol) and the mixture was heated to 85° C. After 5 h the mixture was cooled, diluted with water and the resulting precipitate was filtered. The collected solid was dissolved in THF and MeOH then dry packed onto silica gel. Column chromatography gave the title compound.
Example 8
Step b
2-Amino-9-[6-(4-benzyl-piperazin-1-yl)-pyridin-3-yl]-4-phenyl-indeno [1,2-d]pyrimidin-5-one
[0084]
[0085] Neat 1-benzyl-piperazine (43 μL, 0.04 mmol) was added to an NMP solution (0.3 mL) of 2-amino-9-(6-fluoro-pyridin-3-yl)-4-phenyl-indeno[1,2-d]pyrimidin-5-one (30 mg, 0.08 mmol) and the mixture was heated to 150° C. in the microwave. After 30 minutes the mixture was diluted with THF and EtOAc, washed with water and brine, dried (Na 2 SO 4 ) and dry packed onto silica gel. Chromatography gave the title compound. 1 H NMR (CHLOROFORM-d, 300 MHz): δ=8.46 (d, J=2.6 Hz, 1H), 8.01 (dd, J=7.5, 2.3 Hz, 2H), 7.78 (dd, J=8.9, 2.4 Hz, 1H), 7.71 (d, J=6.0 Hz, 1H), 7.44-7.60 (m, 5H), 7.28-7.41 (m, 5H), 6.72 (d, J=9.0 Hz, 1H), 5.53 (br. s., 2H), 3.62-3.71 (m, 4H), 3.59 (s, 2H), 2.54-2.66 ppm (m, 4H); MS m/e 525 (M+H).
Example 9
2-Amino-9-[6-(4-cyclopropylmethyl-piperazin-1-yl)-pyridin-3-yl]-4-(4-fluoro-phenyl)-indeno[1,2-d]pyrimidin-5-one
Example 9
Step a
2-Amino-4-(4-fluoro-phenyl)-9-(6-piperazin-1-yl-pyridin-3-yl)-indeno[1,2-d]pyrimidin-5-one
[0086]
[0087] The title compound was prepared using 1-[5-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-pyridin-2-yl]-piperazine in place of 2-fluoro-5-pyridylboronic acid, as described in Example 8: step a.
Example 9
Step b
2-Amino-9-[6-(4-cyclopropylmethyl-piperazin-1-yl)-pyridin-3-yl]-4-(4-fluoro-phenyl)-indeno [1,2-d]pyrimidin-5-one
[0088]
[0089] Neat bromomethyl-cyclopropane (22 μL, 0.22 mmol) was added to an NMP solution (1 mL) of 2-amino-4-(4-fluoro-phenyl)-9-(6-piperazin-1-yl-pyridin-3-yl)-indeno[1,2-d]pyrimidin-5-one (100 mg, 0.22 mmol) and i-Pr 2 NEt (77 μL, 0.44 mmol) and the mixture was heated to 70° C. After 16 h the mixture was cooled, diluted with water and the resulting precipitate was filtered. The collected solid was dissolved in THF and dry packed onto silica gel. Column chromatography gave the title compound. 1 H NMR (CHLOROFORM-d, 300 MHz): δ=8.47 (d, J=2.6 Hz, 1H), 8.05-8.15 (m, 2 H), 7.78 (dd, J=8.7, 2.3 Hz, 1H), 7.72 (d, J=6.4 Hz, 1H), 7.56 (t, J=7.3 Hz, 1H), 7.43-7.50 (m, 1H), 7.12-7.23 (m, 2H), 6.74 (d, J=9.0 Hz, 1H), 5.55 (br. s., 2H), 3.62-3.75 (m, 4H), 2.69 (t, J=4.9 Hz, 4H), 2.34 (d, J=6.8 Hz, 2H), 0.87-1.01 (m, 1 H), 0.50-0.62 (m, 2H), 0.11-0.21 ppm (m, 2H); MS m/e 507 (M+H).
Example 10
2-Amino-9-[5-methyl-6-(4-methyl-piperazin-1-yl)-pyridin-3-yl]-4-phenyl-indeno [1,2-d]pyrimidin-5-one
Example 10
Step a
2-Amino-9-(6-fluoro-5-methyl-pyridin-3-yl)-4-phenyl-indeno [1,2-d]pyrimidin-5-one
[0090]
[0091] The title compound was prepared using 2-fluoro-3-methylpyridine-5-boronic acid in place of 2-fluoro-5-pyridylboronic acid, as described in Example 8.
Example 10
Step b
2-Amino-9-[5-methyl-6-(4-methyl-piperazin-1-yl)-pyridin-3-yl]-4-phenyl-indeno [1,2-d]pyrimidin-5-one
[0092]
[0093] The title compound was prepared using 1-methyl-piperazine and 2-amino-9-(6-fluoro-5-methyl-pyridin-3-yl)-4-phenyl-indeno[1,2-d]pyrimidin-5-one in place of 1-benzyl-piperazine and 2-amino-9-(6-fluoro-pyridin-3-yl)-4-phenyl-indeno[1,2-d]pyrimidin-5-one, respectively, as described in Example 8. 1 H NMR (CHLOROFORM-d, 300 MHz): δ=8.45 (d, J=2.3 Hz, 1H), 8.01 (dd, J=7.7, 2.1 Hz, 2H), 7.74 (d, J=6.0 Hz, 1H), 7.68 (d, J=1.9 Hz, 1H), 7.42-7.61 (m, 5H), 5.59 (br. s., 2H), 3.25-3.36 (m, 4H), 2.63 (br. s., 4H), 2.39 (s, 3H), 2.37 ppm (s, 3H); MS m/e 463 (M+H).
Example 11
2-Amino-4-(4-fluoro-phenyl)-9-{6-[4-(3-methyl-butyl)-piperazin-1-yl]-pyridin-3-yl}-indeno[1,2-d]pyrimidin-5-one
[0094]
[0095] The title compound was prepared using 4-fluoro-benzaldehyde in place of benzaldehyde as described in Example 1, and also using 1-[5-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-pyridin-2-yl]-piperazine in place of 2-fluoro-5-pyridylboronic acid, as described in Example 8, and finally using 1-iodo-3-methyl-butane in place of bromomethyl-cyclopropane, as described in Example 9. 1 H NMR (CHLOROFORM-d, 300 MHz): δ=8.47 (d, J=2.3 Hz, 1H), 8.02-8.15 (m, 2H), 7.77 (dd, J=8.9, 2.4 Hz, 1H), 7.71 (d, J=7.2 Hz, 1H), 7.56 (t, J=7.3 Hz, 1H), 7.43-7.50 (m, 1H), 7.09-7.22 (m, 2H), 6.73 (d, J=8.7 Hz, 1H), 5.56 (s, 2H), 3.62-3.72 (m, 4H), 2.55-2.65 (m, 4H), 2.37-2.47 (m, 2H), 1.63 (dt, J=13.2, 6.6 Hz, 1H), 1.39-1.51 (m, 2H), 0.93 ppm (d, J=6.8 Hz, 6H); MS m/e 523 (M+H).
Biological Assays and Activity
Ligand Binding Assay for Adenosine A 2A Receptor
[0096] Ligand binding assay of adenosine A 2A receptor was performed using plasma membrane of HEK293 cells containing human A 2A adenosine receptor (PerkinElmer, RB-HA 2A ) and radioligand [ 3 H]CGS21680 (PerkinElmer, NET1021). Assay was set up in 96-well polypropylene plate in total volume of 200 μL by sequentially adding 20 μL1:20 diluted membrane, 130 μL assay buffer (50 mM Tris.HCl, pH7.4 10 mM MgCl 2 , 1 mM EDTA) containing [ 3 H] CGS21680, 50 μL diluted compound (4×) or vehicle control in assay buffer. Nonspecific binding was determined by 80 mM NECA. Reaction was carried out at room temperature for 2 hours before filtering through 96-well GF/C filter plate pre-soaked in 50 mM Tris.HC1, pH7.4 containing 0.3% polyethylenimine. Plates were then washed 5 times with cold 50 mM Tris.HC1, pH7.4, dried and sealed at the bottom. Microscintillation fluid 30 μL was added to each well and the top sealed. Plates were counted on Packard Topcount for [ 3 H]. Data was analyzed in Microsoft Excel and GraphPad Prism programs. (Varani, K.; Gessi, S.; Dalpiaz, A.; Borea, P. A. British Journal of Pharmacology, 1996, 117, 1693)
Adenosine A 2A Receptor Functional Assay (A 2A GAL2)
[0097] To initiate the functional assay, cryopreserved CHO—K1 cells overexpressing the human adenosine A 2A receptor and containing a cAMP inducible beta-galactosidase reporter gene were thawed, centrifuged, DMSO containing media removed, and then seeded with fresh culture media into clear 384-well tissue culture treated plates (BD #353961) at a concentration of 10K cells/well. Prior to assay, these plates were cultured for two days at 37° C., 5% CO 2 , 90% Rh. On the day of the functional assay, culture media was removed and replaced with 45 μL assay medium (Hams/F-12 Modified (Mediatech #10-080CV) supplemented w/0.1% BSA). Test compounds were diluted and 11 point curves created at a 1000× concentration in 100% DMSO. Immediately after addition of assay media to the cell plates, 50 nL of the appropriate test compound antagonist or agonist control curves were added to cell plates using a Cartesian Hummingbird. Compound curves were allowed to incubate at room temperature on cell plates for approximately 15 minutes before addition of a 15 nM NECA (Sigma E2387) agonist challenge (5 μL volume). A control curve of NECA, a DMSO/Media control, and a single dose of Forskolin (Sigma F3917) were also included on each plate. After additions, cell plates were allowed to incubate at 37° C., 5% CO 2 , 90% Rh for 5.5-6 hours. After incubation, media were removed, and cell plates were washed 1×50 μL with DPBS w/o Ca & Mg (Mediatech 21-031-CV). Into dry wells, 20 μL of 1× Reporter Lysis Buffer (Promega E3971 (diluted in dH 2 O from 5× stock)) was added to each well and plates frozen at −20° C. overnight. For β-galactosidase enzyme colorimetric assay, plates were thawed out at room temperature and 20 μL 2× assay buffer (Promega) was added to each well. Color was allowed to develop at 37° C., 5% CO 2 , 90% Rh for 1-1.5 h or until reasonable signal appeared. The colorimetric reaction was stopped with the addition of 60 μL/well 1M sodium carbonate. Plates were counted at 405 nm on a SpectraMax Microplate Reader (Molecular Devices). Data was analyzed in Microsoft Excel and IC/EC50 curves were fit using a standardized macro.
Adenosine A1 Receptor Functional Assay (A1GAL2)
[0098] To initiate the functional assay, cryopreserved CHO—K1 cells overexpressing the human adenosine A1 receptor and containing a cAMP inducible beta-galactosidase reporter gene were thawed, centrifuged, DMSO containing media removed, and then seeded with fresh culture media into clear 384-well tissue culture treated plates (BD #353961) at a concentration of 10K cells/well. Prior to assay, these plates were cultured for two days at 37° C., 5% CO 2 , 90% Rh. On the day of the functional assay, culture media was removed and replaced with 45 μL assay medium (Hams/F-12 Modified (Mediatech # 10-080CV) supplemented w/0.1% BSA). Test compounds were diluted and 11 point curves created at a 1000× concentration in 100% DMSO. Immediately after addition of assay media to the cell plates, 50 mL of the appropriate test compound antagonist or agonist control curves were added to cell plates using a Cartesian Hummingbird. Compound curves were allowed to incubate at room temperature on cell plates for approximately 15 minutes before addition of a 4 nM r-PIA (Sigma P4532)/1 uM Forskolin (Sigma F3917) agonist challenge (5 μL volume). A control curve of r-PIA in 1 uM Forskolin, a DMSO/Media control, and a single dose of Forskolin were also included on each plate. After additions, cell plates were allowed to incubate at 37° C., 5% CO 2 , 90% Rh for 5.5-6 hours. After incubation, media was removed, and cell plates were washed 1×50 μL with DPBS w/o Ca & Mg (Mediatech 21-031-CV). Into dry wells, 20 μL of 1× Reporter Lysis Buffer (Promega E3971 (diluted in dH 2 O from 5× stock)) was added to each well and plates frozen at −20° C. overnight. For β-galactosidase enzyme colorimetric assay, plates were thawed out at room temperature and 20 μL 2× assay buffer (Promega) was added to each well. Color was allowed to develop at 37° C., 5% CO 2 , 90% Rh for 1-1.5 h or until reasonable signal appeared. The colorimetric reaction was stopped with the addition of 60 μL/well 1M sodium carbonate. Plates were counted at 405 nm on a SpectraMax Microplate Reader (Molecular Devices). Data was analyzed in Microsoft Excel and IC/EC50 curves were fit using a standardized macro.
A 2A Assay Data
[0099] Compound of Formula A displayed surprising and unexpected selectivity for A 2A over A1 receptor antagonism.
[0000]
Example
A 2A Gal2 (μM)
A1Gal2 (μM)
A1/A 2A
1
0.0071
7.5
1056.34
2
0.012653
2.02815
160.288
3
0.05
5.4
108
4
0.0013
0.12
92.3077
5
0.017
0.92
54.1176
6
0.0042
0.225476
53.6847
7
0.017
0.87
51.1765
8
0.0056
0.56
100
9
0.0079
0.58
73.4177
10
0.003
0.19
63.3333
11
0.018
1
55.5556
[0100] While the foregoing specification teaches the principles of the present invention, with examples provided for the purpose of illustration, it will be understood that the practice of the invention encompasses all of the usual variations, adaptations and/or modifications as come within the scope of the following Claims and their equivalents.
[0101] All publications disclosed in the above specification are hereby incorporated by reference in full.
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This invention relates to a novel arylindenopyrimidine, A, and its therapeutic and prophylactic uses. Disorders treated and/or prevented include Parkinson's Disease.
wherein X, R 2 , R 3 , and R 4 are as defined in the specification.
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FIELD OF THE INVENTION
The present invention relates to a circular knitting machine and to electronically controlled actuation devices for such machines.
BACKGROUND OF THE INVENTION
In particular, the present invention relates to a double cylinder type circular knitting machine.
In such knitting machines a double ended knitting needle is used which during knitting can be transferred between the upper and lower needle cylinder assemblies. Such machines are commonly used for knitting of hosiery and/or knitwear and during each knitting cycle the selected needles will undergo various motions such as knit, miss, tuck or transfer between cylinder assemblies. These motions are imparted to the needles by sliders which have butts running along tracks in upper and lower cam assemblies associated with the upper and lower cylinder assemblies respectively.
Actuators are provided which move cam elements such as for example bolt cams in the cam assemblies for altering the path of travel followed by the butts of the sliders and thereby alter the motion undergone by the needles controlled thereby. Normally these actuators are mechanically operated from a cam drum assembly which is driven by the main drive shaft of the knitting machine via a timing transmission which normally comprises a timing chain which is indexed by a pawl mechanism.
Since a separate cam wheel is required for each actuator a large number of cam wheels have to be provided. In addition a large number of rods, cables etc. for transmitting drive from the cam followers to the components to be actuated need to be provided also. Accordingly the conventional construction of providing cam wheel assemblies for operating cam element actuators has inherent disadvantages; for example flexibility of control is restrictive since to change sequences of operation requires time consuming modification to the timing chain and/or the cam wheels. In addition the provision of a large number of mechanical components around the upper and lower cylinder assemblies not only restricts access to the cylinders and associated cam assemblies but also imposes the need to continually lubricate and/or service the mechanical linkages.
An advantage of using a cam drum assembly for operating cam elements is that positive positional control under adequate power is provided for moving the cam element into and out of cam tracks in the cam assemblies. This is particularly so for cam elements which need to be accurately located a several distinct positions when being inserted into or retracted from a cam track. For instance in the cam assembly associated with the lower cylinder of a double cylinder circular knitting machine adapted for knitting half hose having a heel pouch it is necessary for a cam element to be positioned at 4 discrete positions, viz a fully retracted position whereat it does not co-operate with butts on any needle slider, a fully inserted position whereat it co-operates with butts on all needle sliders and two intermediate positions whereat it co-operates with butts of selected needle sliders having a predetermined butt height.
In view of this multi-stage positioning and power capability provided by actuators operated by a cam wheel assembly such assemblies have remained in common usage despite the disadvantages exemplified above.
SUMMARY OF THE INVENTION
A general aim of the present invention is to provide an electronically controlled actuator which possesses the advantage of providing multi-stage positioning with adequate power as associated with mechanically operated actuators and which overcomes or substantially reduces the disadvantages exemplified above. Accordingly, an actuator according to the present invention can be used as a direct substitution of a cam wheel driven actuator and thereby can be used to actuate cam elements without requiring modification of the cam assembly.
According to one aspect of the present invention there is provided a double cylinder knitting machine comprising a lower cylinder assembly mounted on a lower platform and an upper cylinder assembly mounted on an upper platform, the upper platform being movably mounted on the lower platform for movement between a lowered operative position whereat the upper and lower cylinder assemblies co-operate for knitting and a raised in-operative position whereat the upper and lower cylinder assemblies are separated.
According to another aspect of the present invention there is provided a cam actuator for selectively moving cam elements between distinct operative positions, the actuator including a series of adjacent pistons arranged along the axial line of displacement, stop means for limiting the axial stroke of each piston in the direction of extension, each piston co-operating with adjacent pistons such that displacement of a given piston in the extend direction causes the remaining piston or pistons in the series located between the cam element and the given piston to be displaced in the extend direction by the stroke length undergone by the given piston.
According to another aspect of the present invention there is provided a yarn feeder for a knitting machine, the feeder including a plurality of yarn guide fingers pivotally mounted to describe an arc of movement to move between a rest position, a feed position and a park/cross-over position, each yarn finger being deflected through said arc and positioned at one of said positions by means of a first piston acting on a pivoted lever on which the finger is mounted, the first piston being arranged to move the finger from one end of the arc of movement to the other, a two position stop means, preferably in the form of a second piston, acting on the lever to arrest movement of the lever caused by the first piston at an intermediate position along the arc and at said other end of the arc.
BRIEF DESCRIPTION OF THE DRAWINGS
Various aspects of the present invention are hereinafter described with reference to the accompanying drawings in which:
FIG. 1 is a schematic perspective view of a double cylinder circular knitting machine according to the present invention;
FIG. 2 is a view similar to FIG. 1 in which the upper cylinder assembly and associated components have been repositioned;
FIG. 3 is a part sectional view of the upper part of the machine, taken along line III--III in FIG. 1 with the majority of the upper cylinder assembly removed for clarity;
FIG. 4 is a perspective view of an electronically controlled actuator according to the present invention;
FIG. 5 is an axial section through the actuator shown in FIG. 4 which is diagrammatically illustrated mounted on a cam assembly;
FIGS. 5a to 5c are schematic part similar to FIG. 5 showing the actuator at different stages of actuation.
FIG. 6 is a perspective view partly broken away of an electronically controlled yarn feeder; and
FIGS. 7a to 7c are each a sectional view along line VI--VI in FIG. 6 showing actuation of pistons for attaining different positions of a yarn guide finger.
DESCRIPTION OF PREFERRED EMBODIMENT
A double cylinder knitting machine 10 according to the present invention is schematically illustrated in FIGS. 1, 2 and 3.
The knitting machine 10 includes an upper needle cylinder assembly 11 and a lower needle cylinder assembly 12 which are generally of conventional construction. The cylinder assemblies are of the type having stationary cam assemblies 23 which surround the associated needle cylinder. In FIG. 1, the upper needle cylinder is shown as 200 and the lower needle cylinder is shown as 220. A typical machine of this type is one manufactured by Bentley Group Limited and sold under the brand name Komet.
As seen in FIGS. 1 and 2, the upper cylinder assembly is mounted on a support platform 100. The support platform 100 is in turn supported on a base 120 of the machine by a pair of columns 110,111.
As seen more clearly in FIG. 3 the upper needle cylinder 200 is rotatably supported on the platform 100 via a bearing assembly 201. The cylinder 200 is provided with a gear 202 which meshes with a drive gear 203. The drive gear 203 is mounted on a drive shaft 204 which extends from the support platform 100 to the base 120. The drive shaft 204 has a toothed wheel 206 which is driven by a motor 210 via a toothed belt 207. The shaft 204 also has mounted thereon the drive gear 208 which drives a gear 209 mounted on the lower cylinder 220. The drive transmission between motor, upper and lower cylinders (which is shown only diagrammatically in FIG. 1) is synchronised such that the upper and lower cylinder are driven at the same speed and in the same direction at all times.
The drive motor 210 is preferably a brushless DC type motor whose speed and direction of rotation can be accurately electronically controlled.
A yarn feeder unit 300 is provided at each knitting station and each yarn feeder unit is mounted onto the platform 100 either directly as shown or, alternatively, indirectly via the upper cam assembly housing. Each yarn feeder unit 300 is electronically operated and a suitable unit 300 is described below.
The platform 100 is rotatably and slidably attached to column 110 and is detachably attached to column 111. Accordingly the platform is movably mounted for movement between a knitting operative position (as shown in FIG. 1) whereat the upper cylinder assembly 11 is aligned with the lower cylinder assembly 12 for knitting and a knitting inoperative position (as shown in FIG. 2) whereat the upper cylinder assembly is removed from the lower cylinder assembly to thereby permit clear access to the interior of the lower cylinder assembly. Such movement is possible since there are no mechanical linkages extending from the upper cylinder assembly 11 to the base 120. In addition the drive transmission between shaft 204 and the upper cylinder 200 includes drive separation means adapted to be axially separable on raising of platform 100. In this respect, in the illustrated embodiment of the drive separation means is defined by the end of shaft 204 being arranged to be axially withdrawable from the inner race of bearing 206 such that on raising of the platform 100 shaft 204 slides out of bearing 206. All electrical wires for controlling the cam element actuators and yarn feeders are preferably fed to the base 120 via column 110. Preferably column 110 is hollow so as to provide an internal passageway for running of the electrical wires and pneumatic air supply pipes.
The platform 100 is preferably secured to column 110 via a support sleeve 124 which is rotatably and slidably received on the column 110. A locking bolt 115 is conveniently provided to serve as locking means for fixedly securing the sleeve 120 to the column 110 when the platform 100 is located at the knitting operative position.
Similarly, locking bolts 125 are provided for securing the platform 100 to column 111 when in the knitting operative position. Accordingly, during the normal knitting operation, the platform is securely located in the knitting operative position.
When it is necessary to move the platform 100 to the knitting inoperative position, bolts 125 are removed and bolt 115 is released.
It is now possible to raise platform 100 relative to the base 120 so as to axially separate the upper and lower cylinder assemblies by a sufficient distance to enable the platform 100 to be rotated to its knitting inoperative position. Advantageously, lifting means are provided for raising the platform 100. In the illustrated embodiment the lifting means comprise a bolt 130 passing through an arm 131 secured to the column 110; the terminal end of the bolt engaging with the underside of platform 100.
It is envisaged that the electronic control components, eg., the micro processor and related hardware, can be housed in a modular housing 400 which is attached to the main housing 401 of the knitting machine.
The drive shaft of the knitting machine is provided with appropriate sensors to determine the sequence of a knitting cycle.
As indicated above the upper cylinder assembly includes an upper cam assembly 23 for controlling movement of an upper slider for each needle and the lower cylinder assembly includes a first cam assembly for controlling movement of a lower slider for each needle and a second cam assembly for controlling raising/lowering of an intermediate tippable jack which is positioned between a pattern selector jack and the lower slider of each needle.
The cam assemblies include retractable cam elements 21 (see FIG. 5), for example, plunger-type bolt cams which are movable in an axial line between various extended or retracted positions to influence movement of butts of sliders or jacks running therealong.
In accordance with the present invention pneumatically powered actuators 30 are provided which move the bolt cams 21 between their operative positions.
An example of a pneumatically powered actuator 30 is illustrated in FIGS. 4 and 5.
The actuator 30 has a body 31 including a stepped bore 32. In the illustrated embodiment, the bore 32 includes a series of three distinct piston cylinders 33,34 and 35 each of which houses a piston 36,37 and 38 respectively. The body 31 is mounted on a cam assembly, shown schematically by numeral 23.
Each piston 36,37 and 38 in the series has a head portion 36a,37a and 38a respectively which sealingly engages with the wall of its associated piston cylinder. Preferably each head portion is provided with an elastomeric O-ring seal 40 for forming said sealing engagement. The bore is closed at one axial end by an end cap 31a which has an axial face 31b that engages piston 38 to act as an end stop.
Each piston 36,37 and 38 has a body portion 36b,37b and 38b respectively which is of reduced diameter. The body portions 37b and 38b have a diameter less than the diameter of the adjacent piston cylinders 33,34 respectively so that when positioned therein a gas chamber is formed for causing initial movement of the piston located in that cylinder.
Body 36b is of substantially the same diameter as through bore 42 and projects therethrough to the exterior of the body 31 to engage a bolt cam 21 to be moved. This is shown schematically in FIG. 5.
Body 37b and 38b also have an axial shaft projection 44,45 respectively which slidingly project into blind bores 46,47 formed in piston bodies 36b and 37b respectively. Shaft projections 44,45 co-operate with their associated bore 46,47 to restrain axial twisting of the piston bodies 37b and 38b during axial movement.
Three conduits 50,51, and 52 are provided in the body 31 for supplying pressurised air into the piston cylinders and for also enabling exhausting of air from the piston cylinders.
A valve assembly 60 is provided which is operable to selectively connect each conduit 50,51 and 52 to a supply of pressurised air for introduction of pressurised air into the cylinders or to atmosphere for venting of the cylinders.
The valve assembly 60 includes for each conduit 50,51 and 52 a valve slide 62,63 and 64 respectively which is moved between first and second positions by means of a solenoid. Each solenoid is electronically controlled, e.g. by a programmable computer, so as to be activated at appropriate times during each knitting cycle for knitting an article on the knitting machine.
To extend the body 36b (and thus bolt cam 21) from a fully retracted FR position to a fully extended position FE (FIG. 5) via two intermediate extended positions IP1 and IP2 the following sequence is adopted.
Initially all slide valves 62,63 and 64 are positioned such that conduits 50,51 and 52 are vented. Biasing means 22 such as a spring acting on the cam bolt urges the piston assembly in the axial direction of retraction and since conduits 50,51 and 52 are vented the pistons 36,37 and 38 all reside in their fully retracted positions as shown in FIG. 5. As seen in FIG. 5, in the fully retracted position, the pistons are nested together with opposed axial faces in abutment. Accordingly, movement of a larger piston in the extend direction causes the remaining smaller pistons in the series to be moved in unison in the extend direction also.
To move body 36b to position IP1 valve slide 64 is moved to its operative position whereat it connects conduit 52 to the source of pressurised air. Initially air is supplied to chamber 70 which causes the piston 38 to move axially in the extend direction thereby causing movement in the extend direction of the entire rest of pistons 36,37 and 38 in the series between the chamber 70 and the cam element 21. After this initial movement the entire axial end face of piston 38 is exposed to the air pressure and the piston 38 continues to move in the extend direction until the axial face 38e of the piston 38 engages a shoulder at the forward end of cylinder 35. At this position body 36b has reached position IP1 and body 38b has entered cylinder 34 to create a chamber 80 for initialising movement in the extend direction of piston 37. (See FIG. 5a).
To move body 36b to position IP2, valve slide 64 remains in position to supply pressurised gas to cylinder 35 and valve slide 63 is moved to connect conduit 51 to the pressurised air supply. Accordingly pressurised air enters newly formed chamber 80.
The air pressure in chamber 80 acts upon the axial end face of piston 37 and moves it axially in the extend direction and thereby also moves piston 36 which is in the series between the piston 36 and the cam element 21. The axial stroke of piston 37 is terminated when its axial end face 84 engages shoulder 85 at the forward end of cylinder 34. At this position, body 36b is located at position IP2 and the body 37b is located within cylinder 33 and defines a gas chamber 90. (See FIG. 5b).
Advancement of body 36b to position FE is achieved by maintaining supply of pressurised air to cylinders 34 and 35 and operating valve slide 62 to connect conduit 50 to the pressurised air supply. The air pressure in chamber 90 acts upon the axial end face of piston 36 and moves it axially in the extend direction until its axial end face 87 engages shoulder 88 at the forward end of cylinder 33 whereat body 36b is located at position FE. (See FIG. 5c).
Advantageously, there is sufficient clearance between shaft projections 44,45 and blind bores 46,47 respectively to permit air to enter therebetween so that air pressure is applied across the entire cross-sectional area of each piston.
It will be appreciated that during the advancement stroke of each piston a constant advancement force is applied and so during advancement of the body 36b sufficient power is available to enable the body 36b to advance to its next position.
It will be appreciated that by selective operation of valve slides 62,63 and 64 it is possible to move the body 36b to selected positions FE, IP2, IP1 or FR and hold the body 36b thereat. Since the positions FE, IP2, IP1 and FR are each defined by engagement between opposed axial end faces these positions are accurately and positively provided by the construction.
An actuator for each bolt cam is provided at each knitting station around the peripheries of the cylinder assemblies.
The number of discrete axial positions provided by the actuator depends upon the type of bolt cam and so actuators providing 2,3 or 4 discrete positions will normally be provided.
It is envisaged that each body 31 will be directly mounted to the outside of an associated cam assembly and that a single air pressure supply pipe 50 (FIG. 4) be provided for supplying air pressure to each actuator associated with the upper cam assembly and a single air pressure supply pipe be provided for supplying air pressure to each actuator associated with the lower cam assembly.
Accordingly cam selections can be achieved by electronic control thereby providing the versatility of using electronics. In addition, the conventional cam wheel assembly and associated mechanical linkages can be dispensed with and directly substituted by actuators according to the present invention. This therefore enables existing machines to be simply modified and upgraded for electronic control.
It is envisaged that the electrical signals for activating the solenoids of the bolt cam actuators can be transmitted via a serial link and thereby substantially reduce the amount of wiring required.
A suitable yarn feeder unit 300 is illustrated in greater detail in FIGS. 6 and 7. The feeder unit 300 enables different yarns to be fed at its associated knitting station and is pneumatically powered under electronic control to provide a compact unit which can be supported on the upper platform 100 without interfering with the upward movement of the platform 100.
The feeder unit 300 includes a plurality of yarn guide fingers 315 which are each arranged to move through an arc between three distinct positions to enable change over of feed of yarn from one yarn guide finger to another. The three distinct positions are rest position (R) whereat the yarn guide arm remains at one end of the arc in readiness to supply yarn; in this position the yarn is held in a trap; a feed position (F) whereat the yarn guide arm is located at an intermediate position in the arc and resides at this position to feed yarn to the needles; and a park/cross over position (P) at the opposite end of the arc whereat the yarn guide arm temporarily resides during change over. The arrangement of guides and sequence of movement for change over is known and reference should be made to UK Patent 2058152 B (U.S. Pat. No. 4,502,299) for fuller details.
In summary, the following sequence of movements are performed for changing over from a feeder A to a feeder B.
______________________________________ Rest Feed Park/Cross-over Position Position PositionOperation R F P______________________________________Knitting Awith Feeder A BChange over sequence:Step 1 A BStep 2 A BStep 3 A BKnitting with AFeeder B B______________________________________
When knitting with the yarn from Feeder A, Feeder A is positioned at the Feed Position F and all the other Feeders are positioned at the Rest Position B. To change from Feeder A to Feeder B, Feeder A is swung to the Park Position P and Feeder B is swung into the Feed Position F. The Feeder B is then swung into the Park Position B and then the Feeder A is swung back to the Rest Position R. At the conclusion of the change over sequence the Feeder B is swung back to the Feed Position F and knitting resumes with the yarn from Feeder B, as described more fully in U.S. Pat. No. 4,502,299.
In accordance with the present invention to achieve movement of the guide fingers between the three distinct positions R, F and P each guide finger is acted upon by a first piston which moves the finger from one end of the arc to the other end and a two position stop means preferably in the form of a second piston which acts to arrest movement of the first piston at either the intermediate feed position or said other end of the arc. Preferably the first piston acts to move the associated yarn guide from the rest position R to the park/cross-over position P via the feed position F and biasing means, such as a spring acts to return the guide arm from the park/cross-over position P to the rest position R.
Accordingly, in the feed unit 300 illustrated in FIGS. 6 and 7 a piston cylinder block 320 is provided with a plurality of pairs of cylinders 321 for accommodating respective pairs of pistons 322, 323.
Each yarn guide finger 315 is mounted on respective boss 317 which is in turn pivotally attached to a support lever 318 having arms 318a and 318b. Each support lever 318 is mounted on a common shaft 319 secured to the cylinder block 320 (FIG. 6) so that deflection of each lever 318 about the axis of the shaft 319 causes the respective guide finger 315 to describe said arc. The pivotal connection between each boss 317 and support lever 318 extends perpendicularly to the axis of shaft 319 and enables each guide finger 315 to undergo a vertical displacement whilst the finger describes a horizontal arc.
A guide plate 350 is attached to the cylinder block 320 and each guide finger 315 projects through a respective guide slot 351 formed in the plate 350. Accordingly, the vertical position of each guide finger 315 is controlled and determined by the respective guide slot 351 during movement of the guide finger caused by deflection of its respective support lever 318.
Deflection of each lever 318 is achieved by a respective pair of co-operating pistons 322, 323 which respectively engage lever arms 318b, 318a located on opposite sides of the axis of shaft 319.
Piston 323 of each pair is arranged to have a stroke of extension to enable it to deflect the lever 318 so as to move the associated guide finger 315 from the rest position R through to the park/cross-over position P. Return movement of the lever 318 is achieved by means of a tension spring 340. The piston 322 when fully extended has a more limited stroke than that of piston 323 and thereby positively defines an intermediate position for lever 318. Piston 323 has a waisted portion 326 which defines an intermediate gas chamber 327 which communicates with cylinder 321. Accordingly, since both cylinders 321 are provided with the same gas source, the force of displacement on piston 323 is less than that on piston 322.
Accordingly, if both cylinders 321 are pressurised, piston 323 will deflect the lever 318 until it contacts piston 322 whereat further deflection is prevented since piston 323 is unable to overcome the counter force applied by piston 322. Since the fully extended position of piston 322 can be accurately manufactured, positive and accurate positioning of the lever 318 can be achieved.
Fluid supply to the piston cylinders 321 is controlled by conventional solenoid operated valves 370 (shown schematically in FIGS. 7a-7c) mounted to the rear of the cylinder block. FIGS. 7a-7c illustrate the relative positions of pistons 322, 323 in order to achieve positioning of the guide finger at the rest position R, feed position F and park/cross=over position P respectively.
The valves 370 are operated in sequence to either supply pressurised gas to a cylinder 321 or to vent the cylinder.
The sequence is summarised below with reference to the positions R, F, P.
______________________________________ Piston 322 Piston 323Position Cylinder Cylinder______________________________________R* Vent VentF Pressurise PressuriseP Vent Pressurise______________________________________ *Spring 340 holds the lever in this position.
The above construction provides a very compact arrangement which requires only a single supply of pressurised gas and electrical leads for controlling the solenoid operated valves 370. Accordingly, all mechanical linkages normally associated with conventional yarn feeders are eliminated. Conveniently the cylinder block is provided with a support shaft 380 which is attached to an arm 381 pivotally secured to the platform 100 (FIG. 1). In this way the yarn feeder device 300 can be conveniently pivoted between an operative working position (not shown) or as shown in FIG. 1 an inoperative position to provide access to the knitting cylinders or the yarn feeder unit itself. The arm 381 is retained in the operative position by means of a hand bolt 383 which engages in a slot 384 formed in the platform 100.
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A cam actuator for selectively moving cam elements axially between distinct operative positions in a circular knitting machine, the actuator including a series of adjacent pistions arranged along the axial line of displacement, and stop means for limiting the axial stroke of each piston in the direction of extension. Each piston co-operates with adjacent pistons in the series such that displacement of a given piston in the extend direction causes the remaining pistons located between the cam element and the given piston to be displaced in the extend direction by the stroke length undergone by the given piston.
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RELATED APPLICATIONS
[0001] This Patent Application claims priority under 35 U.S.C. 119(e) of the co-pending U.S. Provisional Pat. App. No. 60/609,507, filed Sep. 7, 2004, entitled “Integrated Connector and AC/DC Converter”, which is hereby incorporated by reference. The Patent Application is related to concurrently filed U.S. Pat. App. No. 60/609,507, entitled “Integrated Connector and AC/DC Converter”, which is herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The instant invention relates to a heat dissipating system for electronic devices. More specifically, a heat dissipating system that allows for more compact device packages while maintaining current standards for heat-dissipation, temperature equalization and overheating prevention. In particular, the instant invention reveals a compact AC/DC power converter cooled according to the present invention.
BACKGROUND
[0003] Many electronics circuits depend on reliable heat dissipation systems to ensure stable operation and efficiency. Thermal excitement in electrical systems leads to increased noise. Without an effective heat dissipation system, failure or unstable operation is possible.
[0004] Conventional heat dissipation systems depend on one or more of the following strategies: passive convection operating directly on the heat producing components of the electronic device; addition of an active cooling solution, such as a fan or liquid cooling system; placement of a heat sink in conductive contact with the heat producing components, such that the heat sink and the components are then in thermal equilibrium and both dissipate heat through convective means.
[0005] To offer higher capacity heat transfer, new heat dissipation equipment must be more efficient. It is difficult for air-cooled heat sinks to grow in size, because equipment manufacturers are under tremendous competitive pressure to maintain or diminish the size of their equipment packages, all the while filling them with more and more components. In addition, larger heat sinks typically will increase the cost of the heat sink element. Thus, competitive heat dissipation equipment must be relatively compact in size and must perform at levels sufficient to prevent high-performance components from exceeding their operational heat specifications.
[0006] Conventional heat dissipation systems are at odds with these requirements. Heat sinks and active cooling solutions are bulky and require additional space within the device package. Even passive convective cooling requires the allotment of space within the device to allow for air flow.
[0007] Prior work in the art has shown that a solution analogous to a heat sink need not require additional space within the device package. United States Patent Publication No. 2002-0092160 reveals a device wherein the structural frame is composed of a heat conductive material and is thermally coupled to the electronic components therein, whereby the frame and electronic components are at thermal equilibrium and passive convective cooling of the entire system occurs more rapidly than it otherwise would.
[0008] This type of cooling system, relying on heat dissipation through passive convection, is acceptable for low power, battery-operated, portable applications. Higher power electronics create more heat, and dissipation thereof through the exterior of the device package could presumably allow the exterior surface to reach an unsafe temperature. For the same reasons, attaching any form of heat sink to the exterior of a device would not only increase the package bulk, but allow for possible user contact with a hot element used.
[0009] Traditional AC/DC power converters, such as for cellular telephones typically include a plastic housing with air or other insulation surrounding the electronic power convertor circuit. For cooling, such circuits have relied on large device packages and, in some cases, the presence of vents to facilitate passive convective cooling of an enclosed circuit board including a plurality of electronic components mounted on a PCB. This strategy results in a device inconveniently large in size. Furthermore, the convective means of cooling circuitry in an enclosed space, even with vent holes, has poor efficiency, resulting in a high equilibrium operating temperature for the electronic device.
[0010] This construction method results in large device packages for several reasons. Conventional power conversion circuits include primary and secondary circuits: a primary circuit is connected directly with the AC power input to be converted and power is output through the secondary circuit. Safety regulations require a minimum distance of 6.4 mm between the secondary and primary circuits through air. Further, because government regulations mandate that operating temperatures in such devices not exceed a certain range above the ambient temperature, smaller device packages are not feasible using prior art techniques: a package having a large surface area is often the only means of achieving the needed heat dissipation. Devices constructed according to prior art techniques to have a certain size. This is true since even low powered devices, which might obtain sufficient heat dissipation through a small package, because they are required to meet the through-air requirement of a 6.4 mm spacing.
[0011] In view of this, users must carry an undesirably large power converter to charge their cellular telephone. It is further well known in the art that relatively higher operating temperatures result in relatively higher incidence of device failure and in less efficient operation.
[0012] Because current cooling system designs necessitate large device packages, especially in power conversion devices, many current power converter designs are bulky and inconvenient. Compare the power adapters designed to charge cellular phone batteries with a standard AC power plug. The typical cellular telephone power adapter employs a bulky housing to hold the plug blades and the power conversion circuitry. The relatively large size of the power adapter is necessary because of the heat dissipation requirements outlined above. Exclusive of those requirements, it is apparent that a smaller, more compact device packaging would be advantageous for such power adapters. The advantages of such a construction are especially clear since cellular phone adapters are necessarily portable and thus stand to benefit substantially from a sleeker device packaging.
[0013] In view of the above, there is a demonstrated need for a cooling system capable of handling the large heat loads created in power electronics, but that also allows for compact device packaging and does not present a hazard to the user. This need is especially apparent in the field of power converter manufacturing, where current cooling systems preclude the creation of a compact power converter that is both efficient and reliable.
SUMMARY OF THE DISCLOSURE
[0014] The present invention represents an improvement of prior art cooling systems for externally powered electronic devices. It provides all the advantages of an extended external heat sink assembly, allowing for compact device packaging while maintaining a reasonably cool operating temperature. However, the present invention requires no external apparatus aside from the familiar power supply, which in most cases takes the form of a wall outlet.
[0015] In accordance with the embodiments of the present invention, a compact power conversion device is provided. The device comprises a power conversion circuit coupled to receive electric power from a power supply network via power supply leads, and a heat conductive body thermally coupled with the power conversion circuit for substantially efficient heat transfer from the power conversion circuit and to the power supply leads. Wherein the thermal coupling is such that heat generated by the power conversion circuit is transferred to the power supply network. By conduction through the heat conductive body, then the power supply leads and into the wires of the power supply network.
[0016] According to the present invention, one way to achieve the thermal coupling is to mold the heat conductive body around at least a portion of the power conversion circuit and around at least a portion of the power supply leads. In this construction, the power supply leads are coupled by thermal conduction to the power conversion circuit to allow substantially efficient heat transfer from the circuit to the leads. The leads are thermally conductive and transfer heat into the power supply wall socket and subsequently to the wiring in the wall. In further aspects of the present invention, the device has power output leads coupled with the power conversion circuit to transmit the converted power to a distant load.
[0017] In addition to maintaining good heat dissipation characteristics, the present invention discloses several device designer having good structural integrity. In one aspect, the compact power conversion device further comprises a substantially rigid body coupled with the heat conductive body and with the power conversion circuit to provide structural support. in another aspect, the heat conductive body forms also a structural enclosure for the power conversion circuit and the power supply leads. In this case the heat conductive body should conform to accepted strength of materials standards for use as a structural element in an electrical housing.
[0018] In the compact power conversion device of the present invention, the heat conductive body should have at least a minimum thermal conductivity to allow adequate heat dissipation and a low electrical conductivity to prevent short circuits. Further, when the conductive body is used in a structural capacity, or as insulation between the primary and secondary portions of the conversion circuit, it is formed from a UL recognized insulation material.
[0019] Also in the present invention, a power converter is provided. The power converter comprises a circuit for converting an electric signal, power supply leads coupled to provide the electric signal to the circuit, and an electrically inert, thermally conductive mass coupled with the circuit to transfer heat generated by the circuit to the power supply leads. In the power converter according to the present invention, the power supply leads are also thermally coupled to a power supply network such that the heat generated by the circuit is transferred to the power supply network.
[0020] In a further aspect of the present invention a method of cooling an electronic device supplied by an external power source is provided. The method comprises thermally coupling for substantially efficient heat transfer at least a portion of an electronic device to a thermally conductive body, and thermally coupling for substantially efficient heat transfer at least a portion of each of a plurality of power supply leads to the thermally conductive body.
[0021] The method of the present invention farther comprises enclosing the electronic device, at least a portion of each of the plurality of power supply leads and the thermally conductive body in any appropriate, rigid shell body, whereby the electronic device is simultaneously embedded in the rigid shell material and in the thermally conductive body.
[0022] In accordance with the method of the present invention, the thermally conductive body should have at least a minimum thermal conductivity to allow adequate heat dissipation and a low electrical conductivity to prevent short circuits. Further, when the thermally conductive body is used in a structural capacity, or as electrical insulation between the primary and secondary portions of the conversion circuit, it is formed from UL recognized electrical insulation material.
[0023] An AC/DC converter assembly is provided in the present invention. The AC/DC converter assembly of the present invention comprises an AC/DC converter circuit having a primary portion and a secondary portion, a plurality of AC plugs coupled with the AC/DC converter circuit, and a housing comprising a thermally conductive and electrically resistive body molded around the AC/DC converter circuit and also around at least a portion of each of the plurality of AC plugs so that the thermally conductive and electrically resistive body is thermally coupled with the AC plugs and the AC/DC converter circuit. In the AC/DC converter assembly of the present invention, thermal energy dissipated in the AC/DC converter circuit is thermally conducted to the AC plugs.
[0024] In accordance with the AC/DC converter assembly of the present invention, the heat conductive body should have at least a minimum thermal conductivity to allow adequate heat dissipation and a low electrical conductivity to prevent shorts. Further, if the conductive body is used in a structural capacity, or as electrical insulation between the primary and secondary portions of the conversion circuit, it is formed from a UL recognized electrical insulation material. In another aspect of the AC/DC converter assembly of the present invention, a UL recognized insulation material is formed around the thermally conductive and electrically resistive body for providing a structural enclosure for the AC/DC converter circuit.
[0025] Also in the present invention a device is provided for cooling one or more electronic circuits supplied by an external power source, where each of the circuits comprises a plurality of circuit elements and the elements further comprise heat producing and non-heat producing elements. The device according to the present invention comprises a thermally conductive mass in direct intimate contact with at least the heat producing elements of the circuits and with the power supply leads.
[0026] The present invention also discloses a system for cooling an electronic device, where the device comprises heat dissipating elements and is supplied by an external power source.
[0027] According to the present invention, the device comprises means for conductively capturing heat produced by the heat dissipating elements of the device, and means for conducting the heat captured from the heat dissipating elements of the device into the external power source.
[0028] In a further aspect, the present invention describes a power conversion system. The power conversion system comprises a power supply, a power outlet for coupling an arbitrary device into a circuit containing the power supply, an electronic device with a power input, and, an adapter comprising at least one input and at least one output, the inputs comprising an input capable of coupling into the circuit containing the power supply, the outputs comprising an output compatible with the power input of the electronic device, the adapter further comprising heat dissipating elements and non-heat dissipating elements, wherein the heat dissipating elements are thermally coupled for conductive heat transfer to a heat conductive body, further wherein the heat conductive body is configured to be in direct thermal contact with the circuit containing the power supply.
[0029] Also, the present invention includes a method of manufacturing a power adaptor. The method of manufacturing includes the step of providing a power conversion circuit, including a plurality of power supply leads, power conversion components, and power output leads, and of molding a heat conductive material around the power conversion components to form a plug structure and integrated strain relief structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a perspective view of the device in an assembled state.
[0031] FIG. 2 is a partial cross sectional view of the preferred embodiment of the device wherein the device packaging is formed of multiple materials, at least one material being used in primarily structural way and at least one material being used primarily for heat transfer.
[0032] FIG. 3 is a partial cross sectional view of an alternate embodiment of the device wherein the device packaging is formed of thermally conductive material, used for both heat transfer and also structure.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0033] For illustration purposes only, and by way of example, the present invention is shown to be employed for an AC/DC converter. As will be seen below, the cooling system for the electronic device of the present invention can be easily employed in the fabrication of other electronic devices, such as, and without limitation, power amplifiers and computing devices.
[0034] The invention will be described in detail below in the context of an application for an AC/DC converter; however, such disclosure is not intended to limit the scope of the present invention to such an application of the present invention.
[0035] FIG. 1 shows a compact power conversion device 100 according to the present invention. The power conversion device 100 includes a substantially rigid body 130 from one end of which extend two power supply leads 110 and 120 that in create a standard male AC plug. The power supply leads 110 and 120 and can include apertures as shown or to be solid. The power supply leads 110 and 120 and can both be the same size as shown or have polarity such that one blade is wider. A third power supply lead can be used as a conventional ground terminal. From the opposite end of the substantially rigid body 130 extends a power cord 140 which terminates in a
[0036] DC power coupling 150 . As can be seen, the device bears a strong resemblance to a common AC power cord. The substantially rigid body 130 is shown with a particular industrial design. This industrial design is representative only and can be modified without departing from the invention. Also owing to the present invention, the device is substantially the same as a common AC power cord.
[0037] In FIG. 2 , a partial cross sectional view of a power conversion device 200 is shown to include a substantially rigid body 230 from one end of which extend two power supply leads 210 and 220 that together form a standard male AC power plug. The device of FIG. 2 can but need not be the same as that shown in FIG. 1 . From the opposite end of the substantially rigid body 230 extends a power cord 240 which terminates in a DC power coupling 245 . The power cord 240 contains the power output leads 276 which are coupled with the power conversion circuit 270 . The power conversion circuit 270 is shown schematically only with circuit elements represented by blocks; any conventional circuit could work using the present invention. The power conversion circuit 270 includes primary 272 and secondary 274 portions. Further, the body is seen to contain electrically and thermally conductive ends 215 of both power supply leads 210 and 220 . Also illustrated is the gap 225 of at least 0.4 mm between the primary 272 and secondary 274 sides of the power conversion circuit 270 . The gap 225 being filled with the material that the substantially rigid body 230 is comprised of, which is preferably a UL recognized electrical insulation material that provides the minimum required electrical insulation between the primary 272 and secondary 274 sides of the power conversion circuit 270 . The power conversion circuit 270 is also shown to include heat generating components 260 within the primary portion 272 . In the preferred embodiment, the structural body 230 is coupled to a heat conductive body 250 which is further thermally coupled for substantially efficient heat transfer to the heat generating components 260 and to the thermally conductive ends 215 of the power supply leads 210 , 220 so that the heat generated in the heat generating components 260 is transferred into the power supply leads 210 , 220 and from there to the power supply network (not shown) such as conventional power outlets and wall wiring. The thermal coupling is preferably accomplished by molding the heat conductive body 250 around the heat generating components 260 and the thermally conductive ends 215 , but could be accomplished by any reasonable means. According to the present invention, the heat conductive body has at least a minimum thermal conductivity allow adequate heat dissipation and a low electrical conductivity to prevent shorts.
[0038] In FIG. 3 , a partial cross sectional view of a power conversion device 300 is shown to include a structural enclosure 330 from one end of which extend two power supply leads 310 and 320 that together form a standard male AC power plug. From the opposite end of the structural enclosure 330 extends a power cord 340 which terminates in a DC power coupling 345 . The power cord 340 contains the power output leads 376 which are coupled with the power conversion circuit 370 . The power conversion circuit 370 includes primary 372 and secondary 374 portions. Further, the body is seen to contain electrically and thermally conductive ends 315 of both power supply leads 310 and 320 . Also illustrated is the gap 325 of at least 0.4 mm between the primary 372 and secondary 374 sides of the power conversion circuit 370 . The gap 325 being filled with the material that the structural enclosure 330 is comprised of, which is preferably a UL recognized electrical insulation material that provides the minimum required electrical insulation between the primary 372 and secondary 374 sides of the power conversion circuit 370 . The power conversion circuit 370 is also shown to include heat generating components 360 within the primary portion 372 . In this embodiment, the structural body 330 is comprised of an electrically inert, thermally conductive material which is further thermally coupled for substantially efficient heat transfer to the heat generating components 360 and to the thermally conductive ends 315 of the power supply leads 310 , 320 so that the heat generated in the heat generating components 360 is transferred into the power supply network (not shown) through the power supply leads 310 , 320 . The thermal coupling is preferably accomplished by molding the structural enclosure 330 around the heat generating components 360 and the thermally conductive ends 315 , but could be accomplished by any reasonable means. According to the present invention, the structural enclosure 330 has a sufficient thermal conductivity to allow adequate heat dissipation and a low electrical conductivity to prevent shorts.
[0039] Also in accordance with the present invention, a method of cooling an electronic device supplied by an external power source is provided, which will now be discussed with reference to the above devices, and to FIGS. 2 and 3 . The method of the present invention comprises thermally coupling for substantially efficient heat transfer at least a portion of an electronic device to a thermally conductive body, and thermally coupling for substantially efficient heat transfer at least a portion of each of a plurality of power supply leads to the thermally conductive body. Referring to FIG. 2 , an electronic device 200 is constructed according to the method of the present invention. A portion of the electrical circuit 270 is thermally coupled to the thermally conductive body 270 , which is also thermally coupled to the power supply leads 210 , 220 for substantially efficient heat transfer. In the device 200 , the structural integrity of the device package is maintained by the rigid shell body 230 . Referring to FIG. 3 , an electrical device 300 is constructed according to the method of the present invention. A portion of the electrical circuit 370 is thermally coupled to the thermally conductive body 330 , which is also thermally coupled to the power supply leads 310 , 320 for substantially efficient heat transfer. In the device 300 , the thermally conductive body 330 also provides a structurally sound device package. In the method of the present invention, the structural materials are preferably comprised of a UL recognized insulation material. Also, in the method of the present invention the thermally conductive materials used to thermally couple the power supply leads to the electrical device have at least a minimum thermal conductivity to allow adequate heat dissipation and a low electrical conductivity to prevent shorts.
[0040] Because the device of the present invention comprises a solid mass of material molded around the circuit components of a power converter, a much more compact size is achieved than is present in prior art devices or possible with prior art designs. Though safety regulations dictate a 6.4 mm spacing through air between primary and secondary circuitry in a power converter, only 0.4 mm spacing is required through any homogeneous UL recognized electrical insulation material. In the preferred embodiment of the present invention, a UL recognized insulation material is used to provide the structure of the compact power conversion device. Though other materials are contemplated in the present invention, because of current regulations other contemplated materials that are non-UL recognized at the time of invention cannot be considered equivalent. Of course, any future materials meeting the approval of UL or some similar regulatory authority, would have to be considered equivalents.
[0041] The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of the principles of construction and operation of the invention. As such, references, herein, to specific embodiments and details thereof are not intended to limit the scope of the claims appended hereto. It will be apparent to those skilled in the art that modifications can be made in the embodiment chosen for illustration without departing from the spirit and scope of the invention.
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An electronic device such as an AC/DC power adapter includes a conductive heat dissipation system. The device contains heat generating components and is powered via power supply leads by an external power supply circuit. The device further contains a thermally conductive mass that is thermally coupled to both the heat generating components and to the power supply leads. When the power supply leads are coupled to receive electricity from the external power supply circuit, heat generated by the device is thermally conducted into the external power supply circuit via the power supply leads.
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A portion of the disclosure of this patent document contains command formats and other computer language listings, all of which are subject to copyright protection. The copyright owner, EMC Corporation, has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
The invention relates generally to error detection and correction of errors in a data storage environment, and more particularly to a system and method for augmenting and simplifying the task of service professionals who handle such errors for data storage systems.
BACKGROUND OF THE INVENTION
As is known in the art, computer systems generally include a central processing unit (CPU), a memory subsystem, and a data storage subsystem. According to a network or enterprise model of the computer system, the data storage system associated with or in addition to a local computer system, may include a large number of independent storage devices or disks housed in a single enclosure or cabinet. This array of storage devices is typically connected to several computers over a network or via dedicated cabling. Such a model allows for the centralization of data that is to be shared among many users and also allows for a single point of maintenance for the storage functions associated with the many host processors.
The data storage system stores critical information for an enterprise that must be available for use substantially all of the time. If an error occurs on such a data storage system it must be fixed as soon as possible because such information is at the heart of the commercial operations of many major businesses. A recent economic survey from the University of Minnesota and known as Bush-Kugel study indicates a pattern that after just a few days (2 to 6) without access to their critical data many businesses are devastated. The survey showed that 25% of such businesses were immediately bankrupt after such a critical interruption and less than 7% remained in the marketplace after 5 years.
Recent innovations by EMC Corporation of Hopkinton, Mass. provide business continuity solutions that are at the heart of many enterprises data storage infrastructure. Nevertheless, the systems (including devices and software) being implemented are complex and vulnerable to errors that must be quickly serviced for the continuity to be maintained.
EMC has been using a technique for responding to errors as they occur by “calling home” to report the errors. The data storage system is equipped with a modem and a service processor (typically a laptop computer) for error response. Sensors that are built into its storage systems monitor things such as temperature, vibration, and tiny fluctuations in power, as well as unusual patterns in the way data is being stored and retrieved—over 1,000 diagnostics in all. Periodically (about every two hours), an EMC data storage system checks its own state of health. If an error is noted, a machine-implemented “call home” is made to customer service over a line dedicated for that purpose.
Every day, an average of 3,500 such calls home for help reach EMC's customer service center in Hopkinton. About one-third of the calls from EMC's machines trigger the dispatch of a customer engineer to fix some problem. Remarkably under such a service program, many problems are resolved before the owner of the data storage system is even aware that there has been a problem. However, some error codes that result in calls home are the result of known problems for which a design engineering fix is pending, or minor problems that do not require immediate attention. Such calls can be deferred or ignored so that more urgent and important errors may be dealt with. This is known as screening or filtering errors
However when filtering errors it is important to not introduce costly mistakes. If the error for which screening is intended is not properly filtered then expensive, wasteful, unnecessary, and burdensome calls back to home continue. If, on the other hand, an important error is wrongly ignored, then that could cause harm. These two situations could occur at the same time flooding the customer service center with unimportant calls while important errors are ignored.
What is needed is a way to screen for known errors occurring in a data storage system in a simple and clear manner, while reducing the risk that mistakes are created. Furthermore, it would be an advancement in the art if such a screening tool could be administered on a remote basis so it could handle data storage systems located anywhere in the world.
SUMMARY OF THE INVENTION
The present invention is a data storage management system and method that includes a simple clearly presented tool for screening out or filtering errors occurring in a data storage system.
In one embodiment, the invention includes a method that is useful in a data storage system with more than one storage device. The method provides steps for the management of errors related to a data storage system. The method includes receiving at an error response station a message about an error related to the data storage system, and providing a graphical user interface (GUI) for enabling the selective entry of error handling information in response to receiving the message. The method may be further useful for suppression of such handling information, diagnosing such messages, and taking or recommending corrective action.
In another embodiment the invention includes a system capable of performing the method and computer-executed logic capable of carrying out the method.
In another embodiment, the above-specified techniques are enabled to be remotely deployed to manage response to errors occurring on data storage systems anywhere in the world.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and further advantages of the present invention may be better under stood by referring to the following description taken into conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram of a data storage management system including filter logic that operates with the filter log for operating the present invention and including a data storage system, a service processor, and a remote error response station;
FIG. 2 is a block diagram of the architecture for the logic shown in FIG. 1 as implemented on the service processor of FIG. 1;
FIG. 3 is a block diagram of the architecture for the logic shown in FIG. 1 as implemented on the error response station of FIG. 1;
FIG. 4 is a schematic representation of contents comprising the filter log of FIG. 1;
FIG. 5 is in a schematic representation of contents comprising an embodiment of the filter log of FIGS. 1 and 4;
FIG. 6 is a flow logic diagram of the method of this invention using the filter logic and filter log on the system of FIG. 1;
FIG. 7 is another flow logic diagram and is a continuation of the illustration of the method begun in FIG. 6;
FIG. 8 is another flow logic diagram and is a continuation of the illustration of the method begun in FIG. 6;
FIG. 9 is another flow logic diagram and is a continuation of the illustration of the method begun in FIG. 6;
FIG. 10 is another flow logic diagram and is a continuation of the illustration of the method begun in FIG. 6;
FIG. 11 is another flow logic diagram and is a continuation of the illustration of the method begun in FIG. 6;
FIG. 12 is an example of a graphical user interface (GUI) tool useful for creating an error handling information denoted as a filter entry for the filter log of FIG. 1 and useful for the method shown in FIGS. 6-11;
FIG. 13 is another example of a graphical user interface (GUI) tool useful for placing error handling information in the filter log of FIG. 1 and useful for the method shown in FIGS. 6-11;
FIG. 14 is another example of a graphical user interface (GUI) tool useful for placing error handling information in the filter log of FIG. 1 and useful for the method shown in FIGS. 6-11; and
FIG. 15 is another example of a graphical user interface (GUI) tool useful for placing error handling information in the filter log of FIG. 1 and useful for the method shown in FIGS. 6-11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The methods and apparatus of the present invention are intended for use in data storage systems, such as the Symmetrix Integrated Cache Disk Array system available from EMC Corporation of Hopkinton, MA and in particular are useful for managing errors that may occur on such a system.
The methods and apparatus of this invention may take the form, at least partially, of program code (i.e., instructions) embodied in tangible media, such as floppy diskettes, are the CD-ROMs, hard drives, random access or read only-memory, or any other machine-readable storage medium. When the program code is loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. The methods and apparatus of the present invention may also be embodied in the form of program code that is transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via any other form of transmission. And may be implemented such that herein, when the program code is received and loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. When implemented on a general-purpose processor, the program code combines with the processor to provide a unique apparatus that operates analogously to specific logic circuits.
The logic for carrying out the method is embodied as part of the Data Storage Management System 102 described below beginning with reference to FIGS. 1-3, and which is useful for implementing a method described with reference to FIGS. 6-11. For purposes of illustrating the present invention, the invention is described as embodied in a specific configuration, but one skilled in the art will appreciate that the device is not limited to the specific configuration but rather only by the claims included with this specification
Referring now to FIG. 1, Local System 100 includes a data storage system 119 that in a preferred embodiment is a Symmetrix Integrated Cache Disk Arrays system available from EMC Corporation of Hopkinton, Mass. Such data storage systems and their implementations are fully described in U.S. Pat. No. 6,101,497 issued Aug. 8, 2000, and also in U.S. Pat. No. 5,206,939 issued Apr. 27, 1993, each of which is assigned to EMC the assignee of this invention and each of which is hereby incorporated by reference. Consequently, the following discussion makes only general references to the operation of such systems.
The local system 100 comprises major components including a computer system 113 formed of a computer processor and the data storage facility 119 that includes a system memory 114 and sets or pluralities 115 and 116 of multiple data storage devices or data stores. The system memory 114 can comprise a buffer or cache memory; the storage devices in the pluralities 115 and 116 can comprise disk storage devices, optical storage devices and the like. The sets 115 and 116 represent an array of storage devices that may be arranged in a variety of known configurations. However, in a preferred embodiment the storage devices are disk storage devices.
Channel directors (CD) 117 - 118 provide communications between the computer system 113 and the system memory 114 ; device or disk directors (DD) 120 and 121 provide pathways between the system memory 114 and the storage device pluralities 115 and 116 . A bus 122 interconnects the system memory 114 , the channel directors 117 and 118 and the disk directors 120 and 121 . Remote Data Facility Adapter (RDFA) 132 may provide access along path 112 to an optional remote data storage system (not shown).
System memory 114 is used by various elements within the respective systems to transfer information and interact between the respective channel directors and disk directors. Additionally, a service processor 123 monitors and controls certain operations and provides a primary interface for an external operator to respective systems and may be used for implementing utilities such as a utility for carrying out operations of the present invention.
Logic for carrying out the methods of this invention is preferably included as part of the data storage system 119 , and preferably as part of the service processor 123 and also as part of an error response station 138 that is part of a remote system 111 . Nevertheless, one skilled in the computer arts will recognize that the logic, which may be implemented interchangeably as hardware or software may be implemented in various fashions in accordance with the teachings presented now.
Generally speaking, the local system 100 operates in response to commands from one or more computer systems, such as the computer system 113 , that a connected channel director, such as channel director 117 receives. The channel directors 117 and 118 transfer commands to a command buffer that is part of system memory 114 . The command buffer stores data structures and write requests that the channel directors generate. The disk directors, such as the disk directors 120 or 121 , respond by effecting a corresponding operation using the information in a command buffer. The selected disk adapter then initiates a data operation. Reading operations transfer data from the storage devices to the system memory 114 through a corresponding disk adapter and subsequently transfer data from the system memory 114 to the corresponding channel director, such as channel director 117 when the computer system 113 initiates the data writing operation.
The data storage system 119 includes a service processor 123 that communicates along path 122 to the elements of the data storage system. Although the service processor 123 and shown is being an integral part of the data storage system, one skilled the art will recognize that the service processor only needs to be in communication with the data storage system 119 to complete the operations of this invention. Preferably the service processor and the data storage devices are separated by distance of less than 10 meters; however, greater distances may separate them as long as there is communication between the service processor and the data storage system.
The service processor 123 includes filter logic 128 that enables it to operate as a special-purpose digital computer. Complementary filter logic 142 on error response station 138 likewise enables it to operate as a special-purpose digital computer. The filter logic 128 operates in memory 126 (such as conventional electronic memory, for example RAM or cache memory) on the service processor in a cooperative fashion with filter logic 142 that in turn operates in memory 144 of the error response station to enable the method of this invention.
The service processor 123 further includes a display 124 , the CPU 130 (e.g., a conventional microprocessor), a fixed memory 132 (e.g., a hard disk), and a communications device 136 (e.g., a modem). That communications device 136 communicates across path 135 a through network cloud 137 and across path 135 b to communications device 152 (e.g., a modem) at error response station 138 .
Error response station 138 is located in the remote system 111 so that it is remote from the data storage system 119 . The complementary filter logic 128 and 142 enable the error response station 138 to be used by the operator 104 to have remote control over the service processor 123 . In this fashion, the operator 104 may diagnose, correct, and screen out or filter errors occurring at the data storage system 119 . Regarding the remote aspect of the error response station, it is preferred that the error response station and the data storage devices of data storage system 119 are separated by distance of at least one kilometer.
The error response station 138 also includes a display 140 , memory 142 (such as conventional electronic memory, for example RAM or cache memory), a CPU 146 (e.g., a conventional microprocessor), and a fixed memory 148 (e.g., a hard disk).
Referring again to the service processor 123 (FIG. 1 ), the fixed memory 132 is provided with special information data and files that are used by the respective filter logic elements when 128 and 142 for caring out the method of this invention. A special file for keeping track of “filtering” commands is denoted as the filter.log 133 . One or more text files denoted as Filtertxtfiles 134 may be used as templates for inserting commands in filter.log 133 . Filtertxtfiles 134 may be directly inserted in the filter.log and are operated on by the INCLUDE or EXCLUDE statement discussed with reference to FIG. 6-11 below. Similarly, Filtertxtfiles 150 may be stored in fixed memory 148 for similar purpose as Filtertxtfiles 134 for the convenience of operator 104 using the error response station 138 in a stand-alone, i.e. non-remote controlling fashion over service processor 123 .
FIG. 2 shows further detail regarding service processor 123 . Filter logic 128 operates in memory 126 and includes several interoperating logic modules 154 - 162 . All of the logic modules are preferably implemented as software. The modules include a remote agent 154 , GUI logic 156 , error notification logic 158 , error handling information logic herein denoted as filter entry logic 160 , and communications logic 162 .
FIG. 3 shows further detail regarding service processor 138 . Filter logic 142 operates in memory 144 and includes several interoperating logic modules 164 - 172 . All of the logic modules are preferably implemented as software. The modules include a remote agent 164 , GUI logic 166 , error message or notification logic 168 , error handling information logic herein denoted as filter entry logic 170 , and communications logic 172 .
Referring to FIGS. 2-3, the remote agent 154 may be an integrated or separate module from the other modules. The remote agent 154 acts in cooperation with remote agent 164 that is part of filter logic 139 that operates in memory 138 of the error response station 134 . The remote agents 154 and 164 are each implemented preferably as software, such as the SymmRemote software offered by EMC Corp. of Hopkinton, Mass.
Referring to the error response station 134 (FIG. 3 ), The GUI logic 166 enables a GUI presentation 147 on display 136 , examples of which are shown in FIGS. 12-16. The GUI presentation or tool 147 can be used by operator 104 working at error response station 138 to make changes directly to filter.log 133 to filter errors occurring at data storage system 119 . Since the operator has remote control over the service processor 123 when using the GUI tool 147 he may select Filtertxtfiles 134 for inclusion in the filter.log for reasons that will become clearer upon reading the sections referring to the flowcharts (FIGS. 6-11) describing the method. When the operator saves the filter.log after using the GUI tool 147 presented on display 136 of error response station 138 , it is saved in fixed memory 128 in filter.log 133 .
The GUI logic 166 may be an integrated or separate module from the other modules. It is implemented preferably as software such as the SymmWin software by EMC Corp. of Hopkinton Mass. Conveniently, the SymmWin software provides a graphical user interface that operates in cooperation with the Windows operating system provided by Microsoft Corp. of Redmond Wash.
Service processor 123 also includes GUI logic 156 for presenting a graphical user interface 125 on display 124 . This allows the GUI tool to be used with the filter entry logic 160 for a field engineer (not shown) operating on the data storage system independence from an operator at the error response station.
Referring again to FIGS. 2-3, error message or notification logic 158 sends a signal using communications logic 162 through communications device 136 that an error has occurred at data storage system 119 . The error message or notification is received through the communications device 152 in cooperation with communications logic 172 by error receiving and response logic 168 on error response station 134 . The errors are coded so that the operator 104 may look up the error and attempt to debug the problem. If the error is of the type that is a likely candidate for filtering, then the operator may use filter entry logic 170 that cooperates with GUI logic 166 to enable the operator to make an entry into the filter.log 133 .
The types of errors that may be filtered are those that are determined to be unimportant, or one for which a solution is pending, usually because the engineering group has become involved and is making an engineering change, such as a microcode revision.
Several detailed examples are explained herein; however, it should be understood that this invention is not limited to the particular illustrative examples explained. Rather, this invention that provides a novel and inventive system and process for managing errors occurring on data storage system should only be limited by the claims appended below.
FIGS. 4 and 5 show the contents of filter.log 133 . The file is preferably a text file, including a Header 174 , a Body 176 and Footer 178 . The Header includes introductory information and Footer precedes a group 180 of INCLUDE statements that cause the insertion of many Filtertxtfiles 134 . FIG. 5 shows an exemplary illustration of the contents of filter.log 133 after being operated upon by operator 104 using GUI tool 147 . The example “EXCLUDE ERROR CODE” statement 175 is part of the Body 176 a . When such an EXCLUDE statement 175 is encountered, the filter logic prevents a normal “call home” for the particular error identified by the particular error code. Any of the Filtertxtfiles 134 may have EXCLUDE statements embedded in them, all of which will be encountered when the filter.log 133 a is processed.
The process of filtering errors and filter logs existed prior to the creation of this invention. But the inventors of this invention critically recognized that prior to the creation of the present invention, there was no easy simple way to create entries into a filter log without a significant risk of the operator making mistakes. Such mistakes would result in critical errors being ignored and/or the call center being flooded with calls that should have been deferred or ignored by correctly implemented filtering process.
For example, at EMC, prior to this invention, any changes to a filter log had to be made by laboriously editing a file containing one-character field representations of critical bytes that were arranged contiguously. Each of these critical bytes are known as “sense bytes,” which are specific areas reserved in the memory data storage system 119 for identifying and handling errors. For example, a certain type of error, identified as the “0467” error has sense bytes 12 and 13 reserved for its identification and handling.
Following, in Table 1, is a representation of sense bytes 00 - 21 with information placed in their respective information fields for indicating how to handle certain errors:
TABLE 1
00 —— 02 —— 04 —— 06_07_08 ——— 11_12 ——— 15_16 —— 18_19_20_21
??????????DDDCCH ?? ADADADAD SKFFYYYY ???? AQ ?? PP IN
wherein, for example,
GDP = DEVICE
CCC = CYLINDER
H = HEAD
ADADADAD = ADDRESS FOR MEMORY ERRORS
? = BYTE NOT USED ( Mask representing 0-F (Hex))
Under program control the sense bytes are interpreted to determine which error is present and any specific information related to it. However, one skilled in the art will appreciate the ease with which errors may be introduced. For example, the mere placement of information one or more places off in the information fields will change the interpreted meaning entirely. It can be appreciated that it would be very easy to introduce an error that would produce the kind of problems described above, especially when one considers that the operator attempting to handle such problems has responsibility for dealing with multiple calls from multiple data storage systems from locations all over the world.
FIG. 12 illustrates how such sense bytes are handled using the present invention and is now explained with comparison to prior art techniques. Referring now to FIG. 12, in this example the GUI presentation 147 is shown as display screen presentation capture 1000 (hereafter screen 1000 ). The flex filter contents box 1032 shows the contents of the filter.log created using the GUI tool of this invention. It shows similar information as that described above referenced in Table 1, but the operator is given a much clearer and simpler way of manipulating the information fields than in with prior art techniques.
Referring again to FIG. 12, and box 1032 , line 1032 a shows the case number for identification purposes, line 1032 b shows the type of error, in this example “CEKDRSF,” meaning in this case the error applies to all of the directors in data storage system 119 . Errors may be excluded on a device or director level and each of the fields 1016 - 1028 provide a way for the operator 104 to indicate which action should be taken. In this example, the letter C stands for “Channel.” The letter E stands for “ESCON.” The letter K indicates a special configuration regarding the amount of devices in storage system 119 . The letter D indicates a device or disk director. The letter R indicates a remote device facility adapter. The letter S indicates SCSI. The letter F Indicates Fibre. If for example, the error were only to be excluded from requiring a call home if it dealt with a specific director or device or channel then only the appropriate box on the GUI presentation would be checked. Alternatively, field 1030 may be used to select that the error be excluded from calling home for all directors.
Referring again to FIG. 12, line 1032 c shows the particular error code 0472 and also indicates the quantification threshold that is acceptable before this error requires a call home. The threshold in this example is indicated by BURST_COUNT 4 and BURST_TIME 3 H. In this example, this means the error may occur four times within a three-hour timeframe without requiring a call home. However if the error occurred for a 5th time within this same three-hour team timeframe, then a call home would be required. Furthermore, line 1032 c shows that the threshold is accumulated per director and per device is indicated by the following text “SENSE DIR DV.”
Line 1032 e shows the sense pattern for each sense byte, wherein each sense byte relates to byte of information that is used to actually indicate which errors to exclude or ignore.
Referring now to FIG. 12, Screen 1000 includes a menu bar 1002 with menu selections File, Action, Option, and Help. Field 1004 on the GUI screen 1000 may be used to indicate which error code should be filtered. Regarding terminology, such an action may also be known as “flexing” an error. Hence field 104 is labeled “Error to be flexed.” In this example, the error to be flexed is 0472. Conveniently, field 1005 may be used to include an identifying case number. Field 1006 is used to indicate identification for each sense byte number (#) that may be involved in flexing the error. Field 1010 is used to indicate the count threshold and whether to accumulate per director. Likewise field 1012 is used to indicate the burst length and whether to accumulate per director. Field 1014 is a field for offering menu selections to indicate how the error will be flexed. Examples of such menu options shall be shown in the example figures of screen 1000 below.
The operator may save the file by clicking on Field 1034 . Although the operator can see the GUI presented on error response station 138 , in fact the filter.log 133 is saved on the hard disk 128 of the service processor 123 such that errors can be filtered occurring on data storage system 119 . This remote aspect provides an important advantage of this invention over the prior art.
The GUI tool also provides an important advantage over the prior art. An important aspect of the GUI tool is that the entry fields for the sense bytes for data being interrelated to the filter entry are constrained to follow a predetermined format. This greatly minimizes the risk of inadvertent errors being introduced by the filter entry process. The GUI tool includes menu options for inputting data related to the filter entry that also provides another important advantage over the prior art. The GUI tool is supported by filter logic which is computer-executable and which checks for text entry errors in accordance with predetermined conventions.
The method is now described with reference to FIGS. 6-11. The process starts its step 200 . In step 202 an error notification is sent by the service processor to indicate that an error has occurred at data storage system 119 . This error notification is also referred to as a “call home.” The error notification is received in step 204 by the filter logic 142 in error response station 138 . The error handling routine begins in step 206 . The continuation step 207 a connects with 207 b (FIG. 7 ).
Error analysis begins in step 208 (FIG. 7 ). An inquiry in step 210 poses the question whether human intervention is needed. The operator 104 answers this question. If the answer is “yes” a customer service engineer is dispatched in step 212 . But if the answer is “no,” than the operator determines whether they error can be filtered in step 214 . If the answer to that question is “no,” then the process turns to the beginning of the error analysis routine beginning in step 208 . But if the answer is “yes,” then the filter routine is began in step 222 . The continuation step 223 a connects with 223 b (FIG. 8 ).
The operator may create a filter entry for the filter log with the GUI based tool in step 224 (FIG. 8 ). If applicable the operator may add an error quantification threshold in step 226 . In step 228 , the operator may further use the GUI based tool to place EXCLUDE statements in the log as described above. Any INCLUDE statements are placed in the log in step 230 . The continuation step 231 a connects with 231 b (FIG. 9 ).
Using the GUI based tool, the operator may add a director and/or device level EXCLUDE to the EXCLUDE statements if applicable in step 232 . The filter logic invokes checking for data entry errors in step 234 . In step 236 the operator uses field 1034 (FIG. 12) to save the filter.log. This action saves the filter.log 133 on the service processor 123 , even though the action was presented on the display 140 of station 138 . This is part of the remote aspect of this invention. Error checking, which includes error filtering may now continue at the service processor in step 238 . The continuation step 239 a connects with 239 b (FIG. 10 ).
The filter log process begins in step 240 (FIG. 10 ). All INCLUDE statements are processed in step 242 , and all EXCLUDE statements are processed in step 244 . The INCLUDE statements process Filtertxtfiles such as those in group 180 (FIG. 5) which may cause EXCLUDE statements to be added to the filter.log. Error codes may be excluded on a global, device or director level as shown in respective steps 246 , 248 and 250 . The continuation steps 251 a and 249 a connect with 251 b and 249 b , respectively (FIG. 11 ).
Referring to FIG. 11, if the exclusion is on a device level (e.g., a disk drive), then the device may be made inoperable and all errors excluded for this device. Thus, in step 253 a query is posed to determine whether, in this example, a disk drive should be spun down, i.e., stopped. If the answer is “yes,” then all calls for errors related to that disk drive are prevented from causing a call home, in step 254 . If the answer is “no,” then in step 252 , a query is posed to determine whether thresholds apply in step 252 . Step 252 is reached directly, without doing step 253 , if the exclusion is at the director or global level and not the device level. Regardless, if the answer to the question of step 252 is “no,” then the error is excluded from calling home (step 254 ). If on the other hand the answer is “yes,” then another question is posed to determine whether thresholds have been exceeded in step 256 . If the answer is “no,” then the error is excluded from calling home (step 254 ). ). But, if on the other hand, the answer is “yes,” then the call is made for the error in step 258 .
Additional visual representations of different information appearing on screen 1000 , shown in FIGS. 13-15, further illustrate advantages provided by this invention. FIG. 13 shows a configuration of screen 1000 wherein the menus of filed 1014 presented by the GUI have been used to indicate that exclusions are to be performed globally (denoted as “entire box” in this example).
FIG. 14 shows a configuration of screen 1000 , and wherein in this example the menus of field 1014 exclude errors on a director level (denoted as “Director 4 A” in this example).
FIGS. 14 and 15 each demonstrate the error checking ability of this invention. In FIG. 14, an error message “Symptom code required in field 1032 ,” is presented because in this example shown on screen 1000 has a blank entry in field 1004 . An alert error message 1050 is presented on screen 1000 of FIG. 15 because the burst length is entered without time units, e.g. seconds (S), minutes (M), or hours (H) and the operator is also given a chance to fix the entry error.
A system and method has been described for managing errors occurring in a data storage system. Having described a preferred embodiment of the present invention, it may occur to skilled artisans to incorporate these concepts into other embodiments. Nevertheless, this invention should not be limited to the disclosed embodiment, but rather only by the spirit and scope of the following claims and their equivalents.
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The present invention is a system and method for providing clarity and simplicity to the task of screening for errors occurring in a data storage system and improving the effectiveness of the response to these errors. The system and method includes and employs a graphical user interface (GUI) for providing clarity and simplicity. Also by constraining entry texts into a controlled entry field, the likelihood of text-entry errors are greatly reduced. Further by providing menu options, simplicity and clarity are improved while likelihood of text-entry errors are also further reduced. Text-entry error checking tools are also provided to further decrease the probability that such errors will occur. The system and method employ a mechanism to allow for remote error screening and responding to the error from a remote location also.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 09/175,306, filed Oct. 20, 1998, now U.S. Pat. 6,108,026, issued on Aug. 22, 2000, which is a continuation of application Ser. No. 08/715,746, filed Sep. 19, 1996, now U.S. Pat. 5,838,361, issued Nov. 17, 1998, which is a divisional of application Ser. No. 08/584,246, filed Jan. 11, 1996, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to laser marking techniques and, more specifically, to an apparatus and method for marking the surface of a bare or packaged semiconductor device comprising one or more dice, using a laser and a laser reactive material.
2. State of the Art
Since the first semiconductor devices became commercially available, manufacturers have found it necessary to mark each chip or assembly of chips (bare die or package) with the company name, a part or serial number, or other information such as lot number or die location. Conventional marking methods utilize a mechanical device to transfer ink contained in an ink pad to the surface of a stamp. An individual chip is then stamped, and the automated process is repeated for subsequent chips.
Because of its mechanical nature and the drying time associated with ink, an ink stamping process is relatively slow. Moreover, if the mark is accidentally touched prior to complete drying, the mark will smudge. In chip manufacturing processes using such an ink stamping method, the ink marking operation may have to be included at a relatively early stage of production (if the die itself is to be marked) or just after post-encapsulation processing (if the package is to be marked) to allow for drying time without affecting the production rate. Such early marking may result, however, in marking defective chips that never make it completely through the manufacturing process.
Another problem associated with ink stamping methods is that the quality of ink stamped marks may substantially vary over time. This variation may be dependent upon the quantity of ink applied, ambient temperature and humidity, and/or the condition of the surface of the stamp. In any event, the consistency of a stamped mark may vary widely from chip to chip.
As a result of the deficiencies associated with ink stamping, it has become increasingly popular to use a laser beam to mark the surface of a chip. Unlike ink stamping, laser marking is very fast, requires no curing time, has a consistently high quality, and can take place at the end of the manufacturing process so that only good chips are marked.
Various machines and methods have been developed for marking a chip with a laser. As illustrated in U.S. Pat. No. 5,357,077 to Tsuruta, U.S. Pat. No. 5,329,090 to Woelki et al., U.S. Pat. No. 4,945,204 to Nakamura et al., U.S. Pat. No. 4,638,144 to Latta, Jr., U.S. Pat. No. 4,585,931 to Duncan et al., U.S. Pat. No. 4,375,025 to Carlson, a semiconductor device is placed in a position where a laser beam, usually produced by a carbon dioxide, Nd:YAG, or Nd:YLF laser, inscribes various characters or other information on a surface of the semiconductor device. Basically, the laser beam burns the surface of the chip such that a different reflectivity from the rest of the chip surface is formed. By holding the chip at a proper angle to a light source, the information inscribed on the chip by the laser can be read. Various materials are known in the art that are laser reactive (e.g., capable of changing color when contacted by a laser beam). As described in U.S. Pat. Nos. 4,861,620 to Azuma et al., U.S. Pat. No. 4,753,863 to Spanjer, and U.S. Pat. No. 4,707,722 to Folk et al., the part or component may be partially comprised of the laser markable material or have a coating of the material on the surface of the part or component to be marked.
Using a laser to mark a chip is a fast and economical means of marking. There are, however, certain disadvantages associated with state-of-the-art laser marking techniques that merely burn the surface to achieve the desired mark in comparison to ink stamping. For example, ink stamping provides a clearly visible image on the surface of a chip at nearly every angle of incidence to a light source. A mark burned in a surface by a laser, on the other hand, may only be visible at select angles of incidence to a light source. Further, oils or other contaminants deposited on the chip surface subsequent to marking may blur or even obscure the mark. Additionally, because the laser actually burns the surface of the work piece, for bare die marking, the associated burning may damage the internal circuitry of the chip directly or by increasing internal die temperature beyond acceptable limits. Moreover, where the manufactured part is not produced of a laser reactive material, laser reactive coatings applied to the surface of a component may take hours to cure.
Thus, it would be advantageous to provide a marking technique that combines the speed and precision of laser marking with the contrast and distinctiveness of ink stamping, without any substantial curing or drying time. Moreover, it would be advantageous to develop a method and apparatus for marking the surface of a semiconductor chip that does not harm the circuitry enclosed therein.
BRIEF SUMMARY OF THE INVENTION
According to the present invention, a laser marking apparatus and method are disclosed wherein an object is subjected to a laser beam or other suitable energy source for marking purposes. While the laser beam is actively marking, a substance is introduced into the marking work area that interacts with the laser beam. The substance reacts with the localized heat created by the laser and forms a new compound on the surface of the package or surface of the chip. This new compound is selected to contrast highly with the color and/or surface texture of the surface that has been marked.
In another particular aspect of the invention, the surface of a chip is at least partially covered with a laser reactive substance prior to being contacted by a laser beam. The substance may be in either liquid or powder form and may be rolled on, sprayed on, or otherwise applied by means known in the art. When subjected to the localized heat created by the laser, a semi-permanent, solvent-removable mark is formed and bonded to the surface of the chip. The excess material on the non-irradiated portion, that is, the portion of the surface not contacted by the laser beam, is readily removed by an exhaust or residue removal system and may be recycled for future marking.
In another, more particular aspect of the invention, an ink bearing material, or other pigmented or laser reactive substance-bearing material is disposed adjacent to an exposed surface of a chip. The laser beam transfers ink contained in the ink bearing material to the exposed surface of the chip. For example, the ink bearing material may comprise a ribbon contained in a ribbon dispenser. During the marking process, as the laser beam transfers ink from one point on the ribbon to the chip, another segment of the ribbon may be exposed to the laser beam for subsequent markings. Such an ink bearing material may also help to reduce heat produced by the laser beam from substantially penetrating the surface of the marked chip.
In a more particular aspect of the invention, a stream of atomized particles of B-stage epoxy with an added pigment of a desired color (white for example) is directed at the surface where the laser is actively marking the specimen. The epoxy reacts to the heat of the laser and cures to a visible white image coincident with the path of the laser. The excess particles, those which have not been directly irradiated by the laser beam, may be removed along with other debris from the work area by a debris removal system.
In another, more particular aspect of the invention, much of the epoxy is destroyed by the laser. A thermal gradient, however, along the trailing edge of the laser path causes the epoxy to cure normally into a final and permanent state, thus producing the desired mark.
In another particular aspect of the invention, the laser reactive material absorbs most of the heat produced by the laser. As a result, the delicate internal circuitry of the chip is not exposed to this potentially damaging heat.
In another aspect of the invention, subsequent to or while being marked, the chip is subjected to a jet of coolant to rapidly cool the markings and prevent or reduce the potential for heat damage to the chip. The coolant may be in a liquid, gas, or solid state. In this manner, any residual heat contained in the marking material or present in the surface of the chip may be rapidly dissipated. The markings are thus completely cured and/or cool before exiting the marking apparatus.
In another, more particular aspect of the invention, the laser marking apparatus is computer controlled. In addition to controlling the laser beam, chip location, and other process parameters, the central processing unit (CPU) may control the quality of markings. If so, the marked chips may be subjected to a camera which feeds an image of each chip to the CPU. The CPU compares the pixels of the captured image to a given resolution standard. If the marking is of a sufficiently high quality, the chips are automatically accepted. If not, the chips are automatically rejected for rework and remarking.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a schematic side view of a laser marking apparatus in accordance with the present invention;
FIG. 2 is a perspective view of a chip contained in a first embodiment of a chip carrier in accordance with the invention shown in FIG. 1;
FIG. 3 is a close-up perspective view of a magazine and chips contained therein in accordance with the invention shown in FIG. 1;
FIG. 4 is a perspective view of a second embodiment of a chip carrier in accordance with the present invention;
FIG. 5 is a perspective view of a portion of track in accordance with the chip carrier shown is FIG. 4;
FIG. 6 is a close-up schematic side view of a first embodiment of a laser marking apparatus in accordance with the present invention;
FIG. 7 is a close-up schematic side view of a second embodiment of a laser marking apparatus accordance with the present invention;
FIG. 8 is a close-up schematic side view of an alternate embodiment of a roller-type applicator in accordance with the present invention; and
FIG. 9 is perspective view of a packaged semiconductor device positioned on a track in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a laser marking apparatus 10 in accordance with the present invention is illustrated. Generally, the chips 12 (the term “chips” as used herein refers to both bare and packaged dice, as the invention has equal utility in the marking of both) are automatically fed through the laser marking apparatus 10 for marking purposes. The chips 12 may be fed by a belt, chain, or pneumatic conveyor system as known in the art, gravity fed as shown in FIG. 1, or delivered by other means known in the art. The chips 12 are first stacked in a feed magazine 16 (FIG. 3 ). When released from the feed magazine 16 by a mechanical release mechanism as known in the art, the chips 12 exit through an opening 18 located proximate the bottom 20 of the feed magazine 16 onto the low-friction track 14 .
As shown in FIG. 2, the chips 12 are secured in carriers 11 , preferably made of a statically dissipative material, such as certain plastics and other materials known in the art. The chip carriers 11 may be used to handle the chips 12 during many phases of the manufacturing process, up to and including shipment. The chips 12 are placed on a base 17 and held in place by projections 19 , 21 , 23 , and 27 . Legs 33 , 35 , 37 and 39 extend downwardly from the bottom 41 of the base 17 . The legs 33 and 35 as well as legs 37 and 39 are separated by a distance D 1 sufficient to allow passage of the track 14 . Moreover, legs 35 and 39 , as well as legs 33 and 37 , are separated by a distance D 2 to allow projections 23 and 19 to fit respectively therein whenever the chips 12 are stacked in their respective carriers 11 .
As seen in FIG. 3, the chips 12 are stacked in the feed magazine 16 . The chips 12 , suspended above the track 14 by the feed magazine 16 , are individually released onto the track 14 and allowed to slide by the force of gravity down the track 14 . The feed magazine 16 automatically releases the chips 12 at constant or selectively variable intervals dictated by process requirements. The feed magazine 16 may vary in size to accommodate large or small numbers of chips 12 and each carrier 11 may vary in size to accommodate one or more dice.
Carriers 11 may also be in elongated form to accommodate a plurality of chips 12 to be marked. As depicted in FIG. 4, an empty chip carrier 82 is capable of holding at least four (4) chips 12 . The chip carrier 82 may also be modified to hold several dice that have not been cut apart (if increased in size) or an entire wafer (if modified to hold round rather than rectangular objects). Chips 12 are held in the carrier 82 by elements 84 which provide an interference or resiliently-biased fit as desired between the carrier 82 and a chip 12 . Moreover, the chips 12 rest upon the lip 86 so that each chip 12 held by the carrier 82 extends equally above the top surface 88 of the carrier 82 .
The carrier 82 is adapted to slide along a track positioned in several different orientations, such as a track 90 shown in FIG. 5 . The carrier 82 has legs 92 and 94 depending from and separated by cross-members 96 , 98 , 100 , 102 and 104 extending the length of the carrier 82 . The legs 92 and 94 are parallel to each other and have lateral extensions 106 and 108 , respectively, spaced from the cross-members 96 , 98 , 100 , and 102 , running the length of the legs 92 and 94 and projecting inwardly for grasping the elongate rails 110 and 112 of the track 90 .
The rails 110 and 112 of the track 90 are shown oriented back-to-back and having a “C” shaped cross-section and are spaced apart by members 107 . When the carrier 82 is riding on the top of the track 90 , the lateral extensions 106 and 108 grasp the top portions 114 and 116 of the rails 110 and 112 , respectively. If the carrier 82 is suspended from the bottom of the track 90 (in an inverted orientation), the lateral extensions 106 and 108 grasp the bottom portions 118 and 120 , respectively. Moreover, because the carrier 82 is designed to actually grasp the track 90 rather than merely ride on it, the track may be placed in any orientation.
When the chips 12 are placed in the carrier 82 and the carrier 82 is positioned on the track 90 , the marking operation may occur on either side. That is, because both sides of the chip 12 are exposed, neither the top nor the bottom of the chip 12 has any substantial portion covered by the carrier 82 . If the chips 12 in the carrier 82 are automatically inspected, defective chips 12 may be automatically popped out of the carrier 82 . A solvent or other substance, or even a de-marking laser, may be used to remove the defective mark and the chip 12 may then be reloaded into a carrier 82 and remarked. Thus, the requirements of the process and of the marking and inspection apparatus can dictate the orientation of the track 90 , the carriers 82 thereon, and the chips 12 in the carriers 82 .
The carrier 82 is also suited for stacking with other similar carriers. Extending longitudinally along the length of the top surface 88 of the outside edges 103 and 105 of the carrier 82 are channels 95 and 97 sized and shaped to receive extensions 99 and 101 extending downwardly from legs 92 and 94 , respectively. The extensions 99 and 101 also extend longitudinally the length of the carrier 82 along the bottom 93 of the carrier 82 . The extensions 99 and 101 extend downwardly from the lateral extensions 106 and 108 , respectively, a sufficient distance so that when stacked, the lateral extensions 106 and 108 are spaced above the chips 12 contained in the carrier 82 .
For typical packaged dice (chips) 122 , such as that shown in FIG. 6, the chip 122 can ride directly on the track 14 without being placed in a carrier. The connecting tabs 124 located on the sides 126 and 128 of the chip 122 keep the chip 122 properly aligned on the track 14 . Moreover, the track 14 is of a width W so that the chips 122 stay in longitudinal and latitudinal alignment with the track 14 . The chips 122 can also be loaded onto the track 14 by a feed magazine of a modified version of feed magazine 16 and loaded into a shipping magazine such as tubular shipping magazine 50 (FIG. 1 ).
FIG. 1 shows laser marking apparatus 10 of the present invention in a gravity feed arrangement where the track 14 is placed at an angle A relative to the horizon such that the force of static friction between the carriers 11 and the track 14 is less than the force of gravity along the line of the track 14 on the carriers 11 . When the chips 12 are released from the feed magazine 16 , several chips 12 are staged, six (6) in this case, by automated indexing pins 22 and 24 at the initial staging area 13 . Once the chips 12 are staged, indexing pin 24 is retracted to allow the staged chips 12 to slide on the track 14 until stopped by indexing pin 26 at the marking area 25 . The chips 12 are held in place by indexing pin 26 until all of the chips 12 retained by indexing pin 26 are marked by the laser 28 . The laser 28 may be comprised of a carbon dioxide, Nd:YAG, Nd:YLF laser or other suitable lasers or devices, such as an electron beam emitter, known in the art. The laser 28 is longitudinally translatable along the support 30 in at least one direction so that all of the chips 12 retained by indexing pin 26 can be marked by the laser 28 in a single pass.
Once the laser 28 marks the chips 12 , indexing pin 26 is retracted and the chips 12 are allowed to slide until retained by indexing pin 32 at the debris removal and inspection area 31 . As the chips 12 pass from indexing pin 26 to indexing pin 32 , they slide under the debris removal system 34 . The debris removal system 34 may employ suction, forced air and/or other methods known in the art to clean the surface 54 (FIG. 7) of the chip 12 without disturbing the markings thereon (not shown). Moreover, any marking material that remains in the recovered residue may be reprocessed for future chip marking.
The chip 12 , adjacent the indexing pin 32 , is then inspected by the camera 36 which may be a CCD camera or other suitable camera known in the art. That is, the camera 36 photographs the image of the surface 54 of the chip 12 and the markings contained thereon and sends this image to a central processing unit, such as CPU 80 in FIG. 1 . The image received by the CPU 80 is broken down into individual pixels and the pixels are compared to a minimum standard. Once the image is received and compared by the CPU 80 , each chip 12 is released by the indexing pin 32 . The adjacent, upstream chips 12 are maintained in position by the indexing pin 38 until each is released for inspection. If the chip 12 released by the indexing pin 32 is acceptable according to the comparison made by the CPU 80 , then the chip 12 is allowed to slide on the track 14 to the final staging area 40 . If the chip 12 is determined by the CPU 80 to be unacceptable, a trap door 42 is opened and the chip 12 falls into a bin 44 so that the chip 12 may be reworked and remarked.
An electronic eye 46 is positioned to identify when a proper number, in this case six (6), of acceptable chips 12 are ready to be packaged. Once the proper number of chips 12 is achieved, the indexing pin 48 is activated until all of the chips 12 held in the final staging area 40 have been loaded into a shipping magazine 50 .
The laser marking apparatus 10 , disclosed herein only requires an operator to load the feed magazine 16 with chips 12 to be marked and to remove and replace the shipping magazine 50 when fall. The rest of the marking/inspection operation is completely automated and controlled by the CPU 80 . Moreover, it is possible for the CPU 80 to control multiple track arrangements simultaneously.
Referring now to FIG. 7, a close-up view of the laser 28 in relation to the chip 12 is shown. The laser 28 projects a movable laser beam 52 onto the surface 54 of the chip 12 to mark the chip 12 . As the laser beam 52 is directed toward the chip surface 54 , a laser reactive material 58 is injected through an applicator or pigment nozzle 60 onto the chip surface 54 at the same location 56 that the beam contacts the chip 12 . The heat from the laser beam 52 fuses the laser reactive material 58 onto the chip surface 54 . Laser reactive material 58 present on any non-irradiated portion of the chip 12 that has not been exposed to the laser beam 52 and is therefore unreacted does not bond to the chip surface 54 and is subsequently removed.
A coolant 62 may also be injected from a coolant injector or nozzle 64 onto the surface 54 of the chip 12 and onto the laser reactive material 58 present on the chip surface 54 . If a coolant 62 is used, any residual heat contained in the chip 12 or the laser reactive material 58 may be quickly dissipated. This may be necessary to help protect the delicate circuitry of a bare die from the heat of the laser beam 52 . The laser 28 is shown without the coolant nozzle 64 in FIG. 1 . The use of a coolant 62 also prevents or insures the laser reactive material 58 , which may be an epoxy material that may cure at a relatively low temperature, from curing prematurely, thereby decreasing the need for relatively high curing temperature epoxies to be used in the marking process.
As can be seen, both the pigment nozzle 60 and the coolant nozzle 64 are attached to the laser 28 so that any movement of the laser results in movement of the nozzles 60 and 64 . Thus, the laser 28 and the nozzles 60 and 64 translate together, and are thus synchronous, so that a minimum amount of laser reactive material 58 and coolant 62 is required. Moreover, the marking location immediately surrounding the target surface on each chip 12 for laser beam 52 may be placed in a reduced or negative pressure environment with respect to the surrounding work area, by means known in the art to reduce overspray that may otherwise settle on the chip 12 or drift onto the track 14 or other parts of the laser marking apparatus 10 .
In FIG. 8, an alternate embodiment is shown having a ribbon dispenser 66 comprised of a feed reel 68 and a take-up reel 70 . The ribbon dispenser 66 dispenses a ribbon or strip of ink bearing material 72 from the feed reel 68 to the take-up reel 70 . The ribbon 72 extends over and is proximate to the surface 54 of the chip 12 . The ribbon 72 may also extend over a number of chips 12 or several ribbon dispensers 66 may be placed side by side so that marking of several chips 12 can occur sequentially or so that multiple colors may be used in the marking process. The chips 12 are allowed to pass under the ribbon 72 as they slide along the track 14 . When the chips have moved to the marking area 25 , the laser 28 projects a laser beam 52 onto the surface of the ribbon 72 and transfers ink from the ribbon 72 onto the surface 54 of the chip 12 . One advantage of the embodiment of FIG. 8 is the elimination of liquid pigments and coolants, the latter being due to absorbance of the laser energy by the ribbon 72 carrying the marking material. Another advantage is that the marking process using a ribbon 72 is cleaner in that no excess particles of marking material are present in the marking area to contaminate the marking area and chip in undesired areas.
Referring to FIG. 9, the laser reactive material may be applied by a motorized roller 130 rotatably attached to a roller support 135 . An open-celled sponge or fiber pad 132 is held against the roller 130 by a support member 134 . The support member also supplies the laser reactive material to the pad 132 , the arrangement functioning like a shoe-polish applicator. The roller is held in contact with the top surface 54 of the chips 12 and forces the chips 12 between the roller and the track 14 . Because the pad 132 continually supplies laser reactive material to the roller 130 , each chip 12 receives a consistent layer of material. The chips 12 can then be laser marked. The application of laser reactive material to the roller 130 could also be achieved by spray, drip or other methods known in the art.
While the present invention has been described in terms of certain preferred embodiments, it is not so limited, and those of ordinary skill in the art will readily recognize and appreciate that many additions, deletions and modifications to the embodiments described herein may be made without departing from the scope of the invention as hereinafter claimed. As used in the claims, as in the preceding specification, the term “chip” or “chips” is intended to mean and encompass both the circuit side and/or back (Si) side of the semiconductor dice, and packaged semiconductor dice.
Additionally, while the invention has been described in conjunction with the use of a laser as an energy source for the marking of a chip or chips, any suitable energy source may be used in place of the laser energy source, such as a focused ultraviolet light source, electron beam, focused and directed hot air source, etc.
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A laser marking apparatus and method for marking the surface of a semiconductor chip are described herein. A laser beam is directed to a location on the surface of the chip where a laser reactive material, such as a pigment containing epoxy is present. The heat associated with the laser beam causes the laser reactive material to fuse to the surface of the chip creating a visibly distinct mark in contrast to the rest of the surface of the chip. Only reactive material contacted by the laser fuses to the chip surface, and the remaining residue on the non-irradiated portion can be readily removed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is concerned with stiffener materials for use in the fabrication of shoes and for making other articles.
2. Description of the Related Art
Stiffener materials traditionally are used in the shoe industry to provide varying degrees of resilient, stiffness, and shape-retention to the heel and toe portions of shoes. These materials have been made of either a needle punched non-woven fabric which is saturated with a latex resin composition or a flexible thermoplastic resin that is extruded or powder coated onto a woven fabric or extruded into a sheet. If a non-woven fabric is employed, the typical material which is selected is a polyester mat made from fibers having a denier of between 3 and 6 deniers or mixtures of such fibers. The latex resin compositions may be based on resins selected from styrene resins, styrene-butadiene resins, vinyl acetate resins, vinyl chloride resins or acrylic resins. The extruded thermoplastic or powder coated thermoplastic materials may be selected from the group consisting of polyvinyl chloride, ionomers, high, medium or low density polyethylene, polypropylene, polyesters, polystyrene and copolymers and compatible blends of such polymers. After the initial coating of the woven or non-woven fabrics, a separate hot melt coating operation is carried out to provide a finished stiffener which has self adhesive properties which are sufficient to bond the stiffener to an inner layer and an outer layer of a manufactured article.
The powder-coated resins usually contain particles which measure from about 100 to about 590 microns which prevents the particles from passing through the woven fabrics during the coating operation.
A typical non-woven latex saturated stiffener is made with a polymer latex wherein the dispersed polymer particles have an average latex particle size of less than one micron and a filler such as calcium carbonate which has an average particle size of less than 10 microns. A continuous sheet of the non-woven fabric may be passed through a bath containing the latex composition to saturate the non-woven fabric prior to passing the saturated sheet through calendaring rolls, which are spaced apart with a filer gauge, in order to remove excess latex composition. The saturated non-woven fabric is then clipped onto a tenter frame and passed to a drying oven to remove the water from the latex composition. The dried non-woven fabric is then sized by passing the dried latex saturated non-woven fabric through calendar rolls and wound on a beam. The product may be made heavier, thinner, stiffer or more flexible depending on the weight and thickness of the non-woven fabric, the amount of the latex applied and the formulation of the latex.
Since the dried non-woven fabric has no adhesive properties after the application of the latex and the oven drying, it is necessary to apply a hot melt adhesive, such as a ethylene vinylacetate hot melt adhesive. This results in a product that can be heat activated to provide a finished stiffener which has self adhesive properties which are sufficient to bond the stiffener to an inner layer and an outer layer of a shoe.
U.S. Pat. No. 4,717,496 describes a method of making a stiffening material with non-latex powders. The disclosure of U.S. Pat. No. 4,717,496 is incorporated by reference.
SUMMARY OF THE INVENTION
The present invention provides a novel process that produces a novel stiffener material which is made by adding an effective amount of a finely divided thermally activatable powder adhesive to a latex composition which is used to saturate a non-woven fabric to make a stiffener material.
The process of the invention comprises a method of making a fabric based stiffener material having thermal adhesive properties on its top and bottom surfaces, said process comprising:
(a) preparing a coating composition which comprises a latex forming resin and a finely divided powdered adhesive polymer;
(b) contacting a non-woven fabric with the composition of step (a) to form a latex saturated non-woven fabric;
(c) removing the excess latex from the non-woven fabric; and
(d) drying the product of step(c).
Accordingly, it is a primary object of the invention to provide a process where a treating composition comprising a latex based stiffening resin and a heat activated adhesive resin is used to saturate a non-woven fabric to form a treated fabric and thereafter drying and sizing said treated fabric to make a heat activated adhesive stiffener having adhesive properties on both sides of the stiffener material.
It is also an object of the invention to provide a novel heat activated stiffener material which has adhesive material on the surface and on the interior of the stiffener material.
It is also an object of the invention to eliminate the need to carry out a separate adhesive coating operation whereby an adhesive is applied as a separate manufacturing step to a stiffener which is prepared by a latex coating a non-woven fabric.
It is also an object of the invention to provide a novel polyester containing latex composition which provides a stiffener having a good combination of stiffness, shape-retention, and resiliency.
These and other objects and features of the invention will become apparent from a review of the following detailed description.
DETAILED DESCRIPTION OF THE INVENTION
While woven or non-woven fabrics may be used in the practice of the invention, it is preferred to employ a non-woven fabric that is made with fibers having a denier of about 6 to about 15 or fabrics made with a blend of such fibers. It is especially preferred to use a non-woven fabric made with fibers that are a 70/30 blend of 15 and 6 denier fibers. If fabrics are used that are made with deniers substantially different than the above described results, difficulty can arise when using t he latex containing the adhesive and the polymer material.
The polyester containing latex composition is prepared by taking a conventional latex of a material such a styrene butadiene, an acrylic polymer, a vinyl acetate resin, a vinyl chloride resins or other suitable latex forming polymer and adding an amount of a polyester powder which is sufficient to impart good adhesive properties to the finished stiffener material. Saturated powdered polyesters such as polycaprolactone, azelaic, adipic, sebacic and copolymers of polyethylene terephthalate and the like may be employed as substantially pure resins or in the form of commercially formulated adhesive compositions with conventional dispersants, tackifiers, stabilizers, fillers and the like. If the polyester is employed as a pure resin, conventional dispersants such as non-ionic surfactants, gums, colloids or thickening agents may be added to stabilize the latex containing the polyester. In order to provide an adhesive which adheres to the non-woven fabric without “dropping out”or in other words separating as a discrete powder on the non-woven fabric, it is preferred to grind the powdered polyester to a finely divided state which will remain dispersed on the non-woven fabric when it is applied from a dispersion in a polymeric latex. Generally an average particle size of less than 150 microns and more preferably less than 100 microns will provide good results. The “dropping out” phenomenon is usually observed when the process of the invention is practiced on a full scale commercial apparatus as compared to a laboratory scale operation. Ammonium chloride or other acid forming ingredients may be employed as a catalyst to cross-link certain polymer latex resins. It is preferred to add an effective amount of an organic cross-linking agent to the polyester containing latex to improve resilience and prevent “washing out” of the latex. Melamine-formaldehyde condensates are preferred. Suitable examples of these materials are described in U.S. Pat. No. 2,871,213 and U.S. Pat. No. 3,215,647, which are incorporated by reference. If a cross-linker is used, a total of 1.0% to 2.0% by weight may be used. Compatible fillers such as finely calcium carbonate, and the like may be employed.
The novel stiffener may be evaluated to determine the adhesive bonding strength of the finished product by die cutting a piece of the stiffener to be tested and inserting the stiffener between two pieces of a non-woven lining material that is a 35% poly ester blend having a thickness of 0.029 inches. The three pieces are held together and placed into a back part heel counter molding machine with the female mold at 180° F. and the male mold at 290° F. The mold is closed and held in position for 17 seconds, The mold is opened and the laminate is placed, at room temperature, in a laminate cooling station having the desired shape of the final product. The shaped heel counter is now rigid and the stiffener is bonded to the two pieces of non-woven lining material. The adhesive test requires that the three part laminate remain bonded together when manual pressure is applied to pull the components apart. The resiliency test is based on making a thumb indent on the side of the heel counter and evaluating the degree which the indent bounces back. An acceptable bounce is when the indent bounces back immediately with a “ping-pong” sound.
The latex of the invention will comprise the following formulation:
latex forming polymer dry basis
15 wt % to 35 wt %
dispersant
0.4 wt % to 1.0 wt %
adhesive polymer
10 wt % to 21 wt %
water
35 wt % to 50 wt %
filler
0 wt % to 15 wt %
Generally the preferred latex formulations will comprise the following formulation:
latex forming polymer dry basis
29.5 wt % to 35 wt %
dispersant
.7 wt % to .9 wt %
adhesive polymer
15 wt % to 19 wt %
water
43 wt % to 44 wt %
filler
1.1 wt % to 11.8 wt %
The non-woven fabric should be saturated with an amount of the latex formulation that will result in a dry weight gain of between 300 to 1000 g/meter 2 of coated fabric and preferably between 400 to 900 g/meter 2 of based on the dry weight of the coated fabric after the coating and drying operation as compared to the dry weight of the uncoated fabric. The preferred drying conditions are a temperature of from 200 to 400° F. and preferably from 250° F. to 370° F. which are applied for a period of 5 to 15 minutes in a tenter frame equipped thermostatically controlled oven.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples are added to illustrate the invention. They are not to be construed as limitations on the scope of the invention.
EXAMPLE 1
A formulation was made by adding the ingredients in sequence using a laboratory propeller agitator:
Styrene-butadiene copolymer
318.0
g
(Dow 242 SBR on resin-49% solids; particle
size 1750 Angstroms; Brookfield visc.
#2-50 rpm = 70; Tg 45° C.))
Melamine-formaldehyde condensate cross-linker
8.0
g
(cyrez 933; CAS. No. 88002-20-01)
Water
68.0
g
Oxazolidine surfactant
3.0
g
(Alkaterge T-IV wt av mol wt 545
CAS. No. 95706-86-8)
Polyepsiloncaprolactone-88 micron av. dia.
67
g
(Tone 767-MFI ASTM-D1238-73 1.9 at 80° C.,
44 psi, g/10 min. mp. 140° C.; shore hardness 55D)
Calcium carbonate
46
g
(median particle dia. 6.5μ; Omyacarb 6)
Ammonium chloride
3
g
Aqueous Soln. Sod. polyacrylate
14.5
g
(Alcogum 296; Brookfield vis. 20 rpm, 25° C.
20,000-30,000 cs; 14.7-17.3% solids)
Total mix Viscosity-Brookfield-3 spindle-20 rpm-25° C.
2050
cps
% polyester based on total weight of solids - 25%
% polyester based on total weight of resin - 30%
This formulation applied to a non-woven fabric, 166 g/m2, which was made from a 70/30 blend of 15 and 6 denier fibers. The fabric was provided on a continuous roll. 60″ wide which was passed through a trough to saturate the fabric prior to passing the fabric through a set of steel rolls that were 76″ wide and 9″ in diameter with an opposing hydraulic pressure of 500-600 psi. After passing through the rolls, the fabric was dried in an oven 85 ft. long at a temperature of 130-200° C. and wound on a reel at a speed of 3.25 yards/minute. The product produced had good resiliency and a fair bond.
EXAMPLE 2
A formulation was made by adding the ingredients in sequence using a laboratory propeller agitator:
Styrene-butadiene copolymer
260.0
g
(Dow 242 SBR on resin-49% solids; particle
size 1750 Angstroms; Brookfield visc.
#2-50 rpm = 70; Tg 45° C.))
Melamine-formaldehyde condensate cross-linker
8.0
g
(cyrez 933; CAS. No. 88002-20-01)
Water
75.0
g
Oxazolidine surfactant
4.0
g
(Alkaterge T-IV wt av mol wt 545
CAS. No. 95706-86-8)
Polyepsiloncaprolactone-88 micron av. dia.
85
g
(Tone 767-MFI D1238-73 1.9-80° C., 44 psi, g/10 min.
mp. 140° C.; shore hardness 55D)
Calcium carbonate
0
g
(median particle dia. 6.5μ; Omyacarb 6)
Aqueous Soln. Sod. polyacrylate
22
g
(Alcogum 296; Brookfield vis. 20 rpm, 25° C.
20,000-30,000 cPs; 14.7-17.3% solids)
Ammonium chloride
4
g
Total mix Viscosity-Brookfield-3 spindle-20 rpm-25° C.
2100
cps
% polyester based on total weight of solids 37.7%
% polyester based on total weight of resin 40%
This formulation applied to a non-woven fabric, 166 g/m2, which was made from a 70/30 blend of 15 and 6 denier fibers. The fabric was provided on a continuous roll. 60″ wide which was passed through a trough to saturate the fabric prior to passing the fabric through a set of steel rolls that were 76″ wide and 9″ in diameter with an opposing hydraulic pressure of 500-600 psi. After passing through the rolls, the fabric was dried in an oven 85 ft. long at a temperature of 130-200° C. and wound on a reel at a speed of 3.25 yards/minute. The product produced has a very good bond and good resiliency.
EXAMPLE 3
A formulation was made by adding the ingredients in sequence using a laboratory propeller agitator:
Styrene-butadiene copolymer
227.0
g
(Dow 242 SBR on resin-49% solids; particle
size 1750 Angstroms; Brookfield visc.
#2-50 rpm = 70; Tg 45° C.))
Melamine-formaldehyde condensate cross-linker
7.0
g
(cyrez 933; CAS. No. 88002-20-01)
Water
92.0
g
Oxazolidine surfactant
4.0
g
(Alkaterge T-IV wt av mol wt 545
CAS. No. 95706-86-8)
Polyepsiloncaprolactone-88 micron av. dia.
91
g
(Tone 767-MFI D1238-73 1.9-80° C., 44 psi, g/10 min.
mp. 140° C.; shore hardness 55D)
Calcium carbonate
62
g
(median particle dia. 6.5; Omyacarb 6)
Aqueous Soln. Sod. polyacrylate
14
g
(Alcogum 296; Brookfield vis. 20 rpm, 25° C.
20,000-30,000 cPs; 14.7-17.3% solids)
Total mix Viscosity Brookfield-3 spindle-20 rpm-25° C.
1850
cps
% polyester based on total weight of solids 34.5%
% polyester based on total weight of resin 45%
This formulation applied to a non-woven fabric at a level of 166 g/m2. The non-woven fabric was made from a 70/30 blend of 15 and 6 denier fibers. The fabric was provided on a continuous roll. 60″ wide which was passed through a trough to saturate the fabric prior to passing the fabric through a set of steel rolls that were 76″ wide and 9″ in diameter with an opposing hydraulic pressure of 500-600psi. After passing through the rolls, the fabric was dried in an oven 85 ft. long at a temperature of 130-200° C. and wound on a reel at a speed of 3.25 yards/minute. The product produced had good resiliency and a good bond.
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A process of making a fabric based stiffener material having thermal adhesive properties on its top and bottom surfaces which is based on (a) contacting a non-woven fabric with a latex forming resin and a finely divided powder adhesive polymer to form a latex saturated non-woven fabric; and (b) removing the excess latex from the non-woven fabric formed in step (a); and (c) drying the product of step (b).
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BACKGROUND OF THE INVENTION
This invention pertains to an integrated circuit comprising a binary integrated digital-to-analog converter for generating from the voltage of a voltage source a terminal voltage adjustable with the aid of a digital signal. The printed publication of the firm of Valvo GmbH, entitled "Technische Informationen fur die Industrie", No. 791221, December 1979 describes one such arrangement. In the conventional arrangement, the values of the analog output voltage, i.e., the terminal voltage, may range between 0 and 5 volts, when the integrated digital-to-analog converter with its corresponding external wiring are operated by a positive voltage of 5 volts and a negative voltage of -15 volts. However, this terminal voltage range is too small for many applications, for example, for operating varactor diodes in radio and television receivers. In these cases it is desireable to have a terminal voltage range of about 30 volts.
SUMMARY OF THE INVENTION
In accordance with the invention, an improved integrated digital-to-analog converter provides an optionally large terminal voltage range which, in particular, is so large that the terminal voltage can be used for operating varactor diodes in radio and television receivers. Moreover, independent of the value of the voltage from which the terminal voltage is derived, the number of digits of the digital signal as applied to the input of the digital-to-analog converter, corresponds to the entire terminal voltage range. If, for example, a nine-digit binary digital signal is present, it is possible therewith to distinguish 2 9 =512 voltage stages. These, independently of the momentary value of the voltage, shall always be completely assigned thereto, irrespectively of whether it just amounts to 30, 31 or only to 28 volts.
Advantageously in accordance with the invention, it is not necessary to connect any components from the outside to the integrated circuit, apart from e.g., the varactor diode to be operated therefrom. Another advantage is that in the case of a positive terminal voltage and, consequently, a positive voltage and a positive operating voltage, npn transistors can be used exclusively in the digital-to-analog converter unit. Accordingly, the integrated circuit in accordance with the invention, apart from the two pnp current sources and some further possibly required pnp transistors, contains exclusively npn transistors and, if so required, an insulated-gate field-effect transistor.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained in greater detail with reference to FIGS. 1 to 4 of the accompanying drawings, in which:
FIG. 1 is a basic circuit block diagram of the integrated circuit according to the invention;
FIG. 2 shows the circuit symbol for a npn current mirror circuit;
FIG. 3 shows the circuit symbol for a pnp current mirror circuit; and
FIG. 4 shows is a partially schematic circuit diagram relating to an embodiment of the invention for a positive voltage and operating voltage.
DETAILED DESCRIPTION
In the block diagram of FIG. 1 the integrated digital-to-analog (D/A) converter dw has a digital input to which the digital signal ds is fed either in a parallel or in serial form. In FIG. 1 digital signal ds is shown as a parallel input to converter dw. According to a first feature of the invention, the D/A converter dw is operated from a single operating voltage source bq which, for example, according to the embodiment as shown in FIG. 4, may be connected in such a way that the zero point of the circuit is connected to the negative pole thereof, so that, there is a positive operating voltage +bq.
According to a further feature of the invention, both the reference voltage source ra and the current-to-voltage converter sw are included in the integrated circuit, that is, these circuit parts are embodied on the same monocrystalline semiconductor body as the digital-to-analog converter dw.
From FIG. 1 it can be seen that the current output ai of the digital-to-analog converter is connected to the current input ei of the current-to-voltage converter sw which, in turn, is operated from the voltage source u from which there is derived the terminal voltage uv which is dependent upon the digital signal ds. The voltage source u, like the operating voltage source bq, is a source of dc voltage of which the same pole is applied to the zero point of the circuit as in the case of the operating voltage source bq. Accordingly, in FIG. 4 the negative pole of the voltage source u is applied to the zero point of the circuit, so that in this case there is the positive voltage +u, to which the current-to-voltage converter sw is connected.
The measuring circuit m is connected between voltage source u and the zero point of the circuit. The output signal of measuring circuit m is fed to the source of reference voltage rq so that the maximum value of the digital signal ds is always associated with the voltage u. Unlike prior art control circuits which utilize backward regulation with the aid of the measuring circuit for keeping constant an output signal, the present invention intentionally does not utilize a constant regulation, but intentionally utilizes a forward regulation.
The source of reference voltage rq is connected with one side to the zero point of the circuit and, as already described in the above cited printed publication, controls the current flowing in the converting stages of the digital-to-analog converter dw.
FIGS. 2 and 3 show two circuit symbols used in FIG. 4, for a npn current mirror circuit ns (FIG. 2) and a pnp current mirror circuit ps (FIG. 3), as well as the most simple realization thereof with the aid of two npn or pnp transistors. Accordingly, the most simple current mirror circuit consists of two transistors of the same conductivity type, with the base-emitter paths thereof being connected in parallel, and connected to one another at the one collector and base thereof. The current-mirror property results from the fact that the base-emitter pn junction areas of both transistors are alike. In this case, the same current flows in the two collector-emitter circuits of the transistors, that is, the current flowing in the one transistor "mirrored" in the other. If, however, the base-emitter pn junction areas differ from one another in their sizes, then the current in the one transistor will relate to that in the other transistor in the same relationship as these junction areas. In this case, the circuits are no longer current-mirror circuits, but are current-transformer circuits. If now, as is still to be explained in greater detail hereinafter with reference to FIG. 4, in the one current mirror circuit there is to be mirrored e.g. double the current as in another current mirror circuit, the transistors of this current mirror circuit conducting double the current, must have double the pn junction area as that of the other one.
The above described simple circuit realization, however, does not represent a restriction, because current-mirror circuits of different types are known which comprise two, three and more transistors which, if so required, can likewise be employed with the invention.
For reference purposes the three poles of a current-mirror circuit are referred to herein as the current input se, the current output sa and the summation output ms, with the current input always being that particular terminal to which the transistor with a base-collector connection is connected. The current flowing via the current input se appears mirrored as a current flowing via the current output sa, with the sum of these two currents flowing via the summation output ms.
FIG. 4, partly in the way of a block diagram, shows an embodiment of the invention for a positive voltage and operating voltage, that is, the negative poles of the voltage source u and of the operating voltage source bq according to FIG. 1 are connected to the zero point of the circuit and, consequently, the positive poles thereof are connected to the corresponding circuit parts in FIG. 4. The first pnp current mirror ps is associated with all converting stages of the digital-to-analog converter dw, such that the summation output ms is connected to the positive operating voltage +bq, the current output sa is connected to the input ei of the current-to-voltage converter sw, and that the current input se is connected to all of the switching stages ss. The current output sa is identical with the current output ai of the digital-to-analog converter. The input ei of the current-to-voltage converter sw is identical with the current input se of the first npn current mirror ns1 whose summation output ms is connected to the zero point of the circuit.
Moreover, the voltage converter sw contains the first resistor r1 having one end connected to the positive pole of the voltage source +u. The other end of resistor r1 at which the terminal voltage uv appears is connected to the controlled current path of the transistor t which is voltage stabilized with respect to the voltage u. The controlled current path extends to the current output sa of the first npn current mirror ns1.
The control electrode of the transistor t is connected via the constant current source kq to the positive pole of the source of operating voltage +bq and is also connected via the collector-emitter path of the first npn transistor nt1, to the zero point of the circuit. The base of transistor nt1 is connected to the current output sa of the first npn current mirror nsl. With the aid of the first npn transistor nt1, the terminal voltage deviation is identical with the voltage u offset by the base-em itter threshold voltage of the transistor nt1. Transistor nt1 draws the control electrode of the transistor t to the collector-emitter saturation voltage of the transistor nt1 which is at about 0.1 to 0.2 volt, and therefore is practically identical with the potential of the zero point of the circuit.
The measuring circuit m consists of the second npn current mirror ns2 as well as of the second resistor r2, the one terminal of which is connected to positive voltage +u, and the other terminal of which is connected to the current input se of npn current mirror ns2 whose summation output ms is connected to the zero point of the circuit. The current flowing via the current input se of the current mirror ns2, which is dependent on the voltage of the voltage source +u and the resistance value of the second resistor r2, thus serves as a measure of this voltage.
The source of reference voltage contains the second npn transistor nt2 and the emitter resistor re associated therewith and which, with one side, is connected to the zero point of the circuit. The base electrode of the second npn transistor nt2 is connected to the base electrodes of the transistors ts which are determinative of the current flowing in the individual converting stages. The base-emitter pn junction areas of transistors ts doubling from stage to stage. The current output sa of the second npn current mirror ns2 is connected, across the third resistor r3, and the collector of the second npn transistor nt2 is connected across the fourth resistor r4, to the positive source of operating voltage +bq. The resistance values of the resistors r3 and r4 are preferably alike.
An R-2R type ladder network rr is connected in the emitter circuits of the current-determining transistors ts. The resistors connected to the emitters of transistors ts each have a resistance value 2r, and the resistors connecting these resistors each have the resistance value r. The left most emitter resistor is connected to the zero point of the circuit. A third npn transistor nt3 is used as a terminal element of the R-2R ladder network rr. The base-emitter path of transistor nt3 is connected in parallel with the one of transistors ts in which the smallest current flows, i.e., the one indicated by i/8 (the current associated with the least significant digit of the digital signal ds), and with the collector thereof being connected to the positive source of operating voltage +bq.
The source of reference voltage rq includes the operation amplifier k whose inverting input is connected to resistor r3, and whose noninverting input is connected to resistor r4. The operational amplifier k is supplied with voltage from the positive operating voltage source +bq. With respect to the currents flowing in the individual current-mirror circuits and the circuit parts connected thereto, it is evident that the current i at input se of the second npn current mirror ns2 flowing by repeated mirroring or regulation by means of the operational amplifier is equal to the largest current i of the left most current-determining transistor ts if re=2r and r3=r4, with the full terminal voltage deviation appearing with respect to r2=2r1.
In accordance with the above described area dimensions of the transistors ts, each transistor has one half the current flow of the preceding transistor on the left, so that the sum of the currents of all the transistors ts, which is formed with the aid of the switching stages ss, will in the ideal case approach 2i, and flow via the current input se of the pnp current mirror ps. This current sum 2i, again by way of repeated mirroring, causes a current 2i to flow in the circuit branch including the first resistor r1 and the transistor t. Thus, it will be easily seen that the current i in the measuring circuit m, proportionately influences the terminal voltage v, with a synchronous influence being effected when the resistance value of the resistor r1 is one half of the resistance value of the resistor r2.
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An integrated circuit is described which includes a digital/analog converter which together with a reference voltage generator and a current-to-voltage converter is driven by a single supply voltage. To obtain a variable output voltage from a second supply voltage, the reference voltage is dependent on this second voltage. The output voltage can be used as the tuning voltage of tuner diodes.
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BACKGROUND OF THE INVENTION
The present invention relates to a machine for cutting along a random line a strip-like material by means of a high pressure fluid jet.
Machines are known which make it possible to cut a product or part, whose dimensions do not exceed those of the table supporting the same. In such machines, the cut can be obtained either by the combination of a transverse displacement of the cutting tool and a longitudinal displacement of the table supporting the part, or by a transverse and longitudinal displacement of the cutting tool, the table then remaining fixed. A machine of this second type is described in French Pat. No. 1,479,158.
With both machine types, it is possible to cut a part along a random line. However, the table must either be very long, or as long as the product to be cut, which leads to large overall dimensions during the cutting of very long parts, as well as to significant idle times during the mass production of certain parts, because it is necessary to change the product between each cutting operation.
SUMMARY OF THE INVENTION
The present invention relates to a cutting machine not suffering from the disadvantages of the prior art machines and more particularly permitting, with reduced overall dimensions, the cutting of a product in the shape of a strip, which permits the cutting of parts having a random length and the mass production of parts at elevated speed, as a result of the advance of the strip.
Therefore, the present invention relates to a machine for cutting strip-like material by a high pressure fluid jet comprising a substantially flat bearing surface able to support the strip-like material, a cutting nozzle discharging a fluid jet under high pressure towards the strip-like material, means for displacing the nozzle in a direction Y perpendicular to the strip length, wherein it also comprises means for displacing the strip-like material in both directions according to a direction X parallel to the length of the strip, in such a way that the combined displacements of the strip-like material and the nozzle make it possible to make cuts of a random shape over a random length of the said strip-like material.
It is clear that the combination of the movements of the nozzle and the actual strip make it possible to obtain any form of cut contained in the width of the strip and without any length limitation. Moreover, there are virtually no idle times between the cutting of successive parts.
In view of the fact that the material to be cut is generally wound or reeled and can have a certain rigidity, it can have a tendency to maintain a slight curvature when moving on the machine. This is not desirable because the strip-like material may then get caught on certain parts of the machine and also because the accuracy of the cut may be reduced.
Thus, according to another aspect of the invention, the bearing surface of the machine upstream of the cutting nozzle and on either side of the means for displacing the strip-like material, is in the form of a fixed table on which the latter moves within a guidance tunnel.
In view of the fact that the material to be cut can in particular be a preimpregnated composite material, whose protective sheet or separator covering the lower face is generally removed to facilitate the subsequent use of the cut and in order to reduce the time for producing the same, said lower face can be adhesive. When the strip-like material moves within the tunnel, it is consequently desirable to prevent the said lower face from adhering to the fixed table. Therefore, means can be provided for producing a fluid cushion between the table and the strip-like material.
Preferably, in order to permit a visual inspection of the cut, bearing in mind the fact that the strip-like material can be displaced in both senses, the tunnel is transparent.
Conventionally, the cutting machine according to the invention comprises a system for the recovery of the jet which faces the cutting nozzle and on the side opposite to the material to be cut. According to another aspect of the invention, this system comprises, in the trajectory of the jet, at least one first metal plate ensuring the breaking up of the jet and a device for detecting wear to said plate having a normally tight cavity located below the plate and whose lower wall has at least one further metal plate against which the jet strikes when the first plate is perforated as well as means for detecting the arrival of the jet in said cavity.
Preferably, the latter means comprise an electric circuit having an indicator, whose operation is controlled by the closing of the said circuit resulting from contacting between said other plate and an electrode located in the cavity, when the fluid jet enters the latter.
In order to both confine the noise which occurs in the recovery means within the latter and to prevent vapours formed during the breaking up of the jet escaping upwards, the bearing surface preferably has a fixed false table between the nozzle and the jet recovery system having a slot which is essentially of the same width as the jet discharged by the nozzle, said slot preferably being cut directly in the table by the jet. The jet recovery system moving at the same time as the nozzle then comprises at its upper end in contact with the table, a seal having a reduced friction coefficient with the latter.
It is consequently possible to eliminate the vapour suction system generally provided in this type of generator, the broken up fluid being discharged by gravity.
According to yet another feature of the invention, the machine comprises means for the automatic control of the means for displacing the nozzle and means for displacing the strip-like material, in order to ensure the cutting of pieces and scraps in the latter, the bearing surface having downstream of the cutting nozzle at least one conveyor belt, whose forward movement carries the scraps up to means for removing scraps of the cut material, as well as means for detecting the presence of a piece on the conveyor belt controlling the stoppage thereof, said detection means being respectively activated and deactivated by the automatic control means, as a function of whether they are ensuring the cutting of a piece of a scrap, in order to control the stopping of the conveyor belt to permit the gripping of pieces and for carrying the scraps, without stopping the conveyor belt, up to the scrap removal means.
In this case, a second conveyor belt, whose forward movement is automatically controlled during a given time by the automatic control means following the cutting of a piece or a scrap, can be positioned between the cutting nozzle and the conveyor belt, in order to facilitate the cutting of the strip-like material.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to non-limitative embodiments and the attached drawings, wherein show:
FIG. 1 a perspective view diagrammatically showing a cutting machine according to the invention.
FIG. 2 a cross-sectional view in diagrammatic form of that part of the machine upstream of the cutting nozzle.
FIG. 3 a larger scale perspective view in partial section more particularly showing the recovery system facing the cutting nozzle.
FIG. 4 a plan view diagrammatically illustrating the operation of the machine, as a function of whether the element cut by it is a scrap or a piece.
DETAILED DESCRIPTION OF THE INVENTION
On firstly referring to FIG. 1, it can be seen that the cutting machine according to the invention comprises three separate parts constituted by an electromechanical assembly 10, a control assembly 12 and a very high pressure fluid source 14. These three assemblies can be physically separated from one another as shown in the drawing.
The control assembly 12 comprises a digital control 16 and a control bay 18. It is connected to the electromechanical assembly 10 by connecting cables 20.
The very high pressure fluid source 14 is constituted by a high pressure group usually supplying water under very high pressure and which is carried up to the cutting nozzle 22 of assembly 10 by a pipe 24.
The electromechanical assembly 10 comprises a frame 26 which, at one of its ends, carries a reel 28 of a strip-like material 30, which is to be cut into pieces 32 having a random shape. Reel 28 is mounted on a spindle 34, which can freely rotate on frame 26, so as to permit the free unwinding of strip 30.
The upper horizontal face of frame 26 constitutes a bearing surface formed, from the end of the frame carrying the reel and up to the opposite end, a fixed table 36, a first endless conveyor 38 of limited length and a second endless conveyor 40 of greater length. The width of these different elements constituting the bearing surface on which is received the strip 30 slightly exceeds the width of the latter, so as to permit a guidance of the strip on table 36.
Moreover, table 26 supports, from the end carrying reel 28 up to its opposite end, a device 42 for unwinding strip 30, a device 44 for the advance and guidance of the strip on table 36, a cutting device 46 located between table 36 and the first conveyor 38 and a device 48 for sorting and removing scraps permitting a gripping of pieces.
The unwinding device 42 has a rubber-lined roller 50, which drives the reel 28 by friction. To this end, roller 50 is fixed to a spindle 52 parallel to the reel spindle 34 and said spindle 53 is mounted in rotary manner on the end of a not shown, articulated arm, whose opposite end is articulated about a fixed spindle 54. The rubber-lined roller 50 is consequently pressed against the reel under the action of gravity, which may be reinforced by the action of not shown elastic means.
Two belts 56 and 58 mounted on appropriate pulleys are used for transmitting to the shaft 52 carrying roller 50, the rotary movement of a spindle 60 of the strip advance device 44, whilst passing via the fixed spindle 54.
Device 44 for the forward movement and guidance of strip 30 comprises a drive roller 62 mounted on the spindle 60 of the motor 64 above strip 30. A metal roller 66 is positioned below strip 30 in a slot in table 36, in such a way that its upper generatrix is flush with the upper face of the latter, as illustrated by FIG. 2. Spindles 60 and 68 of roller 62 and roller 66 are parallel to spindle 34 of reel 28 and located in the same vertical plane, so as to press strip 30 between them. This result is obtained by applying roller 62 to metal roller 66 with a given pressure and with the aid of not shown, known means. A coder or counter 70 is associated with the metal roller 66, in order to determine the number of revolutions thereof and consequently the length of the strip passing over table 36.
According to an essential feature of the present invention, the motor 64 used for controlling the forward movement of strip 30 on table 36 can move the said strip parallel to its length in both directions via the mechanism described hereinbefore and as illustrated by arrow X in FIG. 1.
It has been seen that belts 56 and 58 enable motor 64 to simultaneously rotate rollers 50 and 62. The diameters of these rollers, as well as the diameters of the pulleys, on which the belts are received, are chosen in such a way that the peripheral speeds of these two rollers are equal to one another. Thus, the strip advance device 44 does not have to overcome the inertia of reel 28, but solely that of the strip portion located between roller 50 and cutting device 46 and that of the rigid roller 66.
As illustrated by FIG. 1, a precise positioning of the strip in direction X is obtained by maintaining the latter against a smooth guide 71, located along one of the longitudinal edges of table 36.
In order to take account of the fact that the strip-like material 30 to be cut can have a certain rigidity, according to a preferred embodiment of the invention, it is ensured that the strip is maintained on table 36, so as to make sure that the strip does not retain a certain curvature, which could both significantly reduce the accuracy of cut and lead to incidents, such as the strip getting caught on certain projecting parts of the machine.
As is diagrammatically illustrated in FIG. 2, the good flatness of the unwound strip is obtained in the cutting area by placing on the table 36 a tunnel 72 having a slot for the passage of roller 62.
When the strip-like material to be cut is a preimpregnated composite material, the latter is generally stored in the form of a continuous strip in the adhesive state between two sheets called separators. When the composite material strip is unwound for cutting purposes, the separator covering the lower face thereof, i.e. that turned towards the machine plate is removed, so that on the one hand the subsequent use of the cut is facilitated and on the other to reduce the handling times of the cuts. Thus, if the two separators remained in place, the operator would have to turn over the cut to remove the second separator and, in his haste, might leave behind fragments, which would be prejudicial to the quality of the composite material.
Thus, according to a preferred embodiment of the invention, the machine also has orifices 74 in table 36 in accordance with a substantially median plane, as illustrated in FIG. 2. These orifices are supplied with compressed air, which makes it possible to permanently produce an air cushion between the table and strip 30 ensuring that the strip does not adhere to the table. Thus, the precision of the displacement of strip 30 in the direction of axis X is not prejudiced. It should be noted that the air cushion produced between the strip and table 36 tends to move the strip away from the table, but said movement is limited by tunnel 72.
Preferably, tunnel 72 is transparent, so as to permit the visual checking of the cutting operations.
In per se known manner, cutting device 46 has a cutting nozzle 22 arranged vertically above strip 30 and a jet recovery system 76 arranged below the strip and facing nozzle 22. Nozzle 22 and recovery system 76 are mounted on transverse guide columns 78, 80 parallel to the spindle 34 of reel 28. By means of appropriate belts and pulleys designated in a general manner by reference numeral 84, a motor 82 makes it possible to displace nozzle 22 and recovery means 76 along their respective guide column in both senses, in such a way that they are permanently facing one another. The thus obtained transverse displacement is designated by arrow Y in FIG. 1.
According to an essential feature of the invention, it can be seen that it is possible, by simultaneously controlling the operation of motors 64 and 82 with the aid of digital controls 16 and using an appropriate programme, to cut from strip 30 pieces 32 having random shapes and dimensions, within the width and length limits of the strip, by means of an electromechanical assembly 10, whereof the dimensions can remain relatively small. The machine according to the invention also makes it possible to cut in series a large number of pieces, in accordance with a given programme and without loss of time.
On referring to FIG. 3, it can be seen that the system 76 for recovering the jet supplied by nozzle 22 is placed below a false table 86 extending table 36 and having a slot 88, whose width is substantially equal to the width of the jet leaving nozzle 22. In order that the width of slot 88 is as small as possible and that said slot is placed exactly in the alignment of the jet, the false table 86 is preferably made from a material which can be cut by the jet, such as a plastics material and slot 88 is cut from said material by the jet.
In its upper part, the recovery system 76 has a vertically axis tube 90 having at its upper end a cylindrical seal 92 made e.g. from felt, so as to have a minimum friction coefficient with the false table 86. Seal 92 is centrally perforated by a hole 94, whose diameter is substantially equal to the jet diameter. Thus, in combination with the false table 86, this seal makes it possible to confine the noise within the recovery system to the greatest possible extent and prevents water vapour formed therein from escaping through its upper end.
In a conventional manner, after travelling a certain distance within tube 90, the jet is broken up on a horizontal fritted metal plate 96 fixed in the bottom of the tube. Holes 98 formed in tube 90 above plate 96 enable the water vapour formed by the breaking up of the jet to flow by gravity towards a pipe 100. The presence of the false table 96 and the seal 92 make it possible to prevent any risk of water vapour escaping through the top of the tube, so that there is no need, as in the prior art devices, to provide ancillary means for sucking off the water vapour formed as a result of the breaking up of the jet on the plate. Thus, the noise and cost of the machine are reduced.
According to a preferred embodiment of the invention, the recovery system 76 also has means 102 for detecting the perforation of plate 96 by the jet. These means comprise a chamber 104 formed in the lower part of tube 90, below plate 96 and which is normally tight. The lower partition of chamber 104 has, in its central part, a second fritted metal plate 106, as well as an electrode 108 separated from plate 106 by an electrically insulating material block 110. Plate 106 and electrode 108 are connected in a not shown electrical circuit, which also has a wear indicator for plate 96, as well as a power supply.
When plate 96 is perforated by the fluid jet discharged by the cutting nozzle 22, the water passes through chamber 104 and strikes against the plate 106, which ensures the breaking up thereof. The water admitted in this way into chamber 104 brings plate 106 and electrode 108 into contact, which has the effect of closing the electrical circuit and energizing the indicator. It should be noted that the detection of the perforation of plate 96 is substantially immediate and takes place without a single drop of water being discharged to the exterior of recovery system 76.
As stated hereinbefore, the false table 86 is extended by a first conveyor belt 38, whose operation is controlled by a motor 116. A second conveyor belt 50 extends belt 38 and is controlled independently of the latter by a second motor 118. The device for sorting and removing scraps 48 has a means for detecting pieces 32, constituted by a photoelectric barrier 120, placed at the end of conveyor belt 40 and at the end of assembly 10. It also has a reception tank 122 below the end of conveyor 40, so as to receive the scraps carried by the latter.
According to a preferred embodiment of the invention, the different motors 82, 64, 116 and 118 as well as the photoelectric barrier 120 of electromechanical system 10 are controlled by the control assembly 12, in such a way that the cutting of pieces 32 takes place in accordance with a given programme, the scraps resulting from the cutting operation drop automatically into tank 122 and conveyor 40 stops when it supports a piece 32.
In order that device 48 can sort between pieces and scraps, the digital control 16 is designed in such a way that it supplies an activation instruction for the photoelectric barrier 120 when it controls the cutting of a piece in strip 30 with the aid of motors 64 and 82 and transmits a deactivation instruction for photoelectric barrier 120 when it controls the cutting of a scrap in the strip-like material. Bearing in mind the latter remark, the machine operates as follows. The control system 12 continuously transmits and in accordance with a predetermined programme, instructions for cutting pieces and scraps from strip 30. These instructions lead to the combined displacements of the cutting nozzle 22 and the strip to be cut, respectively in directions Y and X, leading to the successive cutting of pieces and scraps in accordance with this programme.
Whenever the cutting of an element is finished, no matter whether this element is a piece or a scrap, the control system 12 starts up the motor 116, which was previously stopped during cutting. The piece or scrap is thus conveyed by conveyor 38 up to conveyor 40, after which conveyor 38, whose motor 116 is applied in a timed manner, stops. Motor 118 of conveyor 40 is normally continuously supplied from control system 12, so that the piece or scrap whose cutting has just been completed is conveyed up to the end of conveyor belt 40. At this stage and as is diagrammatically illustrated by FIG. 3, a distinction must be made between two different cases.
In the first case, the element located on the conveyor 40 is a scrap 33. It has been seen hereinbefore that in this case the photoelectric barrier 120 is deactivated. Thus, the barrier does not detect the passage of the scrap, so that motor 118 remains energized and the scrap drops into tank 122 at the end of conveyor 40.
In the opposite case, where the element which has been cut is a piece 32, photoelectric barrier 120 is activated, so that it immediately detects the piece when it reaches its level. This has the immediate effect of stopping motor 118 and consequently conveyor 40. The piece can then be gripped by any means, i.e. either manually, or by a suitable automatic handling device. This gripping is diagrammatically illustrated by arrow 123 in FIG. 4.
As soon as the piece is removed from conveyor 40, the signal emitted by the photoelectric barrier 120 disappears and motor 118 again controls the forward movement of conveyor 40 up to the arrival of a new piece, which will in turn be detected by the photoelectric barrier.
The invention has been described hereinbefore relative to non-limitative embodiments and obviously numerous variants are possible thereto without passing beyond the scope of the invention.
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Machine for cutting strip-like material by a high pressure fluid jet comprising a substantially flat bearing surface able to support the strip-like material a cutting nozzle discharging a fluid jet under high pressure towards the strip-like material, means for displacing the nozzle in a direction Y perpendicular to the strip length, wherein it also comprises means for displacing the strip-like material in both senses according to a direction X parallel to the length of the strip, in such a way that the combined displacements of the strip-like material and the nozzle make it possible to make cuts of a random shape over a random length of the said strip-like material, wherein the bearing surface of the machine upstream of the cutting nozzle and on either side of the means for displacing the strip-like material, is in the form of a fixed table on which the latter moves within a guidance tunnel.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/810,504, filed Jun. 3, 2006, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field of Invention
[0003] This invention generally relates to methods, systems and apparatus to display images, text and messages on indoor, emissive or reflective e-paper or paper-like displays. More particularly, the invention relates to providing advertising and wayfinding messages using a network of lightweight e-paper displays within well defined indoor areas, such as hanging from the ceiling at the start and end of each store aisle, and the associated system that allows advertisers, marketers and others to place advertisements and messaging on these displays and network the displays so that the advertisement and wayfinding information is visible by consumers walking through these well-defined areas.
[0004] 2. Description of the Related Art
[0005] Electronic signage used as an advertising medium is commonly deployed in retail outlets and stores to display advertising material and the like utilizing a variety of electronic display technologies and traditional paper or plastic signs to provide wayfinding information to customers within a particular area of a store.
[0006] Wayfinding signs provide store navigation information to customers. These signs are lightweight and static, and are made of plastic, paper or similar material. They most often hang from the ceilings of stores. Customers looking at these signs know what department area they are in or near, such as women's clothing, pets, hardware, domestics, electronics, etc. For grocery aisles, these signs will provide the aisle number and list the products and items found in the aisle.
[0007] There are numerous problems with static signs being used to provide store navigation information. New products and items cannot be quickly or easily added to the signs. The size of the font cannot be easily changed and it is impossible to use the sign to highlight specific brand items within a department.
[0008] Indoor electronic signage used for advertisement utilizes LED, plasma and LCD flat-screen displays as well as television and other technologies that emit light which is seen by the individual viewing the display. These are called emissive display technologies because they emit light and the advertisement and information systems that use these technologies are often referred to as “narrow casting” systems and digital signage. An example is the television system that displays in-store advertisements in WAL-MART® stores. Use of indoor emissive displays is undergoing rapid growth and companies are adding electronic displays to multiple outlets to increase advertising reach and to influence buyers. The content of the signs can be electronically changed based upon the needs and desires of the advertising company. Small, emissive display screens are being increasingly used within stores to provide advertisement and product information.
[0009] Despite the technical advances in emissive displays and narrow casting technology there are numerous problems with this approach to indoor advertisement. One problem is the very high cost of bright, high quality LED systems and other electronic displays. Another significant problem is the weight of emissive displays. Specifically, LED, plasma, and LCD flat-screen displays as well as television and other similar display technologies all are heavy due to the electronics package required for emissive displays.
[0010] These problems limit the ability to use a large number of emissive displays within a small, well-defined area and significantly limit the placement of the screens and prevents electronic signs from being used as store navigation wayfinding signs.
[0011] Another drawback with the current art in indoor electronic signage is the high cost and complexity of installation. This cost and complexity prevents current digital signs in stores from being used for both wayfinding and advertising.
[0012] In sum, there is no apparatus, system design or methodology which would allow electronic signage to be deployed in a concentrated number within a well defined area within a store or retail outlet for store navigation and for advertisement at or, extremely close to, the purchase point.
[0013] Neither is there an apparatus, system design or methodology which would allow deployment of indoor digital signs that would provide both navigation information and advertisement on the same sign. Such a system would greatly increase advertising effectiveness.
SUMMARY OF INVENTION
[0014] Accordingly, an apparatus, system design or methodology to deploy numerous indoor digital signs within a well-defined area of a store or retail outlet and capable of being used for both wayfinding and product advertisement would have significant advantages over existing designs.
[0015] Accordingly, it is an aspect of present invention to address the deficiencies in the related art and make possible the deployment of numerous networked, indoor digital signs within a defined area.
[0016] It is another aspect of the present invention to deploy numerous indoor digital signs that are extremely lightweight within a well defined area and utilizing the displays for either advertisements or wayfinding messages or both.
[0017] Additional aspects and/or advantages will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
[0018] The foregoing, and/or other aspects are achieved by providing a modular sign, comprising: a first electronic paper-like display to display information.
[0019] The foregoing, and/or other aspects are achieved by providing a network, comprising: a first modular sign comprising a paper-like display to display first information; and a second modular sign comprising a paper-like display to display second information.
[0020] The foregoing, and/or other aspects are achieved by providing a method, comprising: providing first and second modular signs, each of the modular signs comprising a paper-like display; transmitting the information via a network to the first and second modular signs; and displaying the transmitted information on the first and second modular signs.
[0021] Accordingly, it is another aspect of the present invention to provide modules that, when put together, make an extremely light weight and easily installed indoor electronic sign that can be hung from the ceiling of retail outlets to provide product advertisement, wayfinding information or both.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] These and/or other aspects and advantages will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0023] FIG. 1 is an illustration of the modules of one embodiment of the modular sign according to an embodiment of the present invention;
[0024] FIGS. 2 a and 2 b show front and back views of the modular sign of FIG. 1 ;
[0025] FIG. 3 illustrates a second alternative embodiment of the present modular sign used as a wayfinding sign;
[0026] FIG. 4 shows the second embodiment as used for advertising;
[0027] FIG. 5 shows the modules of the modular sign of FIG. 1 hanging from the ceiling;
[0028] FIG. 6 shows the system used to control messages on the modular sign of FIG. 1 ; and
[0029] FIG. 7 shows how the system and modular sign of FIG. 1 will be used.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0030] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
[0031] 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 as come within the scope of the appended claims and their equivalents. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
[0032] The present invention is intended to, for example display advertisement and wayfinding messaging or a combination of both wayfinding information and advertisements using numerous indoor modular signs containing electronic paper-like displays and located within a well defined in-store area such as the store aisle or a department within a retail outlet. The present invention is also directed to a method and system through which a retailer or advertiser can provide advertisements or wayfinding information or a combination of both advertisement and wayfinding information using numerous indoor modular signs within a well defined area, such as a store aisle or store department.
[0033] Referring to FIG. 1 , there is shown a modular sign 100 containing an electronic paper-like display 30 which may exhibit images, video, text and messages used to advertise or to provide wayfinding information. The display 30 may, for example, take the form of an electronic paper-like display mounted within a 3 feet by 2 feet side of a frame 21 of the modular sign 100 and providing a viewing area of 33 inches by 21 inches. The frame 21 is the supporting structure for the modules that make up the modular sign 100 .
[0034] Electronic paper-like displays 30 represent a category of display that use low power and are made of lightweight, flexible material, most often a plastic material, on which text and images can be displayed and electronically changed. The displays can be reflective, just like real paper, meaning that they can be used in broad daylight or under in-store lighting condition and be easily read. Also, the displays can be emissive, meaning light is output to make the sign readable. Also, the displays have a very wide viewing angle.
[0035] There are a variety of technologies that can be used to create an electronic paper-like display including light emitting polymer, organic electro-luminescence, organic light emitting displays (OLED), suspended particle device technology, electrophoretic and reverse electrophoretic emulsion display material, bistable nematic technology, high resolution electronic ink, cholesteric and encapsulated cholesteric display materials, electrochromic material, nanotechnology-based materials such as quantum dots, carbon nanotubes or nano-emissive materials, displays printed with various layers of conductive ink, nano ink, nano-metallic ink, carbon nanotube ink, and molecular bistable displays. However, these are just examples and other technologies may be used. These displays can be placed on many different lightweight materials such as plastic, paper and canvas.
[0036] Suitable paper-like display material for the display 30 is manufactured by, for example, E-Ink Corporation of Cambridge, Mass., USA, ZDB in the United Kingdom, Xerox Corporation, Samsung, Fujitsu, Kent Display, Quantum Paper and Bridgestone.
[0037] As shown in FIGS. 2 a and 2 b , another display 31 is on the opposite side from the display 30 . Thus, the modular sign 100 contains two electronic paper-like displays 30 and 31 . The displays 30 and 31 may be identical. In this manner, advertisement and wayfinding information is available to be seen by more shoppers within a store.
[0038] Electronic paper is lightweight, flexible, and inexpensive and has very low power requirements. The light weight of the electronic paper-like displays 30 and 31 allows the modular sign 100 to be mounted on existing infrastructure, display racks, shelves or hung from the ceiling.
[0039] FIG. 3 illustrates a second embodiment of the modular sign 100 . The sign 100 is triangular in shape and has a three sided frame 21 and three of the electronic paper-like displays 30 and thereby providing more viewing areas, e.g., three advertising displays per modular sign 100 . This embodiment of the invention may be placed at the start and end of a store shopping aisle where triangular wayfinding signs are often found. Customers approaching the aisle from various directions can see the sign and the information and advertisements it contains. Wayfinding information can be shown on one display 30 while advertisement can be shown on the other display 31 .
[0040] FIG. 4 illustrates the dual nature of the modular sign 100 showing a different message being flashed on the display as opposed to FIG. 3 . Specifically, the display of FIG. 3 shows the products found in aisle 7 , one of these products being coffee. FIG. 4 shows how a coffee advertisement can be displayed on the sign for consumers that are moving down that aisle. FIG. 3 and FIG. 4 have the same structure as the modular sign 100 , switching from a wayfinding display in FIG. 3 to an advertisement in FIG. 4 .
[0041] FIG. 5 illustrates how the modular sign 100 may be connected to power and data. Power line communication devices 50 , 51 are respectively plugged into a wall electrical outlet 49 and into the display 30 . The power line communication technology allows a power line to act as a signal transmission channel. In this manner, both power and data can move over the electrical wires that are part of the store's infrastructure, through the wall outlet 49 , over an electrical cord 52 strung between the communication device 50 and the display device 30 . Power line communication devices are extremely low cost and can be purchased from companies such as Asoka Corp., Philips, Actiontec, Linksys Group, Netgear and Siemens.
[0042] The relative light weight of the electronic paper-like displays 30 , 31 , the frame 21 , the power line communication devices 50 , 51 , and the electrical cord 52 allows the modular sign 100 to be easily and safely hung from the store ceiling using wire cable 47 similar to the cable used to hang conventional signs. The embodiments shown in FIGS. 1, 2 , and 3 will be hung from the store ceiling and have data and power provided though the powerline communication devices 50 , 51 .
[0043] FIG. 6 illustrates the operation of the modular sign 100 . A system 102 includes a server or computer 54 , a power line communications router device 55 , and an Ethernet cable 56 . The router device 55 is plugged into an electrical wall socket 57 . The Ethernet cable 56 connects the computer 54 to the power line communication router device 55 . Commercially available software within the computer 54 will transmit and manage advertisement or wayfinding information over the store electrical wiring system to the displays 30 , 31 via the Ethernet cable 56 , the power line communications router device 55 , the power line communication device 50 and the electrical outlet 49 . The computer 54 is connected to a network 61 such as the internet though a wired connection 60 .
[0044] In the example shown in FIG. 7 , the system 102 may be placed in any location of a store, such as an office or the back store room. The computer 54 uses commercially available software to send data on wayfinding messages and advertisements through the Ethernet cable 56 to the power line communications router device 55 and into the store's electrical wiring system through the electrical outlet 49 . A plurality of the modular signs 100 may be hung from the ceiling throughout the store using standard, light gauge cable 47 . The modular sign 100 uses power line communication devices 50 , 51 connected with the commercial electrical cord 52 . A power line communication device 50 plugged into the electrical outlet 49 provides a communication channel for the data that is in the store electrical wiring system. In this manner, the system 102 is able to input and control the data that goes into the modular sign 100 . This arrangement allows the system 102 to place images and text for wayfinding information or for advertisement onto the paper-like display 30 .
[0045] The present invention provides the low power, high resolution and wide angle viewing, compactness and modularity of a conventional printed sign module with the ability to change the images and text on the electronic paper-like display 30 through the existing electrical systems by using power line communication devices 50 , 51 and 55 .
[0046] Referring to the drawings, there is shown a system 102 for direct placement of wayfinding information, commercial advertisements, public service announcements and other content onto a plurality of electronic paper-like displays 30 that are each part of the modular sign 100 .
[0047] System 102 includes a network comprising a plurality of electronic paper-like displays 30 that are located within a well defined in-store area such as the various departments or within or near shopping aisles. A large number of modular signs may be deployed within each defined area and the plurality of electronic paper-like displays 30 within each modular sign 100 are networked and controlled through the store's electrical wiring that is located within each area by using power line communication devices 50 , 51 , 55 .
[0048] System 102 may be connected to a network such as the internet 61 and is capable of receiving advertisements and other information from a location that is removed from the store.
[0049] System 102 may be located at many different and separate stores, such as all the stores of a certain size within a metropolitan area, may have a customer such as a consumer products company or an advertising agency that purchase time on the system 102 . Each purchased time slot represents time that an advertisement with text and image or other messages will be displayed on the network of a plurality of electronic paper-like displays 30 . The computer 54 within the system 102 controls the time allocation on the electronic paper-like display 30 . Data on new content and time slots is provided to the computer 54 via the internet 61 .
[0050] As schedule changes occur based upon new content and time schedules, the system 102 will send the updates to the network of a plurality of electronic paper-like displays 30 which receive this data through the store's electrical system via the power line communication devices 50 , 51 , 55 .
[0051] Customer content, time schedules and deployment areas are provided to the system 102 based upon contracts which specify the requirements for the appropriate operation to be carried out.
[0052] Those skilled in the art will understand that the preceding embodiments of the modular sign 100 provide the foundation for numerous alternatives and modifications thereto. For example, the display modules may include the use of very thin LCD and very low power LCD displays as a module. Other modifications may include the use of flexible OTFT-LCD (organic thin film transistor-liquid crystal display), polythiophene-based semiconductive ink, carbon-nano-tube technology, nano-electronics, nano-powder, high resolution electronic ink, cholesteric and encapsulated cholesteric display materials, electrochromic material, nanotechnology-based materials such as quantum dots, carbon nanotubes or nano-emissive materials, displays printed with various layers of conductive ink, nano ink, nano-metallic ink, carbon nanotube ink, and molecular bistable displays and other types of very thin, lightweight displays. These other modifications are also within the scope of the present invention. Accordingly, the modular sign is not limited to that precisely as shown and described in the present application. Data connections to the modular sign 100 may be made with wireless connections, standard Ethernet cable and through other means than powerline communications. Accordingly, the system 102 is not limited to that precisely as shown and described in the present application.
[0053] The invention uses either emissive or reflective electronic paper-like display technology which is low cost, very light weight and has very low power requirements. This allows a modular sign to be deployed where the modules are electronic paper-like displays, power and data devices, and the sign frame. The modular signs can easily be installed on existing infrastructure such as clothing racks, product display racks, product shelves, the wall behind merchandise shelves or, most commonly, hung from the store ceiling to create a new category of indoor networked digital signage based upon paper-like or e-paper display technology. These paper-like indoor signage modules deliver reinforced advertising and wayfinding information or a combination of advertising and wayfinding information to consumers walking through the store area or down the aisle where these modular signs are deployed. The lightweight nature of the signs allows them to be hung from store ceilings, where they are easily visible and can be deployed in a greater density.
[0054] The present invention is therefore novel in its application of indoor signage technology, and unique in its capabilities, in that it addresses all of the requirements for deployment of numerous indoor signage within a defined area and using these signs to deliver product advertisement, wayfinding information or a combination of both in a manner not addressed by the related art.
[0055] A first non-limiting advantage of the present invention is that it provides systems and methods for displaying images, text and messages over a network of a plurality of modular signs in a well defined area within a store or retail outlet. Each sign having modules that may contain reflective or emissive electronic paper-like displays, battery packs, wireless ports, powerline communication devices and frames for holding the displays.
[0056] The lightweight displays may be reflective, meaning that in various conditions of light and brightness they appear with the same clarity as standard ink or paint on a conventional sign or they may be emissive meaning that they give off light providing luminance to the display. The displays also have a very wide viewing angle. The images, text, wayfinding information and advertisements displayed on the reflective electronic paper-like displays can be changed wirelessly or through the use of power line communication devices.
[0057] The modular signs are fully contained and are very light weight, allowing them to be mounted on existing infrastructure or hung from the ceiling. It is easy to build the modules in different sizes and shapes allowing a high density of signs to be placed in close proximity to each other in an in-store area such as an aisle or department. Advertisements are easily updated and changed, wayfinding information, such as the addition of new products within a department or on an aisle, can be easily changed.
[0058] Although a few embodiments have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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Provided is a system and corresponding methods for a network of indoor modular signs. The indoor signs are composed of various modules which are combined to make the signs fully contained and operable. The modules include paper and e-paper based displays and frames as well as power line communication devices. The invention includes: a network of modular signs within an indoor area, a computing station with prerecorded data, and said data is presented as scheduled on the electronic paper-like display modules and power line communication networks that provide both power and data to the displays.
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BACKGROUND OF THE INVENTION
The invention concerns a method to assist the drive of at least one moving switch part of an electric compression switch with a quenching medium flow which is generated during the switching-off process by means of a compression device, as well as an electric compression switch, designed in accordance with this method, where the arc arising across the switch components is quenched by the flow of the quenching medium, and where the compression device consists primarily of a piston coacting with a quenching-medium compression chamber.
It is known to blast the arc arising within electric switches, especially by means of a gas flow, where the blast flow by a quenching medium is generated by means of a piston coacting with a quenching-medium compression chamber and driven with the aid of an external drive as shown for example by Swiss patent CH-PS 519, 238.
Switches of this type, when designed for breaking increasingly heavy currents, do require external drives of correspondingly greater motive forces.
SUMMARY OF THE INVENTION
It is the principal object of the invention to utilize the thermal energy of the arc, arising within the switch, at least partially to generate the quenching medium flow, i.e., the blast flow, and thus to assist in the drive of the moving switch parts of an electric compression switch, for example, an SF 6 -blast-piston switch.
The invention solves this problem in that manner that the quenching medium which is present within the compression switch is highly compressed by one end of a piston coacting with a quenching-medium compression chamber, preferably a differential diameter piston, and the highly compressed quenching medium is hereby released to act upon the arc as a quenching flow, that hereby at least one portion of the quenching medium, heated by the arc and placed under increasing pressure, is expanded in a quenching-medium expansion chamber and thereby the other end of the piston and at least one part of the boundary of the quenching-medium expansion chamber are moved, or driven respectively, from one another, and that this portion of the quenching medium during the final period of the switch-off process is diverted from the quenching-medium expansion chamber to a lower pressure region of the quenching-medium compression chamber as well as the quenching-medium expansion chamber, and preferably to the quenching chamber of the compression switch.
This arrangement will be particularly advantageous if the quenching medium that is present within the compression switch is highly compressed by means of a differential diameter piston in that manner that it is compressed by the end of the piston having the smaller piston area end within a quenching-medium compression chamber and the quenching medium flow is being released by at least one component of the compression switch from the quenching-medium compression chamber to act upon the arc arising across this switch element, if at least one portion of the quenching medium, heated by the arc, is injected by a nozzle element of the switch, forming the arc in conjunction with said switch element, into a closed quenching-medium expansion chamber, its volume variable in coaction with the end of the differential piston possessing the larger area so that the end of the piston having the larger area as well as the inner boundary of the quenching-medium expansion chamber are loaded by the expanding quenching medium by at least a mean pressure, thus causing the differential diameter piston and at least one portion of the boundary of the quenching-medium expansion chamber to move relative to one another, and to draw off the quenching medium during the final period of the switch-off process through pressure-equalizing apertures from the quenching-medium expansion chamber into its region of lower pressure or into the region of the quenching-medium compression chamber possessing lower pressure than the quenching-medium expansion chamber, and preferably into the quenching chamber of the compression switch.
It will be expedient if the quenching medium flow is formed by a gas flow.
In the case of a preferred species, the piston is designed in the form of a substantially tubular differential-diameter piston where the piston end with the smaller area runs between the portion of a switch element facing the arc and designed in the form of a nozzle element and between an insulating nozzle surrounding the last-mentioned part at a specific distance, this smaller area piston end, arranged quenching-medium-tight, forming a quenching-medium compression chamber together with one portion of the outer wall of the switch nozzle element, one portion of the inner wall of the insulating nozzle and the switch element engaging the insulating nozzle and the switch nozzle element when in the on-position, where the switch nozzle element is fastened by positioning and holding parts to the end of the insulating nozzle facing the arc, and the insulating nozzle is connected at its other end to the boundary of a closed quenching-medium expansion chamber, its volume variable in coaction with the differential diameter piston, where the switch nozzle element unsupportedly leads into the quenching-medium expansion chamber, and the larger area end of the differential diameter piston runs quenching-medium-tight between the unsupported part of the switch nozzle element and one part of the inner boundary of the quenching-medium expansion chamber, and the boundary of the quenching-medium expansion chamber is provided with apertures for pressure equalization of the quenching medium, the apertures being cleared during the period of current turn-off by the last-mentioned part of the differential diameter piston for access to the region of the quenching-medium expansion chamber as well as the quenching-medium compression chamber, and especially to the quenching chamber of the compression switch.
In a further development of the invention there is at least one moving part of a compression device coupled with at least one switch element of the compression switch, thus facilitating the drive of several moving switch elements of the electric compression switch.
In the case of one species the switch nozzle element, connected with the insulating nozzle by way of positioning and fastening parts, is arranged thusly that it is movable, especially in its axial direction, relative to the boundary of the quenching-medium expansion chamber, while the differential diameter piston remains stationary relative to the parts mentioned above.
In the case of another species the switch nozzle element, connected with the insulating nozzle by way of positioning and fastening parts, is arranged thusly that it is stationary relative to the boundary of the quenching-medium expansion chamber, while the differential diameter piston is coupled by means of an insulating part to the switch element coacting with the switch nozzle element, and the last-mentioned parts are arranged thusly that they can change their positions relative to the first-mentioned parts, and especially are movable in the axial direction of the switch nozzle element.
Furthermore, it is advisable to provide between the quenching-medium expansion chamber and the quenching chamber at least one non-return valve which in case of switching operations involving low currents will prevent the formation of a negative pressure in the quenching-medium expansion chamber relative to the quenching chamber.
By taking into consideration the turn-on of the compression switch, another non-return valve should at least be arranged between the quenching-medium compression chamber and the quenching-medium expansion chamber in such manner that the pressure in the expansion chamber will not be greater than the pressure in the compression chamber.
The main advantage attained by the invention is due to the fact that the quenching medium heated by the arc generated by the switching process, i.e., in case of a switch utilizing gaseous quenching means, the hot gases are not conducted as heretofore into the chamber volume or quenching chamber respectively but are utilized in a closed space, the quenching-medium expansion chamber, to accomplish a pressure increase p K over the initial pressure p O of the quenching medium that is present within the compression switch.
This has the effect from an engineering standpoint that the thermal energy of the arc, generated in the course of the switching process and subjected to a flow or blast by the quenching medium, obtained in the form of a pressure increase p K at the low pressure side of the medium flow, is now utilized for performance efficiency.
The preferred solution, as previously described, is the use of a differential diameter piston, its smaller area end facing the high-pressure side, i.e., the quenching-medium compression chamber, and its larger area end facing the low pressure side, i.e., the quenching-medium expansion chamber.
An additional advantage results from the fact that the differential diameter piston makes it possible to utilize and amplify a relatively low pressure increase p K for the build-up of the much higher pressure p O +p H in the quenching-medium compression chamber, where p H denotes the pressure increase by the compression in the quenching-medium compression chamber.
There is the further advantage that toward the end of the switch-off operation, i.e., the blast movement, respectively, the closed quenching-medium expansion chamber, its volume being variable, is connected with the quenching chamber by way of apertures which equalize the pressure of the quenching medium, thereby avoiding a counterflow of the quenching medium through the switch nozzle element, and preventing in particular hot gases from entering the quenching section.
BRIEF DESCRIPTION OF THE DRAWINGS
Practical examples of the invention are illustrated in a simplified manner by the accompanying drawings and are explained below in detail.
FIG. 1 illustrates a diagrammatic, sectional view of the essential parts of the arrangement proposed by the invention,
FIG. 2 shows the diagram of FIG. 1 with valves added thereto,
FIGS. 3a to 3c depict simplified sectional views of one species of the invention with a stationary differential diameter piston, with FIG. 3a illustrating the on-, and FIG. 3c the off-position, and FIG. 3b showing one switch-off phase with arcing in progress, and
FIGS. 4a to 4c depict simplified sectional views of another species of the invention with a movable differential diameter piston, FIGS. 4a and 4c again illustrating the on- and off-position respectively, and FIG. 4b one phase of the switch-off.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates the essential parts of the invention, most of them in the form of a sectional view. The piston, designed in the form of a differential diameter piston 1, runs with its part 1a, carrying the smaller piston area end 1c, between the arc-facing part 5a of the switch nozzle element 5 and the insulating nozzle 9 tightly sealed against the quenching medium, with the switch nozzle element 5 fastened at its arc-facing part 5a by means of a fixed part 10 to the arc-facing end 9b of the insulating nozzle 9. The other end 9c of the insulating nozzle 9 is connected to the boundary 6a of the quenching-medium expansion chamber 6. The differential diameter piston part 1b, carrying the larger area end 1d, runs between the unsupported part 5c of the switch nozzle element 5 and one portion of the inner boundary 6b of the quenching-medium expansion chamber 6, again tightly sealed against the quenching medium, and the differential diameter piston 1 is therefore able to move in the direction of the central axis which is common to said parts 1, 5, 9, and 6a.
However, if the differential diameter piston 1 is static, the above-mentioned parts 5, 10, 9, and 6a, connected to each other, are obviously jointly movable in the direction of the above-mentioned common central axis along the differential diameter piston 1 acting as a guide.
If the system comprises parts 5, 10, 9, and 6a and is stationary with respect to its surroundings, the differential diameter piston 1 will be moved at the time of switch-off in direction of the arrow K by a, not illustrated, drive device of a type known per se, for example by a spring action. At approximately the same time, and either independently or dependently of this movement of the differential piston 1, there is also being moved the switch contact member 3 by a, not illustrated, device of a type known per se in the direction of the arrow S, the directions of K and S being alike.
The differential diameter piston 1, by moving in direction K, will compress the quenching medium, present in the quenching-medium compression chamber 2 and possessing the initial pressure of p O , to the high pressure of p O +p H , whereby the quenching medium possessing the initial pressure of p O , being located in the antechamber 6f, is forced by the piston part 1b through the pressure-equalizing apertures 7 to the region 8 near the boundary 6a of the quenching-medium expansion chamber 6 where the initial pressure p 0 prevails. As soon as the switch element 3, being moved in the direction of arrow S, or K respectively, disengages the switch nozzle element 5, an arc is generated across the switch elements 3 and 5, while at the same time there is released the highly compressed quenching medium from the compression chamber 2, forming a quenching medium flow, i.e., a gas blast, directed at the arc. During this process the thermal energy of the arc, subjected to the blast, will accrue at the low pressure side of the quenching medium, i.e., within the hollow space 5d of the switch nozzle element 5, serving as quenching-medium conduit, or in the quenching-medium expansion chamber 6 respectively, in the form of a pressure increase p K , raising the initial pressure p O of the quenching medium present within these areas, with the result that the increased pressure p O +p K will become effective in the quenching-medium expansion chamber 6.
Since the system 5, 10, 9 and 6a remains static, the differential diameter piston 1 is pressed in the direction K by the force resulting as the product from the surface A 1d of the larger area end 1d of the piston and the increased pressure p O +p K , that is additionally by the force F Z =A 1d ·(p O +p K ), so that the piston 1 is additionally driven, or the above-mentioned, not illustrated drive mechanism of the piston 1 is correspondingly boosted in its operation, or eased respectively, by the converted thermal energy of the arc.
In order to give a practical example of the pressure ratios during the switch-off operation, it is assumed that the pressure increase p H in the quenching-medium compression chamber 2 by the differential diameter piston 1 is:
p.sub.H =8 to 10 bar
while the pressure increase p K in the quenching-medium expansion chamber 6 is:
p.sub.K =4 bar
If a differential diameter piston 1 is used where its smaller area end 1c, facing the quenching-medium compression chamber, has a surface area of A 1c , and its ratio to the surface area A 1d of the larger end 1d, facing the quenching-medium expansion area, is
A.sub.1c :A.sub.1d =1:2,
the amplified influence and effectiveness of the thermal energy produced by the arc, utilized in connection with the quenching medium flow as well as the drive of the moving components of the switch becomes quite obvious.
The high pressure p O +p H , resulting from the compression in the quenching-medium compression chamber 2, and referred to above in connection with the solution of the problem, is always greater than the first-mentioned increased pressure p O +p K , which is the result of the heating-up of the quenching medium in the expansion chamber 6.
Regarding the possibility that a switching-on of the compression switch might lead to a build-up of pressure in the quenching-medium expansion chamber 6, exceeding the pressure in the compression chamber 2, reference is made to the further development of the invention as illustrated in FIG. 2.
When the flow of the quenching medium, i.e., the period of blasting is about to be ended, the part 1b of the differential diameter piston will clear the pressure-equalizing apertures 7 for passage by the heated quenching medium, thus allowing the increased pressure p K to bleed into the region 8 which is under the initial pressure p O , and preventing a counterflow by the heated quenching medium, into the quenching action.
If the above described arrangement is reversed and the differential diameter piston 1 becomes static while the previously static system, comprising the parts 5,10,9, and 6a, is now moved in the direction of arrow L by a drive mechanism, not illustrated and known per se, the above given explanation, based on FIG. 1 applies correspondingly to the functioning of this inversely operating species of the invention.
Since the differential diameter piston 1 is now stationary, the increased pressure p O +p K in the quenching-medium expansion chamber 6 will act upon the end wall 6e of the boundary 6a of the quenching-medium expansion chamber 6--in a manner equivalent to the action on the piston 1 which was assumed to be movable in the previous example--resulting in a movement by the boundary 6a, or by the entire system 5, 10, 9, and 6a respectively, in the direction of the arrow L, an inverse operation which will not change in any manner the above dsscribed effect of the pressure increase p O +p K .
FIG. 2 depicts a further development of the invention shown by FIG. 1. Components which are identical in FIGS. 1 and 2 are denoted by like reference symbols.
In order to prevent the formation of a negative pressure in the quenching-medium expansion chamber 6 relative to its surrounding region or the quenching chamber 8 respectively in the case of switching operations involving low currents, there is provided at least one non-return valve 12 between the quenching-medium expansion chamber 6 and the surrounding region or quenching chamber 8. If the expansion chamber 6 is under negative pressure, the non-return valve 12 is open and the surrounding region 8 will remain in communication with the quenching-medium expansion chamber 6 by way of the open pressure-equalizing aperture 7 and the antechamber 6f at identical pressure until pressure equalization has been accomplished. FIG. 2 also shows that the non-return valve 12 passes through the ring-shaped flange 1f of the differential diameter piston 1.
Another non-return valve 13 is arranged between the expansion chamber 6 and the compression chamber 2 to prevent a build-up of pressure in the expansion chamber 6 that is greater than the pressure in the compression chamber 2 when the switch is being turned on. This arrangement allows any excess pressrure to flow into the quenching-medium compression chamber 2 by way of the passage 13a arranged within the piston 1 and the non-return valve 13 which is open in case of excess pressure, said passage 13a making its way through the tubular portion 1e and the ring-shaped flange 1f of the differential piston 1.
FIG. 3a gives a simplified sectional view of a compression switch proposed by the invention with static differential piston 1 in the switched-on position. Components which are identical with components shown in FIGS. 1 and 2 are denoted by like reference symbols in this FIG. 3a.
The stationary differential piston 1 is fixedly arranged at the quenching chamber end cover plate 8a, facing the drive mechanism, by means of a rod 1g, and the stationary switching contact member 3 is connected to the quenching chamber cover plate 8b, facing the switching mechanism, and an insulative cylinder 8c is placed between the two end cover plates 8a and 8b.
The drive of the compression switch is indicated figuratively by an insulating rod 14 which at the time of switch-off is moved in the direction of arrow L, with the quenching chamber being stationary, causing the parts 5, 10, 9, and 6a of the compression switch to move likewise in the same direction.
FIG. 3a shows that the quenching-medium compression chamber 2 is closed during the switched-off state by the fixedly arranged switch contact member 3, while the, likewise fixedly arranged, differential diameter piston 1 is arranged thusly that the volume of the quenching-medium compression chamber 2 is at its maximum. The antechamber 6f has likewise its maximum volume and is in communication with the quenching chamber 8 by way of the pressure-equalizing apertures 7. The quenching-medium expansion chamber 6 has, together with the hollow space 5d of the switch nozzle element 5, its minimum volume, this volume being closed off against the quenching chamber 8, the antechamber 6f as well as against the compression chamber 2, with the initial pressure p O existing in the areas 2, 5d, 6, 6f, and 8.
FIG. 3b shows the compression switch of FIG. 3a in an advanced phase of switch-off with arcing 4. The components shown by FIG. 3b are identical with the components of FIG. 3a and are therefore denoted by like reference symbols.
In this specific switch-off phase, the system comprising parts 5, 10, 9, and 6a has been moved by the insulating rod 14, which symbolizes the drive mechanism, in direction L toward the quenching chamber cover plate 8a which faces the drive mechanism. This movement relative to the stationary parts 1 and 3 has reduced substantially the volume of the quenching-medium compression chamber 2, thus causing a compression of the quenching medium, and the switch contact member 3 has opened the way for a flow by this compressed quenching medium in the direction of the arc 4. One portion of the quenching medium, at the same time heated-up by the arc 4, has flown through the hollow space 5d of the switch nozzle element 5 into the quenching-medium expansion chamber 6 and, while expanding there, has increased the size of the closed chamber 6 by moving its boundary 6a in the direction of arrow L to the position illustrated in co-action with the drive 14. The build-up of the high pressure (p O +p H ) within the quenching-medium compression chamber 2 as well as the pressure increase (p O +p K ) in the quenching-medium expansion chamber 6 is realized on the basis of the respective switch, the current to be handled, the drive mechanism of the switch and the like by an appropriately designed switch construction.
FIG. 3c shows the switch of FIGS. 3a and 3b in its off-position, the parts again identified in the same manner as in FIG. 3b.
The parts 5, 10, 9, and 6a which were moved in the direction of arrow L by the drive 14 in co-action with the quenching medium heated by the arc 4 have now reached the position where the switch is turned off completely. The arc is extinguished, the quenching-medium compression chamber 2, now at its minimum volume, is open toward the quenching chamber 8 by way of the insulating nozzle 9, and the pressure equalization can thus take place freely. The quenching-medium expansion chamber 6 has reached its maximum volume and is also in communication with the quenching chamber 8 by way of the apertures 7 which are now open, permitting pressure equalization.
FIG. 4a gives a simplified section view of a compression switch proposed by the invention with a movable differential piston 1 in the on-position, and components which are identical with the components of FIG. 3a are denoted by like reference symbols.
The system comprising the parts 5, 10, 9, and 6a, which is movable in the case of the species illustrated by FIGS. 3a to 3c, is fastened in the case of the species shown by FIGS. 4a to 4c to the quenching chamber cover plate 8a, facing the drive mechanism, by means of a mounting part 6g and is thus arranged stationary together with the quenching chamber 8.
In further development of the invention the, now movable, switch contact member 3 is coupled mechanically with the differential piston 1 by means of an insulating part 11.
The insulating rod 14, which symbolizes the drive of a type known per se, is secured to the movable differential piston 1. When the compression switch is being switched off, the system which now comprises the parts 1, 11, and 3 is moved in the direction of arrow K, and the switch will operate in the same manner as described in connection with FIGS. 3a to 3c.
FIG. 4b shows the compression switch of FIG. 4a, like in FIG. 3b, in an advanced phase of switch-off with arcing 4, and FIG. 4c shows the switch in its completely switched-off position, with like parts identified in the same manner as in FIG. 4a.
The various species of the invention, illustrated in FIGS. 1 to 4c, show in accordance with a preferred design the tubular switch nozzle contact element 5 being surrounded coaxially and at a specific distance by a tubular insulating nozzle 9, where the insulating nozzle 9 is connected by way of an annular spacing flange 6c to the tubular jacket 6d of the boundary 6a of the quenching-medium expansion chamber 6, FIGS. 3a-4a, the jacket 6d being arranged coaxially to the switch nozzle contact element 5, and where the inner diameter of the switch nozzle contact element 5 is smaller than the inner diameter of the jacket 6d, and the tubular jacket 6d is closed off opposite the unsupported part 5c of the switch nozzle contact element 5 by the end wall 6e. The tubular jacket 6d also carries at its end adjacent the flange 6c pressure-equalizing apertures 7 which are cleared by the differential piston part 1b possessing the larger end area 1d when the compression switch is in its off-position.
The differential diameter piston 1 is formed from a tube 1e, its part 1b with the larger end area 1d consisting of an annular flange 1f which has the same inner diameter, but a larger external diameter than the tube 1e, with the result that the illustrated embodiments of the invention are distinguished by their axial symmetry and particularly simple construction.
Obviously, the invention is not limited to the species shown by the drawing.
It is the essence of the invention concerning the compression switch that upon the compression of the quenching medium which is present in the switch as well as its release in the form of a quenching medium flow, the thermal energy produced by the arc at the low pressure side of the quenching medium flow which is directed at the arc will effectively contribute in the form of a pressure increase of the quenching medium in accomplishing the compression of the quenching medium and/or assist in the drive of the compression switch or of the moving parts of this switch, where the drive can be designed for example in the form of a spring-actuated drive.
It is possible, to design the quenching-medium compression chamber, the conduction of the quenching medium with increasing pressure being obtained at the low-pressure side, as well as the quenching-medium expansion chamber in a manner that differs from the arrangements illustrated by the drawings. It is possible, for example, to arrange the piston which compresses the quenching medium in such manner that it will co-act with a compression chamber that is arranged separately with respect to the switching elements and the insulating nozzle, with the compression chamber and the piston being arranged asymmetrically to the switching elements. Even the quenching-medium expansion chamber can be arranged independently of the insulating nozzle, and the conduction of the quenching medium heated by the arc can be accomplished in a manner that differs from the solutions shown by the species illustrated by the drawings, the only requirement being that the thermal energy, obtained in the form of a pressure increase, should be routed to the quenching-medium expansion chamber by way of a conduit involving minimum losses.
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An electrical compression switch operating with a compressed gaseous arc quenching medium comprises a switch chamber containing a pair of disengageable contacts one of which is a pin contact and the other a tubular nozzle contact surrounded by a tubular nozzle made from insulating material engageable with the pin contact and which surrounds the tubular nozzle contact in spaced relation to form a compression chamber. An expansion chamber is secured to the end of the tubular nozzle of insulating material and a differential piston operates within the latter and also within the compression chamber. A switch drive effects movement of the pin contact and differential piston considered as one unit relative to the tubular nozzle contact, the tubular nozzle of insulating material and the quenching medium expansion chamber considered an another unit to effect disengagement of the switch contacts as well as relative movement between the differential piston and tubular nozzle of insulating material in such direction as to decrease the volume of the compression chamber and thereby increase the pressure of the quenching medium at the arc which together with the thermal energy of the arc assists in the switch drive and also assists in arc extinction.
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This application is a national phase of International Application No. PCT/US2010/054593 filed Oct. 29, 2010 and published in the English language, which claims the benefit of U.S. Provisional Application No. 61/256,254 filed Oct. 29, 2009, all of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to gas delivery systems and, more particularly, to systems for connecting gas components.
BACKGROUND OF THE INVENTION
Gas delivery systems are used for the distribution of gases for the fabrication of semiconductor devices. The gases used in the fabrication of semiconductor devices are often highly toxic or corrosive. Many of these materials are drawn as a vapor from a liquid source and must be heated to prevent the vapor from condensing back to a liquid form. These systems require a high degree of modularity, very good leak integrity and must occupy a very small footprint. A typical method of accomplishing these requirements is through a surface mount system.
Surface mount systems typically require a fitting or block to bring the process gas from the outlet of one component to the inlet of the next component in the system. Typical systems couple two manifold blocks together such that they establish a common plane for both inlet and outlet seals. As will be appreciated, this can require tight tolerances of the components in order to ensure alignments of the ports of the manifold blocks with the ports of the gas component. Current systems are fabricated by mounting the manifold substrates down to a metal plate using templates to establish the appropriate substrate locations. This is very time consuming and, since these systems can be quite large with 16 separate gas lines being common, for example, it is typical to make this lower metal plate from aluminum. While aluminum helps to keep down the weight, it acts as a heat sink to draw away heat from the components that require heating.
While there are many variations of such systems available on the market today, such systems generally require very tight machining tolerances, are slow and/or difficult to assemble and can be difficult to heat. Moreover, such systems tend to be expensive.
SUMMARY OF THE INVENTION
The present invention provides a gas supply system that is easily assembled and/or installed and includes an initially flexible clamping system that allows for the gas supply system to adapt to the gas components. As the assembly of the gas components is complete, the clamping system becomes rigid thereby securing the gas components to a support rail. The system eliminates the need for very precise and time consuming layouts of a mounting plate for accommodating typical manufacturing tolerances. The slide lock gas delivery system allows the gas system component bottom surface to establish the sealing plane for the inlet and outlet seals independently. Also, the lateral spacing for the gas component mounting holes are allowed to ‘float’ during assembly such that the mounting holes do not have to be tightly toleranced and there is reduced opportunity for misalignment, which can stress the metal to metal seals.
In accordance with one aspect of the invention, a gas delivery system comprises a rail for supporting at least one manifold block, first and second manifold blocks each having at least one port for connection to a gas component, a gas component, securable to the first and second manifold blocks and having a mount surface with first and second ports for communicating with respective ports of the first and second manifold blocks when secured thereto, and a slide lock member for securing the first and second blocks to the rail. The slide lock member is configured to secure the first and second manifold blocks to the rail under a first level of preload for assembly of the gas component to the manifold blocks, and to secure the first and second manifold blocks to the rail with a second level of preload greater than the first level when the gas component is secured to the manifolds.
The slide lock member also can act as a spacer block to set the appropriate, approximate spacing between the first and second manifold blocks. Accordingly, the slide lock member can include both a slide lock clip portion for engaging the rail, and a spacer block portion for spacing the manifold blocks. The spacer block portion can be separate from the slide lock clip portion or formed integrally therewith. The slide lock member can include a set of protrusions to mate with a corresponding set of recesses in the manifold blocks to thereby interlock the slide lock member with the manifold blocks.
In one embodiment, the spacer block portion supports the slide lock clip portion in a symmetric fashion, approximately ⅓ of the distance from the slide lock clip center towards either clip end. The slide lock clip ends are deformed downwards, towards the rail at assembly until the slide lock clip portion engages the rail. Because the spacer block portion supports the slide lock clip at two fulcrum points, off center, the slide lock clip center is raised up when the edges are depressed down to engage the rail. This is essentially equivalent to a pair of ‘simply supported’ cantilever beams, guided at the center. A cantilever beam that is supported in this manner provides a relatively light holding force. In the case of the present invention, the result is that the slide lock member and the gas manifold blocks can self adjust their position to follow the position of the gas component as the gas component is installed to the manifold blocks.
As the gas component assembly is being completed, the final increment of movement of the gas component down to the manifold blocks, causes the gas component bottom surface to contact the raised center portion of the slide lock clip and drive it down flush or below the two fulcrum points. This final slide lock clip position is now essentially equivalent to a pair of cantilever beams that have fixed supports. Cantilever beams supported in this manner require essentially 2× the force to maintain the position of the deflected beam ends as initial.
The slide lock clip can have a central portion and respective leg portions extending from the central portion for engaging the rail thereby trapping the at least one manifold block between the slide lock member and the rail. The central portion can include a deflectable portion that, when deflected, increases tension on at least one of the leg portions to thereby increase the preload to the second level. The slide lock clip can be generally C-shape, and at least one distal end of the slide lock clip can include an interlock mechanism for interlocking with a surface of the rail. The slide lock clip and spacer block can be formed as a unitary piece. The rail can include a longitudinally extending channel between laterally spaced-apart manifold block support surfaces, and a heating element in the channel for providing heat to the gas components.
According to another aspect, a modular gas supply manifold system comprises a rail for supporting at least one manifold block, a manifold block having at least one port for connection to a gas component, and a slide lock member for securing the manifold block to the rail. The slide lock member is configured to secure the manifold block to the rail under a first level of preload to facilitate securing a gas component to the manifold block, and to secure the manifold block to the rail under a second level of preload greater than the first level when the gas component is secured to the manifold.
The slide lock member can include a slide lock clip and a spacer block for supporting the slide lock member. The spacer block can support the slide lock clip at a central portion thereof at two support locations. The support locations can be spaced apart from a longitudinal axis of the rail.
The slide lock member can have a central portion and respective leg portions extending from the central portion for engaging the rail thereby trapping the at least one manifold block between the slide lock member and the rail. The central portion can include a deflectable portion that, when deflected, increases tension on at least one of the leg portions to thereby increase the preload to the second level. The slide lock member can slidingly engage at least one of the rail or the manifold block to permit relative movement therebetween when under the first level of preload.
The system can also include a spacer block configured to space apart the first and second manifold blocks a predetermined distance on the rail. The spacer block can include a recess or protrusion for mating with a corresponding recess or protrusion on at least one of the first and second manifold blocks to thereby interlock the spacer block with the manifold block. The spacer block can support the central portion of the slide lock member near its outer edges to permit deflection of the central portion when the gas component is attached to the manifold blocks. The spacer block can be deformable to allow relative movement between the first and second manifold blocks during attachment of the gas component. The slide lock member and spacer block can be formed as a unitary piece. The slide lock member can be generally C-shape, and at least one distal end of the slide lock member can include an interlock mechanism for interlocking with a surface of the rail. The rail can include a longitudinally extending channel between laterally spaced-apart manifold block support surfaces, and a heat strip in the channel for providing heat to the gas components.
According to another aspect, a slide lock member for securing a manifold block to a rail of a modular gas supply manifold comprises a central spacer portion for spacing apart a first and second manifold block on the rail, and leg portions extending from the central spacer portion and adapted to engage the rail of a gas supply system. The slide lock member is configured to secure the manifold block to the rail under a first level of preload to facilitate securing a gas component to the manifold block, and wherein the slide lock member is configured to secure the manifold block to the rail under a second level of preload greater than the first level when a gas component is secured to the manifold. The central spacer portion can include a recess or protrusion for interlocking with a manifold block. The central spacer portion can be deformable to allow relative movement between the first and second manifold blocks during attachment of a gas component thereto. The slide lock member can be generally C-shape, and at least one distal end of the slide lock member includes an interlock mechanism for interlocking with a surface of the rail when mounted thereto.
According to another aspect, a method of assembling a gas delivery system comprises the steps of mounting first and second manifold blocks to a support rail with a slide lock member, each of the first and second manifold blocks having at least one port for communicating with a port of a gas component, the slide lock member being adapted to secure the first and second manifold blocks to the rail with a first amount of preload, and mounting a gas component to the first and second manifold blocks. The slide lock member is configured to secure the first and second manifold blocks to the rail under a first level of preload for assembly of the gas component to the manifold blocks, the first level of preload permitting relative, and wherein the slide lock member secures the first and second manifold blocks to the rail with a second level of preload greater than the first level when the gas component is mounted to the manifolds.
Further features of the invention will become apparent from the following detailed description when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exemplary slide lock gas delivery system having a gas component secured to first and second manifold blocks on a rail in accordance with the invention.
FIG. 2 is the slide lock gas delivery system of FIG. 1 with the gas component separated from the manifold blocks.
FIG. 3 is a perspective view of an exemplary slide lock manifold including a slide lock member in accordance with the invention.
FIG. 4 is a cross-sectional view of the slide lock member of FIG. 3 .
FIG. 5 is another cross-sectional view of the slide lock member of FIG. 3 installed on a rail.
FIG. 6 is a cross-sectional view illustrating the final configuration of the slide lock member when a gas component is installed.
FIG. 7 is an enlarged view of an exemplary slide lock clip in a first state.
FIG. 8 is an enlarged view of an exemplary slide lock clip in a second state.
FIG. 9 is a perspective view of another exemplary slide lock gas delivery system, partially assembled, in accordance with the invention.
FIG. 10 is another perspective view of a partially assembled exemplary slide lock gas delivery system in accordance with the invention.
FIG. 11 is a perspective view of the slide lock gas delivery system of FIGS. 6 and 7 with a secured gas component.
FIG. 12 is a perspective view of another exemplary slide lock gas delivery system.
FIG. 13 is an enlarged portion of the slide lock gas delivery system of FIG. 12 .
DETAILED DESCRIPTION
Turning to the drawings in detail, and initially to FIGS. 1 and 2 , an exemplary slide lock gas delivery system is indicated generally by reference numeral 10 . The system 10 includes a rail 14 for supporting first and second manifold blocks 18 and 22 The manifold blocks 18 and 22 each have at least one port 26 adapted for connection to respective ports on a mount surface 30 of a gas component 34 . The gas component 34 is secured to the first and second manifold blocks 18 and 22 via bolts 35 , or other suitable fasteners, that may extend through bores 38 . A slide lock member 42 including a spacer block portion 36 and a slide lock clip portion 44 secures the first and second manifold blocks 18 and 22 to the rail 14 . As will be appreciated, a plurality of manifold and gas component assemblies can be provided on the rail 14 in accordance with the invention.
As will be described in greater detail herein, the slide lock member 42 is configured to secure the first and second manifold blocks 18 and 22 to the rail 14 under a first level of preload for assembly and securing of the gas component 34 to the manifold blocks 18 and 22 , and to secure the first and second manifold blocks 18 and 22 to the rail 14 with a second level of preload greater than the first level when the gas component 34 is secured to the manifolds via bolts or the like. Moreover, by lightly holding the manifold blocks 18 and 22 to the rail 14 , the slide lock member 42 allows the ports 26 of the manifold blocks 18 and 22 to self-align with the ports of the gas component 34 as the gas component 34 is tightened down onto the manifold blocks 18 and 22 .
Turning now to FIG. 3 , a gas manifold assembly, generally indicated by reference numeral 45 , of the slide lock system 10 is illustrated with the gas component 34 removed. Each manifold block 18 and 22 in the illustrated embodiment includes first and second halves, each half having a port 26 . A tubular portion 46 connects the first and second halves together and provides a passageway for the flow of fluid between the two ports 26 of each manifold block. Such manifold blocks 18 and 22 are sometimes referred to as H-blocks, and are often made by welding the tube stub (e.g., tubular portion) of each half together.
The manifold blocks 18 and 22 rest on manifold support surfaces 50 and 52 of the rail 14 . The manifold support surfaces 50 and 52 in the illustrated embodiment are at laterally outer edges of the rail 14 . Between the manifold support surfaces 50 and 52 is a longitudinally extending channel 56 . Supporting the manifold blocks 18 and 22 in this manner creates air space around the manifold blocks thereby limiting the surface area available for thermal conduction between the manifold blocks and the rail 14 . The manifold blocks are secured to rail 14 by the slide lock member 42 .
The slide lock member 42 in the exemplary embodiment includes the generally C-shape slide lock clip 44 having a central portion 57 and leg portions 58 engaged with the rail 14 . The leg portions 58 each have an engagement mechanism, in the form of tabs 62 (see FIG. 4 ), that interlock with an edge of the rail 14 to thereby secure the slide lock member 42 thereto. As will be appreciated, the slide lock member 42 is installed on the rail 14 by slipping the leg portions 58 of the slide lock clip portion 44 over the edge of the rail 14 , as best seen in FIG. 5 . In this regard, the slide lock clip portion 44 can be sized such that the legs 58 can be compressed slightly in order for the tabs 62 to engage the rail. Once engaged, the slide lock member 42 then applies a first level of preload to the manifold blocks 18 and 22 thereby securing the manifold blocks 18 and 22 to the rail 14 .
As will be appreciated, this first level of preload typically will be sufficient to maintain the manifold blocks 18 and 22 at an approximate position on the rail 14 for subsequent installation of the gas component 34 to the manifold blocks 18 and 22 . Further, the level of preload may generally permit relative movement between the manifold blocks 18 and 22 and/or the rail 14 such that final alignment of the ports 26 of the manifold blocks 18 and 22 with the ports of the gas component 34 can occur during attachment of the gas component 34 itself, thus greatly reducing the tolerances needed in the manufacture of the manifold blocks 18 and 22 and/or gas component 34 .
Turning to FIG. 4 , the slide lock member 42 is shown in cross-section. As will be appreciated, in this embodiment, the slide lock clip portion 44 is supported by the spacer block portion 36 at two locations labeled S in the drawing. The spacer block portion 36 supports the slide lock clip portion 44 in a symmetric fashion, approximately ⅓ of the distance from the slide lock clip center towards either clip end.
In FIG. 5 , the slide lock member 42 is shown installed on a rail 14 . As will be appreciated, in order to install the slide lock member 42 , the ends of the central portion 57 of the slide lock clip member 44 are deformed downwards towards the rail 14 assembly until the slide lock clip portion 44 engages the rail 14 . Because the spacer block portion 36 supports the slide lock clip 44 at two fulcrum points, off center, the slide lock clip center is raised up when the edges are depressed down to engage the rail 14 thereby generating a preload when released. This corresponds to the first level of preload.
For example, slide lock clip 44 is essentially equivalent to a pair of ‘simply supported’ cantilever beams, guided at the center. A cantilever beam that is supported in this manner provides a relatively light holding force. In the case of the present invention, the result is that the slide lock member 42 and the gas manifold blocks can self adjust their position to follow the position of the gas component as the gas component is installed. As will be appreciated, the support configuration can be altered depending on the desired preload effects. For example, three support locations could be provided, or the support locations could be in different planes.
Turning to FIG. 6 , the slide lock member 42 is illustrated as it would appear with a gas component secured to adjacent manifold blocks (e.g., as shown in FIG. 1 ). The gas component is not shown in FIG. 6 for clarity. As the gas component assembly to the manifold blocks is being completed, the final increment of movement of the gas component down to the manifold blocks causes the gas component bottom surface (e.g., mount surface) to contact the raised center portion of the slide lock clip 44 and drive it down flush or below the two fulcrum points S. This final slide lock clip 44 position is now essentially equivalent to a pair of cantilever beams that have fixed supports. Cantilever beams supported in this manner require essentially 2× the force to maintain the position of the deflected beam ends as initial. Accordingly, the holding force applied by the slide lock member 42 to the manifold blocks to the rail 14 will be approximately twice as great as the holding force in FIG. 5 , and corresponds to the second level of preload.
Turning to FIG. 7 , an exemplary slide lock clip member 44 is illustrated in detail in as it may appear when secured to the rails 14 but before the gas component is installed on the manifold blocks. As mentioned, the slide lock clip is generally C-shape and includes the central portion 57 and leg portions 58 extending from the central portion 57 . Tabs 62 are provided on the leg portions 58 for engaging the rail 14 as described. The central portion 57 includes a deflectable portion 64 thereof that, in the exemplary embodiment, is generally bow shape but other shapes can be utilized. This deflectable portion 64 can be deflected during installation of the slide lock member 42 to the rail 14 and can thereby provide the first level of preload to secure the manifolds 18 and 22 to the rail 14 . As noted, when the gas component 34 is secured to the manifold blocks 18 and 22 , the deflectable portion is compressed between the spacer block portion 36 and the mount surface 30 of the gas component 34 , and the amount of preload is increased to a second level greater than the first level.
Turning to FIG. 8 , the slide lock clip 44 is illustrated as it may appear when the gas component 34 is secured to the manifold blocks 18 and 22 . As indicated by arrow A, the deflectable portion 64 has been compressed downward by the gas component. Due to the shape of the slide lock clip 44 and the manner in which it is supported by the spacer block 36 , the downward deflection of the deflectable portion 64 causes the legs 58 to draw upward in the direction of arrows B, thereby increasing the preload applied to the manifold blocks 18 and 22 by the slide lock member 42 when the gas component 34 is bolted to the manifold blocks 18 and 22 .
Turning now to FIGS. 9-11 , and initially to FIG. 9 , another embodiment of the slide lock gas delivery system is shown in various stages of assembly. In FIG. 9 , a manifold block 18 and an integral spacer block/slide lock member 68 are supported on the rail 14 . In general, both manifold blocks 18 and 22 will be placed on the rail 14 and then the integral slide lock member 68 will be installed thereto. In order to show details of the integral slide lock member 68 , however, the second manifold block 22 has been removed from FIG. 9 .
The integral slide lock member 68 includes a central spacer block portion 70 and leg portions 72 extending from the central spacer portion 70 . The central spacer block portion 70 is configured to space-apart the manifold blocks 18 and 22 and has locating studs 74 for engaging respective recesses (not shown) in the manifold blocks 18 and 22 to thereby interlock the manifold blocks 18 and 22 with the integral slide lock member 68 . The leg portions 72 engage the rail 14 in a similar manner as the slide lock clip 44 of the previous embodiment. Thus, in this embodiment the slide lock clip and spacer block can be formed as unitary piece.
As will be appreciated, the integral slide lock member 68 of this embodiment is configured to apply the first level of preload when installed to the rail 14 prior to securing the gas component 34 to the manifold blocks 18 and 22 . To this end, the leg portions 72 are configured to be flexible so as to be flexed downward towards the rail 14 in order to permit engagement tangs 78 on distal ends thereof to engage a surface of the rail 14 , such as lip 80 . In this manner, after installation of the tangs 78 to the rail 14 , a preload is applied to the manifold blocks 18 and 22 . FIG. 10 illustrates both manifold blocks 18 and 22 supported on the rail 14 along with the integral slide lock member 68 .
In FIG. 11 the gas component 34 is secured to the manifold blocks 18 and 22 via bolts 82 . Like the previous embodiment, as the gas component 34 is secured to the manifold blocks 18 and 22 , the integral slide lock member 68 tightens the manifold blocks 18 and 22 to the rail 14 . This is accomplished via the compression of the central portion and/or leg portions of the integral slide lock member 68 interposed between the gas component and the rail 14 .
As will be appreciated the rail 14 in this embodiment includes a plurality of optional slots 84 for receiving the tangs 78 of the integral slide lock member 68 when the gas component 34 is secured to the manifold blocks 18 and 22 . The slots 84 are located below the lip 80 on each side of the rail 14 . As will also be appreciated, the legs 72 can be flexed downward during the installation of the gas component 34 thereby allowing the tangs 78 to engage the slots 84 in order to secure the manifold blocks 18 and 22 to the rail 14 . When the gas system component is attached, there will be a sideways gripping action that takes place as the slide lock is displaced.
Returning to FIG. 9 , this gripping action is achieved as a result of a force tending to rotate the distal ends of the leg portions 72 inward towards each other that is developed as the integral slide lock member 68 is compressed between the gas component and the rail. As will be appreciated, the upper portion of the leg portions 72 in the uncompressed state extend above the uppermost surfaces of the manifold blocks 18 and 22 . As such, when a gas component is secured to the manifold blocks, each leg portion 72 is forced downward thereby causing a moment to be applied to the leg portion 72 that results in the gripping action.
Turning to FIGS. 12 and 13 , a slide lock gas delivery system 90 is illustrated having a heating element 92 (e.g., an electric heating element) for supplying heat to the gas flow passages of the manifold blocks 18 and 22 and/or gas component 34 . The heating element 92 is provided in the channel 56 of the rail 14 on an underside of the manifold blocks 18 and 22 . The remainder of the channel 56 can be filled with insulation 94 . Flexible foam insulation can be used to provide an upward load to ensure intimate contact with the manifold substrates. The heating element 92 and/or insulation 94 can be secured to the rail 14 via an adhesive 96 or by any other suitable method.
Slide lock gas supply systems in accordance with the invention is capable of withstanding shipping shock and vibration without developing leaks. This is accomplished in the slide lock design by a variable load cantilever beam. The initial assembly of the gas system substrates with the slide lock system positions the substrate inlet and outlets in the approximate proper location and holds them with an axial force of approximately 14 lbs. A small amount of lateral adjustment is possible to allow the substrate to align with the upper gas component. When the gas component is fully installed, that is, tightened to the manifold substrates to affect a seal, the cantilever beam loading is changed by depressing the center. This results in a higher holding force (e.g., 28 pounds), effectively locking the manifold substrate in the optimum position.
Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.
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A gas supply system that is easily assembled and/or installed and includes an initially flexible clamping system that allows for the gas supply system to adapt to the gas components. As the assembly of the gas components is complete, the clamping system becomes rigid thereby securing the gas components to a support rail. The slide lock gas delivery system allows a gas system component bottom surface to establish the sealing plane for the inlet and outlet seals independently. The lateral spacing for the gas component mounting holes float during assembly to reduce the opportunity for misalignment.
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FOREIGN PRIORITY
[0001] This application claims priority to European Patent Application No. 16461502.3 filed Jan. 14, 2016, the entire contents of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to check valves.
BACKGROUND
[0003] Check valves are valves that allow fluid flow in one direction therethrough and prevent flow in the opposite direction. They are widely used in a range of applications, for example in air conditioning systems, for example in aircraft air conditioning systems.
[0004] Check valves commonly include a pair of valve elements or flappers located at an opening in a valve housing. The flappers are hingedly supported on a hinge pin mounted to the valve housing for rotation between a closed position in which they lie across and close the opening, preventing fluid flow through the opening in one direction and an open position in which, under the pressure of a fluid (gas or liquid) on one side of the check valve, the flappers rotate from their closed positions so as to allow the fluid to flow through the valve in the opposite direction.
[0005] In known check valve arrangements, a stop is provided to limit the rotational movement of the flapper elements as they open. Typically, the stop comprises a stop pin which is mounted to posts arranged on opposed sides of the valve housing opening. The stop pin is spaced from the opening such that when the flappers open, they engage the stop pin.
[0006] The flapper elements may impact the stop pin with some considerable force, meaning that the flapper elements must be sufficiently robust to withstand the impact forces and avoid becoming overstressed which might lead to failure of the flapper element. This may mean that the flapper elements may have to be relatively heavy, which may have implications for example in aircraft applications.
[0007] The present disclosure relates to a check valve which includes a modified stop construction.
SUMMARY
[0008] There is disclosed herein a check valve which comprises a valve housing defining a valve opening, a pair of mounting posts arranged on opposed sides of the valve opening and a hinge pin mounted between the mounting posts. A pair of flapper elements is pivotably mounted to the hinge pin for rotation relative to the housing between an open position in which they permit fluid flow through the respective valve openings and a closed position in which they prevent fluid flow through the valve openings. A stop is mounted between the mounting posts above the hinge pin and extending across the valve opening such that the flapper elements will contact the stop in their open positions. The stop is a coil spring.
[0009] In certain embodiments, the coil spring may be a wire spring.
[0010] In other embodiments, the coil spring may be a machined spring.
[0011] The flapper elements and the coil spring may be configured such that the flapper elements engage the stop in a medial region of the coil spring.
[0012] The coil spring may have a variable diameter, with the diameter in the medial region being larger than the diameter in the end regions of the coil spring. In another arrangement, the coil spring may only be provided with turns in a medial region.
[0013] In either of the above arrangements, the flapper elements may have a planar upper surface region for engaging the medial region of the coil spring.
[0014] In other embodiments, the coil spring may have a constant diameter. The flapper elements have a raised medial region, for example a convexly curved medial region for engaging the medial region of the coil spring.
[0015] The ends of the coil spring may be received within respective bores such as to be rotatable in the bores about the spring axis.
[0016] The ends of the coil spring may be received in the respective bores with so as to be rotatable transversely with respect to the spring axis.
[0017] In one arrangement, the end of the coil spring may be rounded and be received within a rounded, flaring bore recess.
[0018] In an alternative arrangement, the end of the coil spring may be formed with a transverse groove having a rounded base, and the bore is provided with a pin extending vertically thereacross, the pin being received within the groove.
[0019] The disclosure also extends to a method of assembling a check valve as described above, the method comprising axially compressing the coil spring, positioning the coil spring between the mounting posts and releasing the coil spring such that it moves into engagement with the mounting posts.
[0020] Some embodiments of the disclosure will now be described by way of example only with reference to the accompanying drawings in which:
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 shows a perspective view of a first embodiment of check valve in accordance with this disclosure;
[0022] FIG. 2 shows a central vertical cross section through the check valve of FIG. 1 ;
[0023] FIG. 3 shows a side view of the check valve of FIG. 1 ;
[0024] FIG. 4 shows a sectional view along the line B-B of FIG. 3 ;
[0025] FIG. 5 shows a perspective view of a second embodiment of check valve in accordance with this disclosure;
[0026] FIG. 6 shows a sectional view through the check valve of FIG. 5 , along a line corresponding to the line B-B of FIG. 4 ;
[0027] FIG. 7 shows a perspective view of a third embodiment of check valve in accordance with this disclosure;
[0028] FIG. 8 shows a sectional view through the check valve of FIG. 7 , along a line corresponding to the line B-B of FIG. 4 ;
[0029] FIG. 9 shows a perspective view of a fourth embodiment of check valve in accordance with this disclosure;
[0030] FIG. 10 shows a sectional view through the check valve of FIG. 9 , along a line corresponding to the line B-B of FIG. 4 ;
[0031] FIG. 11 shows a part sectional view of a detail of a fifth embodiment of check valve in accordance with this disclosure; and
[0032] FIG. 12 shows a part sectional view of a detail of a sixth embodiment of check valve in accordance with this disclosure.
DETAILED DESCRIPTION
[0033] A first embodiment of check valve 2 in accordance with this disclosure is illustrated in FIGS. 1 to 4 .
[0034] The check valve 2 comprises a valve housing 4 for mounting in a pipe, duct or the like. The valve housing 4 comprises a valve opening 6 in the form of a pair of generally D-shaped openings 6 which are separated by a central web 8 of the valve housing 4 .
[0035] A pair of mounting posts 10 extend upwardly from the valve housing 4 . The mounting posts 10 may be integrally formed, for example cast, with the valve housing 4 . Alternatively, the mounting posts 10 may be separately formed from the valve housing 4 and mounted thereto by suitable means.
[0036] A hinge pin 12 is mounted between the mounting posts 10 above the central web 8 . As shown, the hinge pin 12 is a unitary pin, but it may be formed in one or more parts suitably joined together. The hinge pin 12 may be retained to the mounting posts 10 in any convenient manner.
[0037] The valve openings 6 are closed by a pair of generally D-shaped flapper elements 14 which are pivotally mounted to the hinge pin 12 by mounting lugs 16 . Each flapper element 14 has 4 mounting lugs 16 , the mounting lugs 16 of the respective flapper elements being arranged in an alternating fashion on the hinge pin 12 .
[0038] The flapper elements 14 are received in a recess 18 formed in one face 20 of the valve housing 4 , the recess 18 having a peripheral flange (not shown) against which the periphery of the flapper elements 14 seat in the closed position. The hinge end 22 of each flapper element 14 also seats against the valve housing web 8 in the closed position, so that the flapper elements 14 close the valve openings 6 . As described so far, the construction of the check valve is conventional.
[0039] The check valve 2 is further provided with a stop 24 mounted between the mounting posts 10 . In this embodiment, the stop 24 is in the form of a wire coil spring 24 having a constant coil diameter D along its length. The coil spring 24 has mounting sections 26 at its ends, aligned along the longitudinal axis A of the coil spring 24 . The end sections 26 are received in bores 28 formed in the upper ends of the mounting posts 10 . The bores 28 are sized to be just slightly larger in diameter than the diameter of the coil spring wire in the end sections 26 of the coil spring 24 such that the coil spring end sections 26 may rotate about the longitudinal axis A of the spring 24 in the bores 28 thereby reducing the likelihood of irregular wear of the components.
[0040] In this embodiment, the flapper elements 14 are generally plate like, but, as can be seen from FIG. 4 , the upper surface 30 of the flapper element 14 (i.e. that facing away from the valve opening 6 when the flapper element 14 is closed) is convexly curved. In this embodiment, the upper surface 30 is smoothly curved over the entire width of the flapper element, but this is not essential, and it may be that only a medial section 32 of the upper surface 30 is so formed.
[0041] The effect of the curvature of the flapper element upper surface 30 is seen in FIG. 4 . The curvature means that the flapper element 14 does not contact the coil spring 24 along the entire length of the coil spring 24 , but only in a medial section 34 thereof. This means that the coil spring 24 is able better to deflect upon impact of the flapper element 14 , thereby better dissipating the impact energy. It will be appreciated that as the coil deflects, a central turn of the coil spring 24 will deflected first, after which turns adjacent the central turn will engage the flapper element upper surface 30 . The energy of the impact force is therefore converted into deflection and movement of the respective turns of the coil spring 24 . The damping effect will be best where the impact is asymmetrical (i.e. where one flapper element 14 impacts the coil spring 24 before the other. However, this is what mostly will happen in practice.
[0042] In a variation of this arrangement, instead of a curved upper surface 30 , the medial section 32 of the upper surface 30 of the flapper element may simply be raised with respect to the laterally adjacent sections of the upper surface to create the desired engagement.
[0043] A second embodiment of the disclosure will now be described with reference to FIGS. 5 and 6 .
[0044] The general construction of the check valve 102 of the second embodiment is similar to that of the first embodiment, so only the differences between the check valve 102 of this embodiment and the check valve 2 of the first embodiment will be discussed.
[0045] In this embodiment, the stop is also in the form of a coil spring 124 . However, the coil diameter D of the spring 124 varies along its length, being a maximum in the medial region 134 of the coil spring and reducing toward the end regions 126 of the coil spring.
[0046] This construction simplifies the construction of the flapper element 114 in that its upper surface 130 may be planar as shown, contact between the flapper element 114 and the medial section 134 of the coil spring 124 being assured by virtue of the varying diameter of the coil spring 124 .
[0047] A third embodiment of the disclosure will now be described with reference to FIGS. 7 and 8 .
[0048] The general construction of the check valve 202 of the third embodiment is also similar to that of the first embodiment, so only the differences between the check valve 202 of this embodiment and the check valve 2 of the first embodiment will be discussed
[0049] In this embodiment, the stop is also in the form of a coil spring 224 . In this embodiment, turns 222 are only provided in a medial region 234 of the coil spring 224 , with the coil spring 224 having elongated end mounting regions 226 . The coil diameter D of the medial region 234 is constant.
[0050] The flapper element 214 is similar to that of the second embodiment, having a planar upper engagement surface 230 . The provision of coils turns only in the medial region 234 of the coil spring 234 , however, ensures that there is contact with the flapper elements 214 only in that medial region 234 .
[0051] A fourth embodiment of the disclosure will now be described with reference to FIGS. 9 and 10 .
[0052] The general construction of the check valve 302 of the third embodiment is also similar to that of the first embodiment, so only the differences between the check valve 302 of this embodiment and the check valve 2 of the first embodiment will be discussed.
[0053] In contrast to the first embodiment, the stop 324 in this embodiment is formed as a machined spring 324 . Machined springs are coil springs in which instead of the turns of the coil being made from wire, the turns are machined out of a tubular blank.
[0054] In this embodiment, the spring diameter D is constant along the length of the spring 324 . The end regions 326 of the spring 324 are received in pockets 328 formed in the mounting posts 310 .
[0055] As in the first embodiment, the upper surface 330 of the flapper element 314 is convexly curved so as to ensure contact of a medial region 332 of the flapper element 314 with the medial section 334 of the spring 324 . The upper surface 330 of the flapper element 314 may be shaped appropriately to provide the requisite area of contact with the spring 324 .
[0056] Compared to a wire spring, a machined spring 324 may provide a better contact between the flapper element 314 and the spring 324 , depending on the shape of the upper surface 330 of the flapper element 314 . The spring 324 may be machined to provide the appropriate lateral resilience by controlling the width and thickness of the coil.
[0057] In the various embodiments described above, the spring ends 26 , 126 , 226 , 326 are received in bores or pockets in the mounting posts. The sizing of the spring ends and the bores or pockets will allow the spring ends to rotate about the spring axis A to prevent uneven wear on the spring or mounting posts.
[0058] Lateral deflection of the springs will shorten the length of the spring length by a relatively insignificant distance compared to its side deflection. However, after the spring deflects laterally, the spring ends 26 , 126 , 226 , 326 will no longer be coaxial with the central, deflected region of the spring. This will create a bending force on the mounting bores for the spring ends, which may cause stresses which can damage the mounting posts.
[0059] In further embodiments of the disclosure, therefore, the mounting of the springs may be modified so as to permit rotation of the spring ends relative to the spring mountings.
[0060] A first such modification is shown in FIG. 11 . In this embodiment, the end regions 426 of a coil spring 424 (which may have either a constant or a varying coil diameter as shown in any of FIGS. 1 to 8 ) is formed with a rounded end 440 . The rounded end 440 is received within a flaring closed bore 442 formed in the mounting post 410 . The closed bore 442 has a rounded base portion 444 having a radius of curvature slightly larger than that of the rounded end 440 of the coil spring 424 . It further has a flared mouth portion 446 which opens onto the inner surface 448 of the mounting post 410 . A gap 450 is thereby created between the spring end 440 and the flared pocket portion 446 , which will allow the end regions to rotate out of the spring axis A for example in a direction D in a plane extending transversely, for example perpendicularly, to the longitudinal axis A of the spring when impacted by the flapper elements 414 . This will act to avoid potentially damaging bending stresses being transmitted into the mounting post 410 .
[0061] A second such modification is shown in FIG. 12 . In this embodiment, the end regions 526 of a machined spring 524 are received within respective bores 528 in the mounting posts 510 . A clearance 530 is provided between the bore 528 and the end region 526 .
[0062] Each end region 526 is provided with a transverse groove 540 extending diametrically across its free end. As can be seen, the groove 540 has a curved or rounded base 542 .
[0063] A pin 544 is fixedly mounted within vertically aligned bores in the mounting posts 510 . The pin 544 is in this embodiment circular in cross section and has an outer surface whose diameter is slightly smaller than the radius of curvature of the groove base 542 . This, together with the clearance 530 will allow the ends 526 of the spring 524 to rotate in a direction E around the pin axis F, i.e. transversely to the longitudinal axis of the spring 524 , when the spring 524 is impacted by a flapper element. This arrangement also prevents bending stresses being transmitted into the mounting posts 510 .
[0064] Other arrangements which provide a rotatable joint at the spring mounting also fall within the scope of this disclosure.
[0065] The assembly of the various embodiments of check valve described above is very simple. To install the stop spring 24 , etc., all that is required is that the spring 24 be compressed lengthwise, suitably positioned between the bores or pockets in the mounting posts 10 and then released. The resilience of the spring 24 will retain it in the mounting posts without any additional retaining element being necessary. This is advantageous from a safety and reliability point of view.
[0066] It will be appreciated that various modifications may be made to the embodiments discussed above without departing from the scope of the disclosure. For example, it would be possible in other embodiments to vary both the diameter of the spring and curve the engaging surface of the flapper element.
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A check valve comprises a valve housing defining a valve opening, a pair of mounting posts arranged on opposed sides of the valve opening and a hinge pin mounted between the mounting posts. A pair of flapper elements are pivotably mounted to the hinge pin for rotation relative to the housing between an open position in which they permit fluid flow through the valve opening and a closed position in which they prevent fluid flow through the valve opening. The valve further comprises a stop mounted between the mounting posts above the hinge pin and extending across the valve opening such that the flapper elements will contact the stop in their open positions. The stop is a coil spring.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to plumbing tools, more particularly wrenches for manipulating threaded pipe fittings.
BACKGROUND OF THE INVENTION
[0002] Pipe fittings are used to join together lengths of pipe. They have two or more fitting ends, connected via short lengths of tubing. Fittings for threaded pipe have at least one fitting end that is threaded, and may be male or female in a variety of different diameters, as needed to threadingly mate with a given threaded pipe end.
[0003] Angled fittings have a bend in the tubing between two of the fitting ends. Three of the most common varieties of angled fittings are the elbow fitting, which comprises two female threaded ends joined by a specific angle of tubing (usually 90 degrees, but other angles are available, e.g. 45 degrees, 22.5 degrees); the tee fitting, which comprises three threaded ends, which can be male or female, two of which are joined by a straight length of tubing, and one of which is at a 90 angle to the other two; and the street elbow, which is similar to the elbow fitting, except that one of the threaded ends has a male thread.
[0004] Angled fittings typically require the use of a pipe wrench for installation and removal. A pipe wrench typically comprises a handle and an adjustable/rocking jaw that are arranged such that forward force exerted upon the handle causes the adjustable jaw to rock back in a way that tightens the jaw, and backward force on the handle tends to loosen it. Thus, when the jaw is loosened, the wrench can be rotated while the loosened jaw slips around the pipe. Teeth also line the interior of the jaw such that forward force on the handle causes the teeth to dig into an object (e.g. a pipe fitting) placed within the jaw of the pipe wrench. Thus, forward force exerted upon the handle tightens the jaw until the object within the jaw turns with the wrench. Once the wrench reaches the end of its range of movement, backward force is applied to the handle to loosen the jaw, and the wrench may be rotated back within its range of movement to re-grip the object for further tightening. The range of movement of a conventional pipe wrench is determined by whatever structure or immovable obstacles surround the object being tightened. For example, when installing and/or removing pipe fittings, it is common to be assembling pipe lines along or between walls or joists.
[0005] Several problems exist with the current state of the art in pipe fitting installation and removal, especially when said installation and/or removal occurs in limited access areas. Where angled fittings have been installed in confined spaces or where surrounding equipment has been installed after an initial pipe installation, conventional pipe wrenches can render pipe installation extremely inconvenient. This is because conventional pipe wrenches require the use of a long handle, which places space at a premium during installation. This problem is further exacerbated by the bulkiness of the jaw of a conventional pipe wrench, which often severely restricts the jaw's range of movement. For example, the jaw wraps around three sides of an imaginary square containing the round pipe/fitting, and the jaw has strengthening structure extending outward from the jaw faces. Compounding the problem is the fact that the first part of the tightening movement is lost to the rocking jaw movement until it tightens enough to be able to turn the fitting. Consequently, pipe installation and removal professionals are either forced to remove and reinstall surrounding equipment or else struggle to work around it, using a wrench limited to a very small effective range of movement (10 to 20 degree effective range is not uncommon). Under these conditions, pipe and fitting assembly is frustratingly slow, excessively difficult and inefficient.
[0006] The tendency for conventional pipe wrenches to slip while being forcefully turned adds to the difficulty of tight quarters work and also adds risk of injury to piping professionals and/or damage to nearby equipment and structures. Additionally, the slippage inherent in conventional pipe wrenches can decrease overall productivity. Finally, the teeth in conventional pipe wrenches tend to mar and/or score pipe/fitting surfaces.
[0007] Therefore it is an object of the present invention to provide a tool that is capable of installing and removing pipe fittings more efficiently, especially in limited access areas, thereby increasing productivity and reducing the risk of damage and injury.
BRIEF SUMMARY OF THE INVENTION
[0008] According to the invention an apparatus is disclosed for torquing an angled pipe fitting relative to a fixed threaded end of pipe having a longitudinal axis, wherein the angled fitting has an axial arm and a lateral arm, and wherein the torque must be applied about an axis of the axial arm of the angled fitting while it is coaxially aligned with the longitudinal axis of the fixed threaded end, the apparatus comprising: a socket that has an axial drive attachment defining a socket rotational axis, wherein the axial drive attachment facilitates attachment of an axial driving device to the apparatus; and a fitting cavity axially distal to the drive aperture, wherein: the fitting cavity opens axially outward and comprises an axial canal about the socket rotational axis, and a lateral canal that extends laterally outward relative to the socket rotational axis; the axial canal is shaped and dimensioned to receive the axial arm of the angled fitting and to hold it such that the axial arm axis is coaxial with the socket rotational axis; and the lateral canal is shaped and dimensioned to receive the lateral arm of the fitting and to hold it against torque about the axial arm axis.
[0009] According to the invention the apparatus may further comprise a flange recess in the lateral canal, wherein the flange recess is shaped and dimensioned to accept a fitting flange rimming the end of the lateral arm of the angled fitting.
[0010] According to the invention the apparatus may further comprise a socket flange rimming a laterally outward end of the lateral canal, positioned such that when the angled fitting is inserted into the fitting cavity, the socket flange holds the angled fitting against lateral movement out of the fitting cavity. Preferably there is an opening through the socket flange; wherein the socket flange opening opens both laterally outward and axially outward, and is shaped and dimensioned to accept the diameter of a length of pipe; thereby enabling an angled fitting with the length of pipe threadingly mated to its lateral arm to be axially inserted such that the mated length of pipe extends through the socket flange opening.
[0011] According to the invention the apparatus may further comprise a drive cylinder arranged coaxially about the socket rotational axis, thereby facilitating torquing of the socket by hand. Preferably there are friction elements on its surface; for example a series of grooves extending axially along the surface of the drive cylinder.
[0012] According to the invention the axial drive attachment preferably comprises a drive aperture coaxially aligned with the socket rotational axis, wherein the drive aperture is shaped and dimensioned for removably engaging with a drive stud of the axial driving device.
[0013] According to the invention the axial driving device preferably comprises a ratcheting wrench, or a motor drill.
[0014] According to the invention the apparatus may further comprise hexagonal facets around the axial canal, thereby enabling a hexagonal flange on a fitting to be inserted such that the hexagonal flange's rotational axis is coaxial with the socket's rotational axis.
[0015] According to the invention the axial canal further comprises an arm recess that extends axially inward of the lateral canal, towards the drive attachment end of the socket, the arm recess being shaped and dimensioned to receive an axial arm of the angled fitting.
[0016] Other objects, features and advantages of the invention will become apparent in light of the following description thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Reference will be made in detail to preferred embodiments of the invention, examples of which are illustrated in the accompanying drawing figures. The figures are intended to be illustrative, not limiting. Although the invention is generally described in the context of these preferred embodiments, it should be understood that it is not intended to limit the spirit and scope of the invention to these particular embodiments.
[0018] Certain elements in selected ones of the drawings may be illustrated not-to-scale, for illustrative clarity. The cross-sectional views, if any, presented herein may be in the form of “slices”, or “near-sighted” cross-sectional views, omitting certain background lines which would otherwise be visible in a true cross-sectional view, for illustrative clarity.
[0019] Elements of the figures can be numbered such that similar (including identical) elements may be referred to with similar numbers in a single drawing. For example, each of a plurality of elements collectively referred to as 199 may be referred to individually as 199 a , 199 b , 199 c , etc. Or, related but modified elements may have the same number but are distinguished by primes. For example, 109 , 109 ′, and 109 ″ are three different elements which are similar or related in some way, but have significant modifications. Such relationships, if any, between similar elements in the same or different figures will become apparent throughout the specification, including, if applicable, in the claims and abstract.
[0020] The structure, operation, and advantages of the present preferred embodiment of the invention will become further apparent upon consideration of the following description taken in conjunction with the accompanying drawings, wherein:
[0021] FIGS. 1A-1D are side views of four common angled fittings that can be accommodated by the inventive socket, as well as a side view of a fixed threaded end of pipe to which an angled fitting is to be applied;
[0022] FIG. 2 is a top view of the inventive socket and two examples of axial drive mechanisms accommodated by the inventive socket;
[0023] FIG. 3 is a perspective view of the inventive socket, showing a side, top, and drive end;
[0024] FIGS. 4A-4B are views of a fitting end of two embodiments of the inventive socket;
[0025] FIG. 5 is a cross-sectional side view of the inventive socket; and
[0026] FIGS. 5A-5D are side views of three angled fittings (ghosted outline) that have been inserted into a fitting cavity (also ghosted) of the inventive socket, all according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Although the drawings and the proceeding description disclose angled fittings with female threaded ends (the most common form), it should be understood that the inventive socket accepts angled fittings with male or female threaded ends. The use of angled fittings with female threaded ends in the drawings and proceeding description is meant to be illustrative and is not intended to be limiting in nature.
[0028] It will be shown that the inventive socket 100 is particularly suited to advantageously handle a variety of angled pipe fittings, including the most commonly used ones.
[0029] FIG. 1A shows a first example of an angled fitting 101 , specifically a full elbow 101 c (i.e., a ninety degree elbow), shown coaxially aligned with a fixed threaded end 102 (e.g. a male threaded end of a length of pipe) that has a longitudinal axis 104 . The full elbow 101 c comprises a lateral arm 108 joined perpendicularly to an axial arm 106 , through which runs the axial arm's axis of rotation 126 . A fitting flange 103 rims the end of each of the lateral arm 108 and the axial arm 106 and defines a diameter referenced as dimension C.
[0030] For any angled fitting 101 , when an arm's axis of rotation 126 (e.g. the axial arm 106 ) is coaxial with the fixed threaded end's longitudinal axis 104 , the axial arm 106 may be torqued around the axial arm's axis of rotation 126 , thereby threadingly mating the angled fitting 101 with the fixed threaded end 102 . The fixed threaded end 102 is either male or female, as needed to mate with the angled fitting 101 , and can be an end of any portion of threaded piping that requires assembly with an angled fitting 101 . For example, the fixed threaded end 102 can be at the free end of any length of pipe, including a nipple; or, for example, can be at the free end of a street elbow.
[0031] FIG. 1B shows an example of an angled fitting 101 , specifically a street elbow 101 d. The street elbow 101 d comprises a lateral arm 108 joined perpendicularly to an axial arm 106 , through which runs the axial arm's axis of rotation 126 . Unlike a typical full elbow 101 c , the street elbow 110 d has one female threaded end with a flange 103 , and one male threaded end 107 having a diameter referenced as dimension D. The male threaded end 107 on a street elbow 101 d makes a shorter connection possible between two consecutive elbows that would otherwise need to be interconnected by a pipe nipple. Generally, the male threaded end 107 on a street elbow 101 d extends farther out from the bend than the female threaded end with a flange 103 .
[0032] FIG. 1C shows an example of an angled fitting 101 , specifically a tee 101 a , that can be accepted by the socket 100 . The tee 101 a comprises two axial arms 106 that are joined to form a linear portion, and a lateral arm 108 that is joined perpendicularly to the two axial arms 106 . The lateral arm 108 has a dimension C defined by the diameter of the lateral arm's 108 fitting flange 103 . An axis of rotation 126 is shown for the linearly combined axial arms 108 . A standard fitting flange 103 is shown on each female threaded end.
[0033] FIG. 1D shows an example of an angled fitting 101 , specifically a slant elbow 101 b , that can be accepted by the socket 100 . The slant elbow 101 b comprises a lateral arm 108 joined at a 45 degree angle to an axial arm 106 , through which runs the axial arm's axis of rotation 126 . Although FIG. 1D illustrates a slant elbow 101 b with a 45 degree elbow, slant elbows exist with angles other than 45 degrees. Thus, references to slant elbows herein should be understood to include any angle of elbow other than 90 degrees.
[0034] FIG. 2 illustrates a top view of the socket 100 showing a lateral canal 124 into a fitting cavity 120 , along with two exemplary axial driving devices 110 : a motor drive 110 a and a ratcheting wrench 110 b . The axial driving devices 110 have a drive stud 118 , typically square in cross section, which is insertable into a mating drive aperture 114 of the socket 100 . (As in all of the drawings, hidden lines are shown as ghosted outlines.) When the drive stud 118 is inserted into the drive aperture 114 , the axial driving device 110 becomes coaxially aligned with a rotational axis 116 of the socket 100 , and therefore can easily be used to torque the socket 100 about its rotational axis 116 . The drive aperture 114 is a preferred embodiment of what can be generally called an axial drive attachment for the socket 100 , wherein the axial drive attachment (e.g., aperture 114 ) facilitates attachment of an axial driving device 110 to the socket 100 . Given the teaching herein, other forms of the axial drive attachment may become apparent. For example: The drive aperture 114 form is coaxially aligned with the socket rotational axis 116 , and is shaped and dimensioned for removably engaging with the drive stud 118 . Alternatively, the axial drive attachment could be an externally faceted stud coaxially aligned with the socket rotational axis 116 , and shaped and dimensioned for removably engaging with a ratcheting-ring type of axial driving device 110 . Alternatively, the axial drive attachment could be a permanent connection between a ratcheting wrench mechanism (driving device 110 ) and the socket 100 . Other forms and variations may become apparent, all of which are intended to be within the scope of the present invention.
[0035] FIG. 3 illustrates a perspective view of the socket 100 . Its rotational axis 116 is defined by the drive aperture 114 , which is located in a socket cylinder 117 . The socket cylinder 117 is cylindrically shaped and coaxial with the socket rotational axis 116 so that the socket 100 can be conveniently hand torqued (manually) about the rotational axis 116 . Preferably the socket cylinder 117 has friction/grip-enhancing elements 119 to improve grip and further facilitate hand torquing of the socket, the elements 119 being grooves, ridges, knurling, rubber coating, or the like. The drive aperture 114 is axially distal to the fitting cavity 120 . The fitting cavity 120 comprises a lateral canal 124 , which is normal to the socket's rotational axis 116 (extending laterally outward), and an axial canal 122 , which is aligned with (coaxial with) the rotational axis 116 .
[0036] FIG. 4A illustrates a fitting end of the socket 100 . The fitting end face 121 is open for receiving the angled fitting 101 in the fitting cavity 120 , which comprises the axial canal 122 with an arm recess 127 ; and the lateral canal 124 with a lateral branch 123 , as well as preferably a socket flange opening 125 in a socket flange 128 that defines a flange recess 129 .
[0037] The axial canal 122 is shaped and dimensioned to receive the axial arm 106 of an angled fitting 101 . In particular, the axial canal 122 is shaped and dimensioned to snugly fit around the fitting flange 103 of a female threaded end and the lateral canal 124 is shaped and dimensioned to snugly fit around the lateral arm 108 of the angled fitting 101 . If, as is usually the case, the angled fitting is a full elbow 101 c with a flanged 103 female threaded end on the lateral arm 108 , then the fitting flange 103 will rest in the flange recess 129 , held in by the socket flange 128 which prevents the angled fitting 101 from rocking or falling out the top of the lateral canal 124 . As best illustrated in FIG. 5 , the socket flange 128 preferably rims the entire socket flange opening 125 , minimizing jiggling of the fitting 101 when the fitting 101 is inserted into the fitting cavity 120 . The socket flange 128 partially surrounds the lateral canal 124 , forming the socket flange opening 125 . Because an inside dimension D of the socket flange opening 125 is smaller than an inside dimension C of the flange recess 129 , the angled fitting 101 is held snugly within the fitting cavity 120 . Dimension C also matches outside dimension C of the fitting flange 103 of the full elbow 101 c and the tee 101 a , further minimizing rocking of the fittings 101 c and 101 a inside the fitting cavity 120 . Additionally, dimension C matches the diameter of both the arm recess 122 and the axial canal 120 , which consequently matches the diameter of the fitting flange 103 , minimizing lateral jiggling of the axial arm 106 in the axial canal 122 . For the street elbow 101 d , inside dimension D of the socket flange opening 128 matches outside dimension D of the male fitting end 107 of the street elbow 101 d , further minimizing rocking of the male fitting end 107 inside the lateral canal 124 . Furthermore, because inside dimension D of the socket flange opening 128 matches outside dimension D of the street elbow's 101 d male fitting end 107 , it should be obvious that dimension D is also sized to receive the diameter of a fixed threaded end 102 . Consequently, the socket 100 will also accommodate an angled fitting 101 with a length of pipe (e.g., a nipple) already mated to the lateral arm 108 of the angled fitting 101 .
[0038] Since threaded pipe and its fittings come in a variety of nominal sizes (e.g., ¼ inch, ½ inch, ¾ inch, 1 inch, and so on), the inventive socket 100 will also come in the same variety of sizes, each one being suitably dimensioned for working with a particular nominal size of angled fittings. Although not a limiting part of the invention, it may be noted that as the pipe size increases, the axial drive stud size and/or driving mechanism is preferably increased correspondingly to accommodate any need for increased amounts of applied torque. Of course other means (e.g., reinforcement, stronger materials, etc.) could also be used.
[0039] In a preferred embodiment of the invention, as shown in FIG. 4A , the axial canal 122 is substantially circular and dimensioned to receive the typically circular fitting flange 103 on the axial arm(s) 106 of an angled fitting 101 . FIG. 4B illustrates an optional embodiment of the invention, wherein the axial canal 122 has hexagonal facets, i.e., is hexagonally shaped, enabling it to receive, and grip for torquing, a hexagonally shaped fitting flange on an axial arm 106 of a pipe fitting that may be, but isn't necessarily, an angled fitting 101 .
[0040] FIG. 5 illustrates a cross sectional side view of the socket 100 , and FIG. 5A illustrates a full elbow that has been inserted into the fitting cavity 120 . Referring to FIG. 5A , the lateral arm 108 extends along the lateral canal 124 , where the flange recess 129 accepts the fitting flange 103 of the female threaded end. The axial arm 106 extends along the axial canal 122 such that the axial arm's rotational axis 126 is coaxial with the socket's rotational axis 116 , and consequently the axial arm 106 can be torqued by an axial driving device 110 onto a fixed threaded end 102 when its longitudinal axis 104 is also aligned (as shown in FIG. 1A ).
[0041] A dimension E bounded by the face 121 of the fitting end of the axial canal 122 and the axially opposite side of the lateral branch 123 is sized such that the axial arm's fitting flange 103 is contained within, and ideally flush with, the face 121 of the fitting end of the axial canal 122 , preventing the angled fitting 101 from wiggling relative to the rotational axis 116 . The angled fitting 101 thus fits snugly into the socket 100 .
[0042] FIG. 5B illustrates an optional socket embodiment wherein a slant elbow 101 b can be inserted into the socket 100 . The lateral arm 108 extends part way into the lateral canal 124 , which is hollowed out to accommodate a fitting flange 103 on the slant elbow 101 b such that the end of the lateral arm 108 butts against an edge of the arm recess 127 , and is shaped and dimensioned such that the axial arm's fitting flange 103 is contained within, and ideally flush with, the face 121 of the fitting end of the axial canal 122 . The slant elbow fitting 101 b thus fits snugly into the socket 100 . The axial arm 106 extends along the axial canal 122 such that the axial arm's rotational axis 126 is coaxial with the socket's rotational axis 116 , and consequently the axial arm 106 can be torqued onto a fixed threaded end 102 . This embodiment is optional because the hollowed out part of the fitting cavity 120 may cause a somewhat sloppy fit for the more commonly used full elbow 101 c and tee 101 a types of angled fittings 101 . If desired, the socket 100 could be made in different versions, with one version being specifically fitted to a slant fitting 101 b only.
[0043] FIG. 5C illustrates a tee 101 c that has been inserted into the socket 100 . The lateral arm 108 extends along the lateral canal 124 , where the flange recess 129 accepts the fitting flange 103 of a female threaded end. Both of a first axial arm 106 a and a second, collinear, axial arm 106 b extend along the axial canal 122 . The arm recess 127 extends the axial canal 122 deep enough to receive the second axial arm 106 b while aligning the lateral arm 108 and the first axial arm 106 a with the rest of the fitting cavity 120 substantially the same as the alignment of a full elbow 101 c . Thus the tee 101 a fits snugly into the socket 100 , and the axial arm's rotational axis 126 is coaxial with the socket's rotational axis 116 , such that the first axial arm 106 a can be torqued onto a fixed threaded end 102 .
[0044] FIG. 5D illustrates a street elbow 101 c that has been inserted into the fitting cavity 120 of the socket 100 . The lateral arm 108 extends along the lateral canal 124 , and the male threaded end 107 of the lateral arm 124 extends through the socket flange opening 125 such that the socket flange 128 snugly grips the male threaded end 107 . The axial arm 106 extends along the axial canal 122 such that the axial arm's rotational axis 126 is coaxial with the socket's rotational axis 116 , and consequently the axial arm 106 can be torqued by an axial driving device 110 onto a fixed threaded end 102 when its longitudinal axis 104 is also aligned (as shown in FIG. 1A ).
[0045] Once an angled fitting 101 has been positioned snugly into the socket 100 via the fitting cavity 120 , the socket 100 can be torqued about the rotational axis 116 defined by the drive aperture 114 . Torque to start the mating can be applied by manually turning the socket cylinder 117 , thereby allowing the greatest control to avoid cross threading. When the parts are mated enough to make manual torquing difficult, then the axial driving device 110 is used. Because the socket rotational axis 116 is coaxial with the fitting axial arm's rotational axis 126 , which in turn is coaxial with the longitudinal axis 104 of the fixed threaded end 102 , the angled fitting 101 is rotated about the axial arm's rotational axis 126 and is easily torqued onto the fixed threaded end 102 .
[0046] The socket 100 renders the process of torquing the angled fitting 101 onto a fixed threaded end 102 both safer and more efficient than it is with a conventional pipe wrench. This is because the snug fit afforded by the socket 100 minimizes wiggling and also because the socket 100 has no jaw that can come loose and slip during torquing. Additionally, the fact that the drive aperture 114 accepts the drive stud 118 of an axial driving device 110 means that the socket 100 can be easily used to install an angled fitting 101 in very limited access areas. Unlike the offset drive of a pipe wrench, an axial drive need not have any structure protruding radially beyond the fitting, and the handle (if present) extends radially rather than tangentially from the fitting. Therefore, given the same set of obstacles around the pipe fitting installation point, the axial drive has a larger range of motion than the pipe wrench. Furthermore, a ratcheting axial drive device, having virtually zero slack re-gripping motion, also has a larger effective range of motion. Even further, if a motor drive is used, especially with a flexible shaft, the effective range of motion becomes virtually infinite.
[0047] Although the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character it being understood that only preferred embodiments have been shown and described, and that all changes and modifications that come within the spirit of the invention are desired to be protected. Undoubtedly, many other “variations” on the “themes” set forth hereinabove will occur to one having ordinary skill in the art to which the present invention most nearly pertains, and such variations are intended to be within the scope of the invention, as disclosed herein.
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A pipe fitting socket for use with an axial driving device accepts a variety of angled fittings (e.g. tees, full elbows, slant elbows) snugly within a fitting cavity for torquing onto a fixed threaded end of pipe. Torquing of the fitting is accomplished by inserting a drive stud of the driving device into a drive aperture defining a rotational axis and torquing the driving device, thereby rotating the socket about the rotational axis, or through manually torquing a cylindrical portion of the socket. The socket offers superior efficiency and safety over conventional pipe wrenches by maximizing the effective range of movement available for a wrench used for angled fitting installation and/or removal, while virtually eliminating a wrench's loss of grip on the fitting.
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TECHNICAL FIELD
This invention relates to an audio browser for vehicles and, more particularly, to the application of a common usability model to multiple modes of operation of the vehicle car stereo.
BACKGROUND OF THE INVENTION
Many car stereo systems (including vehicle computer systems and vehicle entertainment systems) include multiple bands, such as AM, FM1, FM2, and CD. The selected band represents the operating state of the car stereo (e.g., receiving AM stations, receiving FM stations, or playing an audio CD). After selecting a particular band, the user selects a preset button to select between radio stations (or CD in a CD Changer) or a tuning buttons (seek and/or scan) to tune a particular radio station (or select a particular CD track).
Certain vehicle computer systems provide the opportunity to add new features and functions to existing car stereo systems. For example, a vehicle computer system may provide navigational functions in addition to conventional car stereo functions.
As more functions are added to car stereos (or other vehicle computer systems), it may be necessary to add additional buttons to the car stereo to support the new functions. It is important to minimize the number of changes to the current car stereo model to allow the user the easiest adoption path for the new functionality and minimize the negative effects of putting more secondary activities into the car environment. The primary task of a driver of a vehicle is the driving of the vehicle, not manipulating the car stereo controls. Adding a significant number of new buttons to support the new car stereo functions may distract the driver from the primary task of driving the vehicle. Therefore it is important to provide a usability model that is familiar to the user of the car stereo to minimize distractions while driving the vehicle.
SUMMARY OF THE INVENTION
The systems and methods described herein provide a common usability model for multiple modes of operation of a car stereo system. The basis of the invention is the extension of the current car stereo into a more flexible “audio browsing” model. The common usability model extends the typical car stereo usability model with new functionality while maintaining the typical car stereo functions that have been learned by many vehicle users. By maintaining typical car stereo functions, users can more easily interact with a more intelligent device because they already know how to perform, for example, the radio and CD player functions. The addition of a small number of buttons to implement new car stereo functionality minimizes the differences between the new audio browser and conventional car stereos to the user of the new audio browser.
According to one aspect of the invention, an audio browser includes a first set of buttons that select a preset item. A second button selects between a set of primary audio control bands and a set of conditional audio control bands. A third button selects a band from the set of bands selected by the second button.
Another embodiment of the invention includes a fourth button that activates a function that varies based on the selected band.
BRIEF DESCRIPTION OF THE DRAWINGS
The same reference numerals are used throughout the drawings to reference like components and features.
FIG. 1 is a diagrammatic illustration of an in-vehicle audio browser.
FIG. 2 is a flow diagram illustrating an embodiment of a procedure for handling operation of the “BND” button.
FIGS. 3–8 illustrate a car stereo faceplate in different modes of operation.
DETAILED DESCRIPTION
FIG. 1 shows an example implementation of an in-vehicle audio browser 20 . The audio browser 20 has a centralized computer 21 coupled to various peripheral devices, including speakers 25 , vehicle battery 26 , and antenna(s) 27 . The computer 21 is assembled in a housing 28 that is sized to be mounted in a vehicle dashboard, similar to a conventional car stereo. Preferably, the housing 28 has a form factor of a single DIN (Deutsche Industry Normen). But, it possibly could be housed in a 2 DIN unit or other special form factor for an OEM. The methods and systems described herein may be applied to any type of vehicle computer system, vehicle entertainment system, or vehicle stereo system. In a particular embodiment, the in-vehicle audio browser is a car stereo system.
The computer 21 runs an open platform operating system which supports multiple applications. Using an open platform operating system and an open computer system architecture, various software applications and hardware peripherals can be produced by independent vendors and subsequently installed by the vehicle user after purchase of the vehicle. This is advantageous in that the software applications do not need to be dedicated to specially designed embedded systems. The open hardware architecture is preferably running a multitasking operating system. One preferred operating system is a Windows® brand operating system sold by Microsoft Corporation, such as “Windows Xp™”, “Windows NT®”, “Windows CE™”, or other derivative versions of Windows®. A multitasking operating system allows simultaneous execution of multiple applications.
The computer 21 includes at least one storage media which permits the vehicle user to store and transfer data (i.e. audio content) and possible new programs. One aspect of the invention is the ability to introduce new audio content into the in-vehicle environment. The purpose of the storage media component is to allow for the transportation of audio content in a format that can be played back and navigated by the audio browser. The storage media must either be removable or have some other mechanism (such as wireless access) for update. In the illustrated implementation, the computer 21 has a CD ROM (or DVD-ROM) drive 29 which reads application-related CDs, as well as musical, video, game, or other types of entertainment CDs. In this manner, the CD ROM drive 29 performs a dual role of storage drive and entertainment player. A CD can then be used to transport the audio content to the audio browser. Also, a hard disk drive (not shown in FIG. 1 ) is included on the computer module which can be used for storing both application programs and user data. In combination with an optional 802.11x interface 24 the hard disk drive can have audio content wirelessly transported to the audio browser. 802.11x represents a family of IEEE standards for wireless networks used for the wireless communication of data between various devices. Alternatively, other wireless communication standards may be used to communicate data between the audio browser 20 and another computing device, such as a personal computer providing data to and from the audio browser.
The computer 21 has an optional smart card reader 31 , and dual PCMCIA card sockets 32 which accept PCMCIA card types II and III or CF cards. Hereinafter, the acronym “PC-Card” will be used in place of the acronym “PCMCIA.” The smart card and/or any bulk storage PC-Card (memory or hard drive) can also be used to transport audio content to the audio browser.
The storage drives are mounted in a stationary base unit 33 of housing 28 . The base unit 33 is constructed and sized to be fixedly mounted in the dashboard. The housing 28 also has a faceplate 34 which is pivotally mounted to the front of the base unit 33 . The faceplate can be rotated to permit easy and convenient access to the storage drives. It is possible to build an audio browser without a pivoting faceplate, but there still has to be a way to access to the removable storage media. This could be done by having a CF card reader mounted vertically on the faceplate, or having only 802.11x access to an internal hard drive.
Faceplate 34 functions as an operator interface, having a keypad 35 and a display 36 . The faceplate is mountable for viewing by a vehicle operator. The display 36 is preferably a backlit LCD panel having a rectangular array of pixels that are individually selectable for illumination or display. However, it is also possible to have only a set of alpha-numeric (text) enunciator for the display. An enunciator based display will have to have a defined set of areas to display band, preset, and song information. An exemplary set of areas are: 3 characters band area, 1 character preset number area, 10 character preset title area, and 15 character song information area.
The LCD panel is preferably a medium-resolution, bit-mapped display system having at least 10,000 pixels. In the described implementation, the array of pixels has a size of at least 256×64 pixels, which is quite limited in comparison to most desktop displays. The operating system of computer 21 interacts with faceplate keypad 35 and faceplate display 36 as peripheral devices when the faceplate 34 is attached to the housing 28 . The operating system will allow for and abstract display models for both the enunciator based display type and bitmap based display. The keypad 35 includes multiple number keys, labeled “1” through “6”.
The faceplate 34 has a “Rev” button 40 that represents a reverse (or rewind) function, a “Play/Pause” button 42 that toggles operation between play and pause functions, and a “Fwd” button 44 that represent a forward (or advance) function. The faceplate 34 also has a volume control input 38 , an “ACT” button 46 that represents an “action” function, a “SRC” button 48 that represents a “source” function, and a “BND” button 50 that represents a “band” function. The operation of the action, source, and band functions are discussed in greater detail below.
A CD slot 52 allows a CD, such as a music CD, to be inserted into the CD ROM drive 29 . Alternatively, a CD may be inserted into CD ROM drive 29 by pivoting or otherwise moving faceplate 34 such that the CD ROM drive is accessible by the user. A power button 54 toggles power to the vehicle computer system 20 .
In general, the audio browser 20 is used to integrate new audio content and sources onto one user model and one open platform hardware and software architecture. The basic mode of operation is the playback of audio content that has arrived at the audio browser via the required removable media. This audio content has been collected and organized on some remote device (such as a personal computer) and delivered to the audio browser for playback. The audio content will include configuration information to instruct the audio browser as to which audio content is associated with which band/preset content and if there are special instructions needed for the behavior of the other buttons on the faceplate.
The configuration file is represented in an XML manifest. The manifest contains exemplary information about the behavior and type for each band/preset.
Here is an example of the XML:
<?xml version=“1.0” encodinq=“utf-8”?>
<Manifest Version=“0.5” ID=“2452346234”
Name=“MikkyA_Stuff”>
<Bands CurrentBand=“FM”>
<Band ID=“FM” Title=“FM” Type=“radio”
CurrentPreset=“1”>
<Preset ID=“88.5” Title=“KPLU 88.5”
Setting=“1” Freq=“FM:88.5”/>
<Preset ID=“96.5” Title=“KPNT 96.5”
Setting=“2” Freq=“FM:96.5”/>
</Band>
<Band ID=“WM1” Title=“WM1” Type=“playlist”
CurrentPreset=“2”>
<Preset ID=“NPR-ME” Title=“Morning
Edition” Setting=“1” Src=“Band0\Preset0\Preset0.ASX”
CurrentIndex=“” CurrentTime=“”/>
<Preset ID=“Market” Title=“Market Place”
Setting=“3” Src=“Band0\Preset2\Preset2.ASX”
CurrentIndex=“” CurrentTime=“”/>
<Preset ID=“CBC-W@6” Title=“CBC”
Setting=“4” Src=“Band0\Preset3\Preset3.ASX”
CurrentIndex=“” CurrentTime=“”/>
</Band>
<Band ID=“WRK” Title=“WRK” Type=“playlist”>
<Preset ID=“OutlookToday”
Title=“OutlookToday” Setting=“1”
Src=“OutlookToday\OutlookToday.asx” CurrentIndex=“”
CurrentTime=“”/>
</Band>
<Band ID=“PT” Title=“Phone Tasks”
Type=“phonetask”>
<Preset ID=“Phone Mail” Title=“Phone
Mail” Setting=“1” Src=“Phone\PhoneMail\PhoneMail.asx”
CurrentIndex=“” CurrentTime=“”/>
<Preset ID=“Home Tasks” Title=“Home
Tasks” Setting=“2”
Src=“Phone\PhoneTaskshome\PhoneTaskshome.asx”
CurrentIndex=“” CurrentTime=“”/>
<Preset ID=“Work Tasks” Title=“Work
Tasks” Setting=“3”
Src=“Phone\phonetaskswork\phonetaskswork.asx”
CurrentIndex=“” CurrentTime=“”/>
</Band>
<Band ID=“NT1” Title=“Navigation”
Type=“direction”>
<Preset ID=“To Airport” Title=“To
Airport” Setting=“1” Src=“nav\toairport\toairport.asx”
CurrentIndex=“” CurrentTime=“”/>
<Preset ID=“To Gas Station” Title=“To Gas
Station” Setting=“2”
Src=“nav\togasstation\togasstation.asx” CurrentIndex=“”
CurrentTime=“”/>
<Preset ID=“To Museum of Flight”
Title=“To Museum of Flight” Setting=“3”
Src=“Nav\tomuseumofflight\tomuseumofflight.asx”
CurrentIndex=“” CurrentTime=“”/>
</Band>
<Band ID=“CL” Title=“Contact List”
Type=“contacts”>
<Preset ID=“Home” Title=“Home Numbers”
Setting=“1” Src=“Contacts\Home.asx” CurrentIndex=“”
CurrentTime=“”/>
<Preset ID=“Work” Title=“Work Numbers”
Setting=“2” Src=“Contacts\Work.asx” CurrentIndex=“”
CurrentTime=“”/>
</Band>
</Bands>
</Manifest>
This example manifest is one possible format that can be used to convey the configuration information from a personal computer or service or even between different audio browsers in different vehicles. With the flexibly of XML, this format can easily change to meet the needs for any new bands that are created in the future.
In the embodiment discussed above, the faceplate 34 is pivotally mounted to the base unit 33 . In alternate embodiments, faceplate 34 may be detached from the base unit 33 . In other embodiments, faceplate 34 is permanently fixed to the base unit 33 .
As shown in FIG. 1 , many of the buttons on faceplate 34 have been found on car radios for many years. For example, the keypad 35 contains various radio station presets. Additionally, the “Rev”, “Play/Pause”, and “Fwd” buttons should be familiar to most radio users. However, the “ACT” button has not been included on previous car stereos and provides additional functionality for the new car stereo system shown in FIG. 1 .
The BND button ( FIG. 1 ) causes the car stereo to cycle through the various bands supported by the car stereo. In a particular embodiment, the car stereo has the following bands: AM, FM, CD (Audio CD), WM (Windows Media), PT (Phone Tasks), NT (Navigation Tasks), and CL (Contact Lists). The selected band identifies the current function of the car stereo, such as playing the selected FM radio station or providing navigation instructions to a selected destination.
The bands are divided into two different classes: primary audio control and conditional audio control. Primary audio control bands automatically take over the audio output of the audio browser when they are selected. However, conditional audio control bands do not immediately take over the audio output of the audio browser, thereby not interrupting the audio signal listened to by the user. In a particular embodiment, AM, FM, CD, and WM are primary audio control bands. Switching to one of these primary audio control bands causes the car stereo system to switch to the source's current state (e.g., a preset radio station or CD track) and start playing the appropriate audio signal. PT, NT and CL are examples of conditional audio control bands. Switching to one of these conditional bands does not interrupt the current audio signal playing from the last selected primary band. If some action on this conditional band requires an audio output (such as providing audible directions, making a cellular phone call, or providing an audible task), then the primary audio will be paused or muted until the audio output is finished being used by the conditional band. When the conditional band function is finished using the audio output, the audio is returned to the primary band and the audio output is resumed.
In one embodiment, the “SRC” button ( FIG. 1 ) on the faceplate switches between primary and conditional band types and the “BND” button switches between bands within the current type. In another embodiment, the “BND” button switches between all band types.
FIG. 2 is a flow diagram illustrating an embodiment of a procedure 200 for handling operation of the “BND” button. Initially, a user selects a particular band on the car stereo using the BND button on the faceplate (block 202 ). The functions associated with the other buttons on the faceplate are modified based on the selected band (block 204 ). The user then manipulates the other buttons on the faceplate to perform the desired function (block 206 ). The car stereo performs the selected function (block 208 ). The procedure then determines whether the user has pressed any buttons on the faceplate (block 210 ). If the user has not pressed any buttons, the operation of the car stereo continues unchanged until one of the buttons is pressed. If the user presses a button, the procedure determines whether the button pressed was the BND button (block 212 ). If the button was the BND button, then the procedure returns to block 204 to modify the functions associated with the other buttons on the faceplate based on the new band selection. If the button pressed was not the BND button, then the procedure returns to block 208 , where the car stereo performs the selected function.
Once a particular band has been selected, the behavior of the other buttons on the faceplate changes to the appropriate behavior for the selected band type. The appropriate behavior of the various buttons for each band type is discussed below.
FIG. 3 illustrates a car stereo faceplate in the FM1 mode. The faceplate shown in FIG. 3 is substantially the same as faceplate 34 shown in FIG. 1 . The faceplate display indicates that the first preset has been selected (indicated by “ 1 :”), which is radio station KNDD having a frequency of 107.7. In the FM1 mode, the buttons on the faceplate perform the following functions:
1–6 Presets: Press: Switches to a preset radio frequency.
Press & Hold: Sets the preset to the current radio frequency.
Reverse: Press: Scans backwards through the radio frequencies. Press & Hold: Scans backward through the cache of the currently playing radio frequency. Forward: Press: Scans forward through the radio frequencies.
Press & Hold: If the radio frequency currently playing was paused then it scans forward through the cache of the currently playing radio frequency.
Play/Pause: Press: Pauses or restarts radio broadcast by saving the audio stream to storage. Action: Press: Saves the current playing song or small historical time segment (the last 5 minutes and the next five minutes).
Similar functions are associated with the buttons in other radio band modes (e.g., FM2, FM3, and AM).
FIG. 4 illustrates a car stereo faceplate in the CD mode. The faceplate display indicates that the first CD in a CD changer has been selected, which is an audio CD containing music from the Beatles' album “Abbey Road”. In the CD mode, the buttons on the faceplate perform the following functions:
1–6 Presets: Press: Switches to a CD within a CD changer. Reverse: Press: Skips to previous track on the current CD.
Press & Hold: Scans backward within the current track on the current CD.
Forward: Press: Skips to next track on the current CD.
Press & Hold: Scans forward within the current track on the current CD.
Play/Pause: Press: Pauses or plays the current track on the current CD. Action: Press: Saves the current playing track to storage and places the song in the next available preset track on a WM band.
Press & Hold: Save the current playing CD to storage and places the CD in the next available preset on a WM band.
FIG. 5 illustrates a car stereo faceplate in the WM (Windows Media) mode. The WM band presents represent an audio playlist. The WM band may also be referred to as a digital media band. The playlist could represent a saved CD, a random set of 10 songs from a musical collection or songs from a radio collection. The faceplate display indicates that the first playlist has been selected, which is a morning issue of the NPR broadcast. In the WM mode, the buttons on the faceplate perform the following functions:
1–6 Presets: Press: Switches to a preset playlist that has either been saved (from radio or CD) or loaded via (wireless or removable) storage medium. Reverse: Press: Skips to previous track in the current playlist.
Press & Hold: Scans backward within the current track in the current playlist.
Forward: Press: Skips to next track in the current playlist.
Press & Hold: Scans forward within the current track in the current playlist.
Play/Pause: Press: Pauses or plays the current track in the current playlist. Action: No function for this band.
FIG. 6 illustrates a car stereo faceplate in the PT (Phone Task) mode. The faceplate display indicates that the first phone task has been selected, which is a phone task to cancel a dentist appointment. In one embodiment, phone tasks are personal information manager (PIM) tasks that require a phone call to complete the task. Phone tasks contain a simple set of text reminders as to what needs to be done with the task and an associated phone number to call to complete the task. In the PT mode, the buttons on the faceplate perform the following functions:
1–6 Presets: Press: Selects a phone task that has been loaded via (wireless or removable) storage medium. The first line of the text description of the task is placed on the display. The primary audio output is not interrupted. Reverse: Press: Display is changed to previous line of text description of the current task.
Press & Hold: Display is changed to the first line of the text description of the current task.
Forward: Press: Display is changed to the next line of the text description of the current task.
Press & Hold: Display is changed to the last line of the text description of the current task.
Play/Pause: Press: Translates the description of the current task from text to speech. Interrupts the current primary audio output while the translation is playing and resumes once the translation is completed. Action: Press: Dials the phone number associated with the current task. Interrupts the primary audio output while the call is being made and resumes once it is completed. If a call was in progress, then the phone is hung up.
Press & Hold: Marks the task as completed.
FIG. 7 illustrates a car stereo faceplate in the NT (Navigation Tasks) mode. The faceplate display indicates that the first step in navigating to the desired destination (Turn Left on 148th Street). Navigation tasks is a list of directions that are used to get from one point to another. In the NT mode, the buttons on the faceplate perform the following functions:
1–6 Presets: Press: Selects a navigation task that has been loaded via (wireless or removable) storage medium. The first line of the text direction of the task is placed on the display. The primary audio output is not interrupted. Reverse: Press: Display is changed to the previous line of the text direction of the current task.
Press & Hold: Display is changed to the first line of the text direction of the current task.
Forward: Press: Display is changed to the next line of text direction of the current task.
Press & Hold: Display is changed to the last line of the text direction of the current task.
Play/Pause: Press: Translates the current line of the text direction of the current task from text to speech. Interrupts the current primary audio output while the translation is playing and resumes once the translation is complete. Action: No function for this band.
FIG. 8 illustrates a car stereo faceplate in the CL (Contact List) mode. The faceplate display indicates that the first preset (1) in has been selected (Sherry's home phone number). In the CL mode, the buttons on the faceplate perform the following functions:
1–6 Presets: Press: Selects a preset contact from the list. The name and phone number of the contact is placed on the display. The primary audio output is not interrupted.
Press & Hold: Saves the current contact to the current preset.
Reverse: Press: Skips to the previous contact in the entire contact list.
Press & Hold: Skips backwards 10 contacts.
Forward: Press: Skips to the next contact in the entire contact list.
Press & Hold: Skips forwards 10 contacts.
Play/Pause: Press: Translates the contact name from text to speech. Interrupts the current primary audio output while the translation is playing and resumes when the translation is completed. Action: Press: Dials the currently selected phone number. Interrupts the current primary audio output while the call is being made and resumes once it is completed. If a call was in process then the phone is hung up.
The various bands and functions discussed above are provided by way of example. A particular car stereo system may offer any number of different bands and functions, including bands and functions not discussed herein.
A particular audio browser includes a memory capable of storing an operating system and one or more application programs that execute on one or more microprocessors. The microprocessor(s) are programmed by means of instructions stored at different times in various computer-readable storage media of the device. This storage media may include, for example, smart cards, a disk drive, or other volatile or non-volatile storage mechanism. Application programs are typically installed or loaded into the secondary memory of a computer. At execution, the application programs are loaded at least partially into the computer's primary electronic memory. The invention described herein includes these and other various types of computer-readable storage media when such media contain instructions or programs for implementing the steps and features described herein in conjunction with a microprocessor or other data processor. The invention also includes the computer and other devices themselves when programmed according to the methods and techniques described herein.
Although the invention has been described in language specific to structural features and/or methodological steps, it is to be understood that the invention is defined in the appended claims is not necessarily limited to the specific features or steps described. Rather, the specific features and steps are disclosed as preferred forms of implementing the claimed invention.
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An in-vehicle audio browser includes a first set of buttons that are configured to select a preset item. A second set of buttons move forward and backward through a list of items in the audio browser. A third button selects among multiple bands associated with the audio browser. A fourth button activates a function that varies depending on the selected band. The audio browser supports primary audio control bands that affect the audio outputs when selected and conditional audio control bands that do not affect the audio output unless some action on the band requires audio output.
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[0001] The present invention relates generally to an improved fuel rod design for use in nuclear reactors. More paticularly, the present invention provides nuclear reactor fuel rods in which one or more metal oxides are present within the fuel rod to mitigate secondary hydriding.
BACKGROUND OF THE INVENTION
[0002] When an LWR fuel rod cladding is breached, for example as a result of debris fretting, the coolant water/steam ingresses to the interior of the fuel rod where an oxidation reaction occurs with the fuel and zirconium alloy cladding to produce hydrogen and zirconium and uranium oxide moieties. The net effect of this oxidation reaction is that the oxygen in the steam is progressively removed and the interior space of the fuel rod is filled with a mixture of hydrogen and steam. At a sufficient distance from the primary breach location, the hydrogen is extremely dry, as most of the steam has been reacted out. Under these conditions, the hydrogen is rapidly absorbed by the cladding to form massive secondary hydrides which are brittle in nature. Subsequent loading of the cladding leads to a new rupture at these secondary hydrided locations. The rupture may be cirucumferential or, in some instances, could lead to axial crack propagation. In all cases, there is additional exposure of the fuel and fission products to the coolant. For this reason, it is important to mitigate secondary hydriding of the cladding.
[0003] The conditions that relate to the formation of secondary hydrides in zirconium-alloy cladding have been discussed extensively in the literature. It is now well-recognized that massive secondary hydriding takes place when the steam fraction in the steam-hydrogen mixture interior to the cladding falls below a threshold level. Very dry hydrogen conditions are generally needed for massive secondary hydriding of the cladding, and even small quantities of steam will serve to mitigate secondary hydriding.
[0004] A need exists for a fuel rod design which will not be susceptible to secondary hydriding of zirconium-alloy fuel cladding in the event of cladding breach and ingress of water or steam to the interior of the fuel rod. The present invention seeks to fill that need.
SUMMARY OF THE INVENTION
[0005] It has now been discovered, surprisingly, that secondary hydriding can be mitigated or eliminated by providing one or more metal oxides within the fuel rod. The invention is particularly directed to providing improved fuel rod design for use in a Light Water Reactor (LWR).
[0006] In a first aspect, the invention provides a method of fabricating a fuel rod in which the tendency for secondary hydriding is mitigated, comprising the step of providing an effective amount of a metal oxide in the fuel rod. The composition of the metal oxide is generally such that if the hydrogen fraction is above the equilibrium condition for the M/MOx couple, a back reaction occurs between the hydrogen and the metal oxide to generate steam and mitigate secondary hydriding. The metal oxide may be selected from oxides of iron, nickel, tin, bismuth, copper, colbalt, chromium, manganese and/or combinations of such oxides.
[0007] In a further aspect, the invention provides a fuel rod with reduced tendency to undergo secondary hydriding, fabricated according to the method of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention will now be described with reference to the accompanying drawings, in which:
[0009] [0009]FIG. 1 is a container with perforations or slits in the wall thereof; and
[0010] [0010]FIG. 2 is a fuel rod with the metal oxide within the rod.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The present invention resides in the surprising discovery that secondary hydriding in nuclear reactor fuel rods can be sigificantly mitigated, and in some instances substantially eliminated, by providing in the interior of the fuel rod an effective amount of one or more metal oxides. The oxides may be those of iron, nickel, tin, bismuth, copper, colbalt, chromium, manganese and/or combinations of such oxides. Specific examples of suitable metal oxides are iron oxides (Fe 3 O 4 ; Fe 2 O 3 ), nickel oxide (NiO), tin oxide (SnO 2 ), copper oxide (CuO) and bismuth oxide (Bi 2 O 3 ). The invention finds particular application to uranium oxide fuel contained within zirconium-alloy based cladding. Such fuel rods are commonly employed in LWRs.
[0012] When steam enters the interior of the fuel cladding, an oxidation reaction occurs with the fuel/cladding which results in the generation of hydrogen. This may be described generally as follows:
x H 2 O+Zr=ZrO x +x H 2
x H 2 O+UO 2 =UO 2+x +x H 2
[0013] The hydrogen:steam ratio within the rod in the region near the metal oxide will be dictated by the thermodynamic equilibrium for the Metal/Metal Oxide (M/MOx) couple, evaluated at the temperature within the fuel rod where the metal oxide is located. If the hydrogen fraction rises above the equilibrium condition for the M/MOx couple, back reaction between the hydrogen and MOx will generate steam and maintain the interior at the posited equilibrium.
[0014] It is to be noted that in some instances the equilibrium could correspond to a couple such as MOz/MOx where MOz is a lower oxide, that is z<x, and not pure metal. The back reaction is therefore described as follows:
MO x +H 2 =M (or MOz, z<x)+H 2 O
[0015] Provided the ratio of steam to hydrogen in equilibrium with the metal oxide is such that the steam fraction is above the threshold level for secondary hydriding, secondary hydriding will be mitigated. Since the steam generated by the back reaction between the hydrogen and metal oxide can easily diffuse over a certain length, secondary hydriding can be mitigated even if the metal oxide is present only at discrete intervals.
[0016] The presence of metal oxide may be in accordance with several possible embodiments. In a first embodiment, the metal oxide may be present as a coating on the cladding interior surface. The metal oxide may be selected from iron oxides (Fe 3 O 4 ; Fe 2 O 3 ), nickel oxide (NiO), tin oxide (SnO 2 ), copper oxide (CuO) and bismuth oxide (Bi 2 O 3 ). Bismuth oxide is generally employed as it has a lower cross-section for absorption of neutrons than the other oxides. Generally, the coating is applied to a thickness in the range of 1 mil (25 microns) or less, for example 0.25-0.5 mil.
[0017] As a second embodiment, the metal oxide may be present as a coating on the fuel pellet surfaces. The metal oxide may be selected from iron oxides (Fe 3 O 4 ; Fe 2 O 3 ), nickel oxide (NiO), tin oxide (SnO 2 ), copper oxide (CuO) and bismuth oxide (Bi 2 O 3 ). Bismuth oxide is generally employed as it has a lower cross-section for absorption of neutrons than the other oxides. Generally, the coating is applied to a thickness in the range of 1 mil (25 microns) or less, for example 0.25-0.5 mil.
[0018] As a third embodiment, the metal oxide may be present as individual pellets or as wafers between fuel pellets, or at the bottom of the fuel stack or at the top of the fuel stack or combinations thereof. Generally, the individual pellets or wafers will be of nearly the same geometry (diameter) as the pellet, possibly a little larger. In the instance where they are present between the fuel pellets, the pellet or wafer thickness will depend upon the number of pellets or wafers used. The pellets or wafers are generally fabricated by sintering the metal oxide powder selected from iron oxides (Fe 3 O 4 ; Fe 2 O 3 ), nickel oxide (NiO), tin oxide (SnO 2 ), copper oxide (CuO) and bismuth oxide (Bi 2 O 3 ).
[0019] As a fourth embodiment, reference is made to the accompanying FIG. 1 showing a container 2 with perforations or slits 4 in the wall thereof which provide free access to the surrounding gases. The container is typically fabricated of a material that does not react with the metal oxide, such as stainless steel. The container wall has a thickness of 10 mils or less and an outside diameter which is essentially the same as fuel pellets, or slightly larger. The metal oxide may be present in the container 2 as a powder or pellet, as described above.
[0020] In a fifth embodiment, the metal oxide may be discretely distributed (rather than in a continuous manner) along the fuel rod. The metal oxide may be in any of the configurations described in the first through fourth embodiments above.
[0021] In a sixth embodiment. referring to FIG. 2, there is shown a fuel rod 6 comprising an outer cladding 8 and a fuel pellet stack 10 . A container 2 as described above, is provided at the bottom of and retained in place by bottom end cap 12 and the fuel stack 10 . containing metal oxide. FIG. 2 illustrates the situation where the container is at the bottom of the fuel stack. However, a similar container may also be placed at the top of the fuel stack. In the usual arrangement, a container is placed at the bottom of the fuel stack, and a further container may optionally be present at the top of the stack. When a container is at the top of the fuel stack, there is a plenum and a retainer spring (not shown) which presses down on the container to hold it in place.
[0022] The specific metal oxide to be used for secondary hydriding mitigation may be selected from the oxides of Ni, Fe, Sn, Bi, Cu, Co, Cr, and Mn. The metal oxide is typically present in each fuel rod in an amount of up to about 15 grams, more usually up to about 12 grams, for example 2 to 10 grams.
[0023] The specific metal oxide to be chosen is to be based on whether the metal oxide reacts with hydrogen rapidly enough. The rapidity of this reaction must be such that the rate is sufficiently fast so that it can counteract the rate at which hydrogen is produced in the forward reaction.
[0024] A further factor in the choice of metal oxide is whether the equilibrium hydrogen:steam ratio is sufficiently rich in steam to avert secondary hydriding. Generally, if the pressure of steam is greater than about 5% of the hydrogen pressure, it is believed that hydriding can be avoided.
[0025] Generally, the oxides of iron, nickel, tin, bismuth and copper are employed. Bismuth oxide (Bi 2 O 3 ) is typically employed when the metal oxide is to be placed in the fuel pellet column space as it minimizes parasitic neutron absorption from the introduction of metal oxide into the core. Copper oxide (CuO) is typically employed when the metal oxide is to be located at the bottom or at the top of the fuel column where parasitic neutron absorption is not a prime consideration. Oxides of specific isotopes of these materials that minimize parasitic absorption may also be employed.
EXAMPLE
[0026] The following example serves to illustrate the present invention.
[0027] Tests have been conducted where a zirconium strip was placed in a confined space within a stainless stell container and hydrogen admitted to the confined space through a very small hole in the container. The strip was shown to be massively hydrided within one day at 400° C. However, when specific metal oxides were present within the confined space, in addition to the zirconium strip, no hydriding was evident when tested under the same configuration and test conditions. The tests were conducted with Fe 2 O 3 , Fe 3 O 4 , CuO, Bi 2 O 3 , NiO and SnO 2 .
[0028] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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Method of fabricating a fuel rod, comprising providing an effective amount of a metal oxide in the fuel rod to generate steam and mitigate the tendency for secondary hydriding. Fuel rods fabricated according to the method of the invention are also provided.
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This is a continuation of application Ser. No. 08/605,601, filed Feb. 22, 1996, now U.S. Pat. No. 5,810,084, such prior application being incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates generally to tools used to complete subterranean wells and, in a preferred embodiment thereof, more particularly provides apparatus for use in gravel pack operations and methods of using same.
Gravel pack operations are typically performed in subterranean wells to prevent fine particles of sand or other debris from being produced along with valuable fluids extracted from a geological formation. If produced (i.e., brought to the earth's surface), the fine sand tends to erode production equipment, clog filters, and present disposal problems. It is, therefore, economically and environmentally advantageous to ensure that the fine sand is not produced.
In the subterranean well, a tubular protective casing usually separates the formation containing the fine sand particles from the wellbore. The casing is typically perforated opposite the formation to provide flowpaths for the valuable fluids from the formation to the wellbore. If production tubing is simply lowered into the wellbore and the fluids are allowed to flow directly from the formation, into the wellbore, and through the production tubing to the earth's surface, the fine sand will be swept along with the fluids and will be carried to the surface by the fluids.
Conventional gravel pack operations prevent the fine sand from being swept into the production tubing by installing a sand screen on the end of the production tubing. The wellbore in an annular area between the screen and the casing is then filled with a relatively large grain sand (i.e., "gravel"). The gravel prevents the fine sand from packing off around the production tubing and screen, and the screen prevents the large grain sand from entering the production tubing.
A problem, which is present in every conventional gravel pack operation, is how to place the gravel in the annular area between the screen and the casing opposite the formation. If the screen is merely attached to the bottom of the production tubing when it is installed in the wellbore, the gravel cannot be pumped down the production tubing because the screen will prevent it from exiting the tubing. The gravel cannot be dropped into the wellbore annular area from the earth's surface because a packer is usually installed between the production tubing and the casing above the formation, and this method would be very inaccurate in packerless completions as well.
One solution has been to run the production tubing into the wellbore without the screen being attached to the tubing. A landing nipple is installed at or near the bottom of the tubing before running the tubing into the well. When the landing nipple has been properly positioned above the formation, a screen is lowered into the tubing from the earth's surface on a slickline or wireline. The screen is landed in the nipple in the tubing so that it extends outwardly and downwardly from the tubing and is positioned opposite the formation. Gravel is then pumped down the tubing from the earth's surface, through a small space between the nipple and the screen, and outwardly into the annular area between the screen and the casing opposite the formation. This method is known as "through tubing gravel packing", since the gravel is pumped through the tubing.
This method has several disadvantages, however. One disadvantage is that the screen must be installed into the tubing as a separate operation. This requires coordination with a slickline or wireline service, time spent rigging up and rigging down special equipment such as lubricators needed for these operations, and the inability to conveniently perform such operations in wells which are horizontal or nearly horizontal. In some instances, the screen is run in with the tubing, already landed in the nipple in the tubing. In those instances, a slickline operation is still needed to retrieve the screen from the tubing.
Another disadvantage of the above method is that the screen must be able to pass through the tubing. This means that the size of the screen (at least its outer diameter) can be no larger than the tubing's inner drift diameter. In order to have a sufficiently large screen surface area, very long screens must sometimes be utilized with this method. Additionally, since there is usually only a very small radial gap between the screen (or the slickline tool used to place the screen in the nipple) and the landing nipple, only a very small flow area is available for pumping the gravel out of the tubing and into the annular area of the well.
Yet another disadvantage of the above method is that the tubing may not be conveniently removed from the wellbore for replacing the packer, completing other formations in the well, maintenance, etc. The method requires the screen to be removed along with the tubing, or the screen must be removed by wireline or slickline prior to removing the tubing. In either case, the gravel pack will be destroyed as the gravel falls into the void created when the screen is removed.
From the foregoing, it can be seen that it would be quite desirable to provide apparatus for gravel pack operations which does not require the screen to be positioned as a separate operation and does not require the screen to pass through the tubing, but which provides a large flow area for pumping the gravel into the annular area of the well and provides for convenient detachment of the tubing from the screen for removal of the tubing from the wellbore. It is accordingly an object of the present invention to provide such apparatus and associated methods of using same.
SUMMARY OF THE INVENTION
In carrying out the principles of the present invention, in accordance with an embodiment thereof, gravel pack apparatus is provided which is a unique valve and release mechanism. The valve permits pumping gravel therethrough with the screen attached to the bottom of the tubing, and the release mechanism permits convenient detachment of the tubing from the screen.
In broad terms, apparatus is provided which includes tubular first and second housings, a ball seat, a plurality of collets, a flow passage and a tubular sleeve. The second housing is coaxially disposed relative to the first housing, with an end of the first housing being proximate an end of the second housing. The flow passage extends through the first and second housings.
The collets extend axially between the first housing and the second housing and releasably secure the first housing against axial displacement relative to the second housing. The tubular sleeve is coaxially disposed within the first and second housings and has an outer diameter radially inwardly adjacent the collets. The sleeve outer diameter radially outwardly biases the collets, and the sleeve is disposed adjacent the ball seat, such that the sleeve is capable of axial movement relative to the collets when a pressure differential is created across the ball seat.
Additionally, apparatus is provided which includes tubular first and second housings, a ball seat, a lug, a flow passage, and a tubular sleeve. The flow passage extends through the first and second housings.
The first housing has an end portion and a radially extending opening formed through the end portion. The second housing has an end portion radially outwardly and coaxially disposed relative to the first housing end portion.
The lug extends radially through the opening and between the first housing end portion and the second housing end portion. The lug releasably secures the first housing against axial displacement relative to the second housing.
The tubular sleeve is coaxially disposed within the first housing. It has an outer diameter radially inwardly adjacent the lug which radially outwardly biases the lug. The sleeve is disposed adjacent the ball seat, such that the sleeve is capable of axial movement relative to the lug when a pressure differential is created across the ball seat.
A method of completing a subterranean well having a wellbore intersecting a formation is also provided, which method includes the steps of providing a gravel pack device, providing production tubing, attaching the gravel pack device to the production tubing, and inserting the gravel pack device and production tubing into the wellbore.
The gravel pack device includes first and second tubular housings, a collet member releasably securing the first tubular housing in a coaxial and adjoining relationship with the second tubular housing, an expandable circumferential seal surface, an internal flow passage extending axially through the seal surface and the first housing, and a tubular sleeve having an outer side surface. The tubular sleeve has a first position, in which the sleeve outer side surface radially biases the collet member to secure the first and second housings against axial displacement therebetween, and a second position, axially displaced relative to the collet member from the first position, in which the sleeve outer side surface unbiases the collet member to release the first and second housings for axial displacement therebetween.
The seal surface is capable of biasing the sleeve to axially displace from the first position to the second position when a pressure differential is created across the seal surface. The method also includes the steps of creating the pressure differential across the seal surface and releasing the first and second housings for axial displacement therebetween.
Additionally, a method of gravel packing a formation intersected by a subterranean wellbore is also provided. The method includes the steps of providing a device, production tubing, and a sand control screen, attaching the device between the tubing and the sand control screen, and inserting the tubing, device, and sand control screen into the wellbore.
The device includes first and second tubular housings, a ball seat, collets, a flow passage, a plug releasably secured in the flow passage, a flow port, and a tubular sleeve. The second housing is coaxially disposed relative to the first housing with an end of the first housing being proximate an end of the second housing. The ball seat is coaxially disposed within the first housing. The flow port is capable of permitting fluid communication between the flow passage and the wellbore.
The collets extend axially between the first housing end and the second housing end and releasably secure the first housing against axial displacement relative to the second housing. The sleeve is coaxially disposed within the first and second housings and has an outer diameter radially inwardly adjacent the collets. The sleeve outer diameter radially outwardly biases the collets, and the sleeve is disposed adjacent the ball seat, such that the sleeve is capable of axial movement relative to the flow port and the collets when a first predetermined pressure differential is created across the ball seat. The plug is capable of being expelled from the flow passage when a second predetermined pressure differential is created across the plug.
The method further includes the steps of positioning the sand control screen in a predetermined axial position in the wellbore relative to the formation and forcing a gravel pack slurry through the production tubing, into the flow passage, through the flow port, into the wellbore, and into an annular area radially intermediate the sand control screen and the formation. The first predetermined pressure differential is created across the ball seat by sealingly engaging a ball with the ball seat and applying pressure to the production tubing. The second predetermined pressure differential is created across the plug by applying pressure to the production tubing after the first predetermined pressure differential is created.
The use of the disclosed apparatus and methods of using same permits larger screens to be used in through-tubing gravel pack operations, provides larger flow areas through which to pump the gravel, eliminates separate screen installation and removal by wireline or slickline operations, and permits convenient removal of the tubing while the screen and gravel pack remain undisturbed in the well.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1B are cross-sectional views of a first apparatus embodying principles of the present invention;
FIGS. 2A-2B are highly schematicized cross-sectional views of a method embodying principles of the present invention, using the first apparatus;
FIGS. 3A-3B are cross-sectional views of a second apparatus embodying principles of the present invention;
FIGS. 4A-4B are cross-sectional views of a third apparatus embodying principles of the present invention;
FIGS. 5A-5C are cross-sectional views of a fourth apparatus embodying principles of the present invention; and
FIGS. 6A-6B are cross-sectional views of a sixth apparatus embodying principles of the present invention.
DETAILED DESCRIPTION
The following descriptions of preferred embodiments of the present invention describe use of the embodiments in gravel packing operations in subterranean wellbores. It is to be understood, however, that apparatus and methods embodying principles of the present invention may be utilized in other operations, such as fracturing or acidizing operations.
Illustrated in FIGS. 1A and 1B is a gravel pack apparatus 10 which embodies principles of the present invention. In the following detailed description of the apparatus 10 representatively illustrated in FIGS. 1A and 1B, and subsequent apparatus, methods, and figures described hereinbelow, directional terms such as "upper", "lower", "upward", "downward", etc. will be used in relation to the apparatus 10 as it is depicted in the accompanying figures. It is to be understood that the apparatus 10 and subsequent apparatus and methods described hereinbelow may be utilized in vertical, horizontal, inverted, or inclined orientations without deviating from the principles of the present invention.
The apparatus 10 includes a tubular upper housing 12, a tubular lower housing 14, an expandable ball seat 16, a plug 18, collets 20, and a tubular sleeve 22. FIG. 1A shows the apparatus 10 in a configuration in which it is run into the wellbore prior to the gravel pack operation. FIG. 1B shows the apparatus 10 in a configuration subsequent to the gravel pack operation. Comparing FIG. 1B to FIG. 1A, note that the expandable ball seat 16 has expanded radially outward within the upper housing 12, the sleeve 22 has been shifted downward within the upper housing, the plug 18 has been ejected out of the sleeve, and the lower housing 14 has separated from the upper housing 12.
When initially run into the wellbore prior to the gravel pack operation, as shown in FIG. 1A, the apparatus 10 is installed between the production tubing and the sand control screen (not shown in FIGS. 1A and 1B). The tubing is threadedly and sealingly attached to the upper housing 12 at upper connector 24. An interior axial flow passage 26 is thus placed in fluid communication with the interior of the production tubing. The screen is threadedly and sealingly attached to the lower housing 14 at lower end 28. Plug 18 in sleeve 22 prevents fluid communication between the interior of the production tubing and the interior of the screen via the flow passage 26.
Plug 18 prevents gravel, pumped down the tubing from the earth's surface, from filling the interior of the sand screen during the gravel pack operation. The plug 18 is later ejected, as shown in FIG. 1B, to permit flow of fluids from the interior of the screen, through the flow passage 26, and into the production tubing for transport to the earth's surface. A circumferential seal 34 sealingly engages the plug 18 and sleeve 22 and permits a pressure differential to be created across the plug to shear shear pins 36 which extend radially through the sleeve 22 and into the plug.
Radially extending ports 30 on the sleeve 22 are initially aligned with radially extending ports 32 on the upper housing 12, permitting fluid communication between the flow passage 26 and the wellbore external to the apparatus 10. During the gravel pack operation, gravel may be pumped through the ports 30 and 32 and into the annular area between the screen and the casing. Radially extending and circumferentially spaced splines 33 formed on lower housing 14 permit fluid flow longitudinally between the wellbore external to the upper housing 12 and the wellbore below the lower housing as further described below.
The aligned relationship of the ports 30 and 32 is releasably secured by shear pins 38 threadedly installed radially through the upper housing 12 and into the sleeve 22. When shear pins 38 are sheared, sleeve 22 is permitted to move downwardly until radially sloping shoulder 40 on the sleeve 22 contacts radially sloping shoulder 42 on the upper housing 12.
When sleeve 22 has been downwardly shifted, as shown in FIG. 1B, circumferential seals 44, which sealingly engage the sleeve and upper housing 12, straddle the ports 32 on the upper housing 12 and prevent fluid communication between the flow passage 26 and the wellbore external to the apparatus 10. Circumferential seals 46, 48, and 50 sealingly engage the upper connector 24 and an upper end 52 of the upper housing 12, the sleeve 22 and the upper housing, and the sleeve and the lower housing 14, respectively, also preventing fluid communication between the flow passage 26 and the wellbore external to the apparatus 10.
Sleeve 22 is downwardly shifted within the upper housing 12 by the expandable ball seat 16. The expandable ball seat 16 is of conventional construction and is in a radially compressed configuration, as viewed in FIG. 1A, when installed into the upper connector 24. Upwardly facing seal surface 54 on the ball seat 16, when in the radially compressed configuration, is smaller in diameter than, and is thus capable of sealingly engaging, a ball 56 dropped or pumped down through the production tubing. It is to be understood that the ball 56 would preferably not be dropped through the production tubing during the gravel pack operation as it would interfere with the pumping of gravel through the apparatus 10. The ball 56 is preferably dropped through the production tubing when the gravel pack operation has been completed and it is desired to shift the sleeve 22 to close ports 32.
When the ball 56 sealingly engages the seal surface 54, a pressure differential may be created across the ball seat 16 by applying pressure to the interior of the production tubing at the earth's surface. Such a pressure differential downwardly biases the ball seat 16 against the sleeve 22, forcing radially sloping surface 57 on the ball seat 16 against radially sloping surface 58 on the sleeve. The contact between the sloping surfaces 57 and 58 further biases the ball seat 16 radially outward.
When sufficient pressure differential has been created across the ball seat 16, shear pins 38 shear, permitting the sleeve 22 to downwardly shift, as described above, and permitting the ball seat 16 to expand radially outward into radially enlarged inner diameter 60 within the upper housing 12. Such expansion of the ball seat 16 causes the seal surface 54 to have an inner diameter larger than that of the ball 56, which permits the ball to pass through the ball seat and the flow passage 26 to the plug 18. Thus, when the plug 18 is later expelled from the sleeve 22, as shown in FIG. 1B and described above, the ball 56 will also be expelled.
Lower housing 14 is initially coaxially attached to the upper housing 12, as shown in FIG. 1A, with collets 20 which are threadedly installed onto the upper housing. Radially enlarged outer diameter 62 on the sleeve 22 biases the collets 20 radially outward so that radially extending projections 64 on the collets are radially larger than reduced inner diameter 66 on the lower housing 14. When, however, the sleeve 22 has been downwardly shifted, as shown in FIG. 1B, the collets 20 are no longer radially outwardly biased by diameter 62 on the sleeve, and the collets are permitted to flex radially inward. Inner diameter 66 on the lower housing 14 may then pass over the projections 64, permitting the lower housing to separate from the upper housing 12.
In a preferred mode of operation, the apparatus 10 is installed between the production tubing and the sand control screen as described above. During the gravel pack operation, gravel is pumped down through the tubing and into flow passage 26. The gravel exits through the aligned ports 30 and 32 and flows into the wellbore. When the gravel pack operation is completed, the ball 56 is dropped or pumped down through the tubing to the ball seat 16. Pressure is applied to the tubing at the surface until a first predetermined pressure differential is created across the ball seat 16, shearing the shear pins 38 and forcing the sleeve 22 to shift downward. At this point, ports 32 are closed, preventing fluid communication between the wellbore and the flow passage 26, and collets 20 are no longer biased radially outward. The ball 56 passes through the ball seat 16. A second predetermined pressure differential is then created across the plug 18 by applying pressure to the tubing at the earth's surface, thereby shearing shear pins 36, and expelling the plug 18 and the ball 56 from the sleeve 22. The tubing may be removed from the wellbore when desired, without displacing or otherwise disturbing the screen or gravel pack.
Turning now to FIGS. 2A and 2B, a method 70 of using the apparatus 10 is representatively illustrated. It is to be understood that, with suitable modifications, other apparatus may be utilized in method 70, including other apparatus described hereinbelow, without departing from the principles of the present invention.
FIG. 2A shows the apparatus 10 operatively installed between production tubing 72, which extends to the earth's surface and is attached to the upper housing 12, and sand control screen 74. The screen 74, apparatus 10, and tubing 72 are lowered into wellbore 76, which intersects formation 78 and is lined with protective casing 80. A conventional tubing hanger 82 has previously been set in the casing 80 a predetermined distance above the formation 78. As the screen 74, apparatus 10, and tubing 72 are lowered into the wellbore, splines 33 on the lower housing 14 engage the tubing hanger 82, thereby positioning the screen 74 in the wellbore 76 opposite the formation 78. Alternatively, splines 33 could engage, for example, a nipple (not shown) disposed in a string of production tubing (not shown), or the nipple could be suspended from a packer (not shown) set in the casing 80.
A gravel pack slurry 84 is then pumped down the tubing 72 from the earth's surface. The slurry 84 enters the flow passage 26 of the apparatus 10 and then exits the apparatus through open ports 32. The slurry 84 then flows downwardly in the wellbore 76 and passes between the splines 33 and the tubing hanger 82. From the tubing hanger 82, the slurry 84 enters an annular area 86 below the tubing hanger and radially intermediate the screen 74 and the casing 80.
Slurry 84 is pumped into the annular area 86 until it forms a gravel pack 88 as shown in FIG. 2B. The ball 56 is then dropped or pumped down the tubing 72, the ball sealingly contacting the ball seat 16. Pressure is applied to the tubing 72 to shift the sleeve 22 downward and close ports 32 as described above. The collets 20 are also no longer biased radially outward after the sleeve 22 is downwardly shifted, but the upper housing 12 is not yet separated from the lower housing 14.
Pressure is again applied to the tubing 72 to expel the plug 18 and ball 56 from the sleeve 22 as described above. The plug 18 and ball 56 then drop into the screen 74 as shown in FIG. 2B. At this point the tubing 72 is in fluid communication with the screen 74 and fluids 90 may flow from the formation 78, through the gravel pack 88 in the annular area 86, through the screen 74, through the flow passage 26 of the apparatus 10, and upwardly through the tubing 72 to the earth's surface.
If desired, the tubing 72 may be conveniently removed from the wellbore 76 by raising the tubing to separate the upper housing 12 from the lower housing 14. The lower housing 14 remains in the wellbore 76, supporting the screen 74 opposite the formation 78 in the gravel pack 88 as shown in FIG. 2B. The screen 74 and gravel pack 88 are not disturbed when the tubing 72 is removed from the wellbore 76.
Note that, in the above-described method 70, screen 74 is not required to pass through the tubing 72 and, therefore, has an outer diameter which is limited only by the casing 80 or tubing hanger 82. Note also, that a relatively large flow area is available for slurry 84 to flow between the lower housing 14 and the tubing hanger 82 via the splines 33. Additionally, no separate wireline or slickline operation is needed in method 70 to position or remove the screen 74.
Turning now to FIGS. 3A and 3B, an apparatus 10a is shown which is a modified form of the apparatus 10 shown in FIGS. 1A-2B. Elements of apparatus 10a which are similar to those elements previously described are indicated in FIGS. 3A and 3B with the same reference numerals, but with an added suffix "a".
Apparatus 10a functions similar to apparatus 10, the major difference being that ports 32a are initially closed, as shown in FIG. 3A. Ports 32a are axially displaced from ports 94 on sleeve 96. Circumferential seal 98 sealingly engages the sleeve 96 and upper housing 12a and is disposed axially intermediate ports 94 and 32a, thereby preventing fluid communication between the ports.
When the sleeve 96 is downwardly shifted, as shown in FIG. 3B, ports 94 and 32a are aligned and fluid communication is established between the flow passage 26a and the wellbore external to the apparatus 10a. It will be readily appreciated by one skilled in the art that if the flow passage 26a is in fluid communication with the wellbore and the interior of lower end 28a is in fluid communication with the wellbore, a pressure differential cannot be created across the plug 18a to expel the plug and ball 56a from the sleeve 96. Thus, if the plug 18a is desired to be expelled from the sleeve 96 of apparatus 10a by pressure differential created across the plug, a means, such as gravel pack 88 (see FIG. 2B), to restrict fluid communication between the flow passage 26a and the interior of the lower end 28a via the wellbore must be utilized.
Thus, apparatus 10a is useful in circumstances in which it is desired to run the apparatus into the wellbore with ports 32a initially closed. The ports 32a may then be opened by dropping or pumping ball 56a down the tubing and applying a predetermined pressure to shear shear pins 38a and downwardly shift the sleeve 96.
When sleeve 96 has been shifted downward, ports 32a and 94 are aligned and permit flow therethrough, and collets 20a are no longer radially outwardly biased by enlarged outer diameter 62a. The upper housing 12a may then be separated from lower housing 14a, and, if a means to seal flow passage 26a against fluid communication with lower end 28a has been utilized, the ball 56a and plug 18a may be expelled from the sleeve 96 by applying a second pressure differential to shear shear pins 36a.
Illustrated in FIGS. 4A and 4B is an apparatus 10b which is another modified form of the apparatus 10 shown in FIGS. 1A-2B. Elements of apparatus lob which are similar to those elements previously described are indicated in FIGS. 4A and 4B with the same reference numerals, but with an added suffix "b".
Apparatus 10b functions similar to apparatus 10, the major difference being that there are no ports 30 and 32 and no plug 18. The flow passage 26b extends axially through the apparatus 10b, permitting flow therethrough at all times, except for when ball 56b is dropped or pumped down to ball seat 16b and engages seal surface 54b. Circumferential seal 102 sealingly engages sleeve 100 and upper housing 12b and is disposed axially intermediate shear pins 38b and upper connector 24b.
The sleeve 100 is shifted downward by pumping or dropping ball 56b into the apparatus 10b so that the ball 56b sealingly engages the ball seat 16b. A predetermined pressure is created across the ball seat 16b, shearing shear pins 38b. The ball seat 16b then expands radially outward and ball 56b is permitted to pass through flow passage 26b.
When sleeve 100 is downwardly shifted, as shown in FIG. 4B, collets 20b are no longer radially outwardly biased by enlarged outer diameter 62b. The upper housing 12b may then be separated from lower housing 14b. Thus, apparatus 10b is useful in circumstances in which it is desired to run the apparatus into the wellbore with no fluid communication between the flow passage 26b and the wellbore external to the apparatus 10b, or when such fluid communication is otherwise provided, and then to separate the upper housing 12b from the lower housing 14b.
FIGS. 5A-5C show an apparatus 10c which is yet another modified form of the apparatus 10 shown in FIGS. 1A-2B. Elements of apparatus 10c which are similar to those elements previously described are indicated in FIGS. 5A-5C with the same reference numerals, but with an added suffix "c".
Apparatus 10c functions similar to apparatus 10, the major difference being the inclusion of annular ring 106 in annular space 108 axially intermediate sloping surfaces 40c and 42c, and radially intermediate the sleeve 22c and upper housing 12c. Annular ring 106 has upper and lower radially sloping surfaces 110 and 112, respectively, and is releasably secured by shear pins 114 against axial movement relative to the upper housing 12c. As will be readily appreciated by consideration of the following description, annular ring 106 permits the steps of closing the ports 32c and separating the housings 12c and 14c to be performed separately.
When the sleeve 22c is downwardly shifted, as shown in FIG. 5B, ports 32c are closed, preventing fluid communication between the flow passage 26c and the wellbore external to the apparatus 10c. In this configuration of the apparatus 10c, sloping shoulder 40c on sleeve 22c is in contact with sloping shoulder 110 of annular ring 106. The ball seat 16c is expanded radially outward, permitting the ball 56c to pass through the flow passage 26c. Plug 18c and ball 56c may be expelled from the sleeve 22c by creating a sufficient differential pressure across the plug to shear shear pins 36c. However, unlike apparatus 10 as shown in FIG. 1B, the upper housing 12c may not be separated from the lower housing 14c with the apparatus 10c in the configuration shown in FIG. 5B, because the collets 20c remain radially outwardly biased by outer diameter 62c on the sleeve 22c.
In order to separate upper housing 12c from lower housing 14c, a second ball 116 is dropped or pumped down into the apparatus 10c. The ball 116 has a larger diameter than the first ball 56c, but is still able to pass through the expanded ball seat 16c as shown in FIG. 5C. The ball 116 has a diameter which is, however, too large to pass through the sleeve 22c. Instead, the ball 116 sealingly engages a circumferential seal surface 118 on the sleeve 22c, disposed adjacent the sloping surface 58c. A pressure differential may now be created across the ball 116 to downwardly bias the sleeve 22c and shear shear pins 114. The sleeve 22c and annular ring 106 may then shift downwardly until sloping shoulder 112 contacts sloping shoulder 42c. When the sleeve 22c is thus further shifted downwardly, outer diameter 62c no longer radially outwardly biases the collets 20c and the upper housing 12c may be separated from the lower housing 14c. Additionally, ports 32c are again opened, permitting fluid communication between the wellbore and the apparatus 10c interior above the ball 116.
In a preferred mode of operation, the apparatus 10c is installed between the production tubing and the sand control screen as described above. During the gravel pack operation, gravel is pumped down through the tubing and into flow passage 26c. The gravel exits through the aligned ports 30c and 32c and flows into the wellbore. When the gravel pack operation is completed, the ball 56c is dropped or pumped down through the tubing to the ball seat 16c. Pressure is applied to the tubing at the surface until a first predetermined pressure differential is created across the ball seat 16c, shearing the shear pins 38c and forcing the sleeve 22c to shift downward. At this point, ports 32c are closed, preventing fluid communication between the wellbore and the flow passage 26c. The ball 56c passes through the ball seat 16c. A second predetermined pressure differential is then created across the plug 18c by applying pressure to the tubing at the earth's surface, thereby shearing shear pins 36c, and expelling the plug 18c and the ball 56c from the sleeve 22c. The well may then go into production, with fluids flowing from the formation, through the gravel pack, through the screen, and upwardly through the flow passage 26c and the tubing to the earth's surface. If it is later desired to remove the tubing from the wellbore without displacing or otherwise disturbing the screen and gravel pack, a second ball 116 is dropped or pumped down the tubing and a third predetermined pressure differential is created across the ball to shear shear pins 114. The sleeve 22c then shifts further downwardly, permitting the collets 20c to flex radially inward. The tubing may then be removed from the wellbore, any fluid remaining in the tubing being able to flow out of the re-opened ports 32c into the wellbore during the tubing's removal.
Thus, apparatus 10c is useful in circumstances in which it is desired to run the apparatus into the wellbore with ports 32c initially open, perform the gravel pack operation, close the ports, and expel the plug 18c and ball 56c before putting the well into production, but it is not desired to concurrently release the upper housing 12c for separation from the lower housing 14c. This permits the tubing, apparatus 10c, and screen to later be removed from the wellbore together (the upper and lower housings 12c and 14c, respectively, remaining attached), or, if it is desired to remove the tubing, but not the screen, from the wellbore, the second ball 116 may be dropped or pumped down through the tubing to separate the upper and lower housings 12c and 14c, respectively.
FIGS. 6A and 6B show another apparatus 124 embodying principles of the present invention. The apparatus 124 includes an upper housing 126, a lower housing 128, an expandable ball seat 130, a plug 132, collets or lugs 134, and a sleeve 136. FIG. 6A shows the apparatus 124 in a configuration in which it is run into the wellbore prior to the gravel pack operation. FIG. 6B shows the apparatus 124 in a configuration subsequent to the gravel pack operation. Comparing FIG. 6B to FIG. 6A, note that the expandable ball seat 130 has expanded radially outward within the lower housing 128, the sleeve 136 has been shifted downward within the lower housing, the plug 132 has been ejected, and the lower housing 128 has separated from the upper housing 126.
When initially run into the wellbore prior to the gravel pack operation, as shown in FIG. 6A, the apparatus 124 is installed between the production tubing and the sand control screen. The tubing is threadedly and sealingly attached to the upper housing 126 threaded connection 137. An interior axial flow passage 138 is thus placed in fluid communication with the interior of the production tubing. The screen is threadedly and sealingly attached to the lower housing 128 at threaded connection 140. Plug 132 is retained in an annular sleeve 142 disposed in an inner diameter 144 of lower housing 128 and prevents fluid communication between the interior of the production tubing and the interior of the screen via the flow passage 138. Circumferential seal 146 sealingly engages the annular sleeve 142 and inner diameter 144.
The plug 132 prevents gravel, pumped down the tubing from the earth's surface, from filling the interior of the sand screen during the gravel pack operation. The plug 132 is later ejected, as shown in FIG. 6B, to permit flow of fluids from the interior of the screen, through the flow passage 138, and into the production tubing for transport to the earth's surface. A circumferential seal 148 sealingly engages the plug 132 and sleeve 142 and permits a pressure differential to be created across the plug to shear shear pins 150 which extend radially through the sleeve 142 and into the plug.
Radially extending ports 152 formed through the lower housing 128 are initially open, as shown in FIG. 6A, permitting fluid communication between the flow passage 138 and the wellbore external to the apparatus 124. During the gravel pack operation, gravel may be pumped through the ports 152 and into the annular area between the screen and the casing.
Shear pins 154, extending radially through the upper housing 126 and the sleeve 136, releasably secure the sleeve against axial movement relative to the upper housing. When shear pins 154 are sheared, sleeve 136 is permitted to move downwardly until shoulder 156 on the sleeve 136 contacts shoulder 158 formed on the lower housing 128.
When sleeve 136 has been downwardly shifted, as shown in FIG. 6B, circumferential seals 160 straddle the ports 152 on the lower housing 128 and prevent fluid communication between the flow passage 138 and the wellbore external to the apparatus 124. Circumferential seal 162 sealingly engages the upper housing 126 and an upper end 164 of the lower housing 128, also preventing fluid communication between the flow passage 138 and the wellbore external to the apparatus 124.
Sleeve 136 is downwardly shifted within the lower housing 128 by a first predetermined pressure differential created across the expandable ball seat 130. The expandable ball seat 130 is of conventional construction and is in a radially compressed configuration, as viewed in FIG. 6A, when installed into the sleeve 136. Upwardly facing seal surface 166 on the ball seat 130, when in the radially compressed configuration, is smaller in diameter and is thus capable of sealingly engaging a ball 168 dropped or pumped down through the production tubing. It is to be understood that the ball 168 would preferably not be dropped through the production tubing during the gravel pack operation as it would interfere with the pumping of gravel through the apparatus 124. The ball 168 is preferably dropped through the production tubing when the gravel pack operation has been completed and it is desired to shift the sleeve 136 to close ports 152.
When the ball 168 sealingly engages the seal surface 166, a pressure differential may be created across the ball seat 130 by applying pressure to the interior of the production tubing at the earth's surface. Such a pressure differential downwardly biases the ball seat 130 against a ring 170, forcing radially sloping surface 172 formed on the ball seat 130 against radially sloping surface 174 on the ring. The contact between the sloping surfaces 172 and 174 further biases the ball seat 130 radially outward. The ring 170 is releasably secured against axial movement within the sleeve 136 with shear pins 176 extending radially through the sleeve and the ring.
When a first predetermined pressure differential has been created across the ball seat 130, shear pins 154 shear, permitting the sleeve 136 to downwardly shift, as described above. Lower housing 128 is initially coaxially attached to the upper housing 126, as shown in FIG. 6A, with lugs 134 which are installed radially through openings 178 formed on the upper housing. Radially reduced outer diameter 180 on the sleeve 136 biases the lugs 134 radially outward so that they are radially larger than reduced inner diameter 182 on the lower housing 128. When, however, the sleeve 136 has been downwardly shifted, as shown in FIG. 6B, the lugs 134 are no longer radially outwardly biased by diameter 180 on the sleeve, and the lugs are permitted to displace radially inward. Inner diameter 182 on the lower housing 128 may then pass over the lugs 134, permitting the lower housing to separate from the upper housing 126.
Application of a second predetermined differential pressure across the ball seat 130, greater than the first pressure differential, will then cause the shear pins 176 to shear and permit the ball seat and ring 170 to downwardly shift and move axially into the inner diameter 144 of the lower housing 128, as shown in FIG. 6B. The ball seat 130 is thus permitted to expand radially outward into the inner diameter 144. Such expansion of the ball seat 130 causes the seal surface 166 to have a diameter larger than that of the ball 168, which permits the ball to pass through the ball seat and the flow passage 138 to the plug 132. Thus, when the plug 132 is later expelled from the annular sleeve 142, as shown in FIG. 6B and described above, the ball 168 will also be expelled.
In a preferred mode of operation, the apparatus 124 is installed between the production tubing and the sand control screen as described above. During the gravel pack operation, gravel is pumped down through the tubing and into flow passage 138. The gravel exits through the ports 152 and flows into the wellbore. When the gravel pack operation is completed, the ball 168 is dropped or pumped down through the tubing to the ball seat 130. Pressure is applied to the tubing at the surface until a first predetermined pressure differential is created across the ball seat 130, shearing the shear pins 154 and forcing the sleeve 136 to shift downward. At this point, ports 152 are closed, preventing fluid communication between the wellbore and the flow passage 138, and lugs 134 are no longer biased radially outward. A second predetermined pressure differential is then created across the ball seat 130, causing the shear pins 176 to shear and forcing the ring 170 and ball seat 130 to shift downward into diameter 144 of the lower housing 128 and permitting the ball seat to expand radially outward. The ball 168 passes through the expanded ball seat 130. A third predetermined pressure differential is then created across the plug 132 by applying pressure to the tubing at the earth's surface, thereby shearing shear pins 150, and expelling the plug 132 and the ball 168 from the sleeve 142. The tubing may then be removed from the wellbore when desired, without displacing or otherwise disturbing the screen or gravel pack.
The foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims.
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A gravel pack apparatus and associated method of completing subterranean wells provides convenient and economical gravel packing operations, permitting a sand control screen to be run into the well attached to the apparatus which is, in turn, attached to production tubing, and further permitting the tubing to be detached from the screen. In a preferred embodiment, a gravel pack apparatus has interoperable valve and tubing release portions. The valve portion may be closed after the gravel packing operation is completed. Closure of the valve portion activates the release portion, permitting the apparatus to be separated.
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This is a continuation of application Ser. No. 903,262, filed 9/3/86, now abandoned, which is a continuation of application Ser. No. 685,313, filed 12/24/84, now abandoned, which is a continuation of application Ser. No. 565,162, filed 12/23/85, now abandoned.
BACKGROUND OF THE INVENTION
In many polymer processes the polymerization reaction is carried out in a vehicle which is a solvent for both the monomers to be polymerized and the polymer formed. In such solvent polymerization processes, the separation of the polymer from the vehicle is generally an energy intensive step where the separation is usually carried out by steam stripping or other suitable solvent evaporation techniques. It has long been recognized that substantial economies in polymer processes could be achieved if the energy requirements of the solvent-polymer separation step could be minimized.
It is well known that many solvent-polymer solutions are stable over a limited temperature range and can be caused to separate into a solvent rich and polymer rich phase by heating or cooling. Upon heating, these solutions exhibit a lower critical solution temperature (LCST) above which separation of the polymer from the solvent system will occur. This separation results in the formation of two distinct phases, one a solvent rich phase, the other a polymer rich phase. These phase separation phenomena are generally pressure dependent, and the two phase systems can be made to revert to a homogeneous single phase by isothermally increasing the pressure of the system above a critical value which depends upon the composition of the solution and the molecular weight of the polymer. The phase behavior of a typical polymer solution is shown schematically in FIG. 1A, as is discussed later.
The LCST is that temperature above which a solution will separate into two distinct phases, a solvent rich phase and a solute rich phase. The separation phenomenon can also occur at a second lower temperature termed the Upper Critical Solution Temperature (UCST). Below the UCST a two phase separation again occurs. The measurement of LCST and UCST end points are made at the vapor pressure of the solution. The prior art teaches a number of methods of utilizing the LCST as a means for causing a polymer solution to separate into a polymer rich phase and a solvent rich phase.
Illustrative prior art processes which have utilized the LCST phenomenon in polymer separation processes are those described in U.S. Pat. Nos. 3,553,156; 3,496,135; and 3,726,843 incorporated herein by reference.
These prior art processes are disadvantageous in that a significant amount of heat energy is required to raise the temperature to the point where the desired phase separation occurs. Furthermore, separation occurs at elevated temperatures which may result in polymer degradation. Separation processes utilizing the UCST are also disadvantageous because of the need to cool the solutions. More recently, in their U.S. Pat. No. 4,319,021, Irani, et al. have taught an improvement in the foregoing phase separation processes which permits the use of lower separation temperatures. The technique described in this patent includes the addition of a low molecular weight hydrocarbon to the polymer solution. Suitable low molecular weight hydrocarbons are the C 2 -C 4 alkenes and alkanes which are utilized at about 2 to about 20 weight percent. While this improved process substantially reduces the phase separation temperature, heating is still required in order to affect the desired separation.
There is need for a process technique which would permit the aforedescribed separation processes to be carried out at or near the polymerization reaction exit temperature. In that way, little or no additional heat input would be required to effect the separation. Heretofore, such idealized, improved processes have not been achieved.
SUMMARY OF THE INVENTION
It has been surprisingly found that a temperature independent phase separation can be caused to occur in a polymer solution by introducing into the polymer solution a critical amount of phase separation agent. Below the critical concentration of the phase separation agent, the mixture exhibits a normal, lower critical solution temperature ("LCST"). Compounds useful as phase separation agents in the practice of this invention include CO 2 , C 1 -C 4 alkanes, C 2 -C 4 alkenes, C 2 -C 4 alkynes, hydrogen, nitrogen and its various oxides, helium, neon, CO and mixtures thereof.
Sufficient phase separation agent (PSA) is introduced into the polymer solution so that the solution, under appropriate pressures, can separate out a polymer rich phase at all temperatures between the LCST and the UCST of the pure polymer-solvent system, essentially free of PSA. The consequent phase separation results in a polymer rich phase and a solvent rich phase. Where methane is used as the PSA, under appropriate conditions for hydrocarbon polymers, the solvent rich phase comprises about 80% or more by volume of the total system and is substantially free of polymer.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A - Prior Art Phase Diagram
FIG. 1B - Phase Diagram of this Invention
FIG. 2 - Phase Diagrams as a Function of PSA Concentration
FIG. 3 - Illustration of a Critical Concentration Diagram
FIG. 4 - Process Flow Diagram
FIG. 5 - Illustration of a Critical Concentration Diagram for Methane, Ethylene and Propylene
FIG. 6 - Phase Diagrams for PSA-Hexane-EPM Systems
FIG. 7 - Comparison Phase Diagrams for PSA-Hexane
EPM Systems
DETAILED DESCRIPTION
This invention relates to a method for separating a polymer from solution. The prior art teaches methods for utilizing the LCST as a means for causing a polymer solution to separate into a polymer rich phase and a solvent rich phase. The disadvantages of these prior art methods have been disclosed.
The method of the instant invention relies on the discovery that the addition of a critical amount of a particular phase separation agent will cause phase separation to occur, under appropriate pressure conditions, over a broad temperature range, thereby eliminating the need for heating or cooling the solution in order to cause separation. As used in the specification and claims, the "phase separation agent" (PSA) is a compound that is normally gaseous at 1 atmosphere and 25° C. When used in the system according to this invention, the PSA is normally near or above its critical conditions. Below a particular pressure, unique to each PSA-polymer-solvent system, the system can be caused to separate into distinct phases. Increases in pressure reverse the phenomenon and result in a homogeneous system.
Reference has been made to separation occuring over a broad temperature range. As used in the specification and claims the term "broad temperature range" means the temperature range that encompasses the UCST and LCST as determined for a solvent-polymer system, free of monomers, PSA or other extraneous compounds. By comparison of FIG. 1A and FIG. 1B, it can be seen that the "broad temperature range" for which the separation phenomena of FIG. 1B can be practiced encompasses the temperature region between the UCST and LCST illustrated for FIG. 1A.
The separation method of this invention can be applied to solutions of polymers It is most advantageously used in conjunction with a solution polymerization process. It has particular utility where the solvent from which the polymer is to be separated is a hydrocarbon solvent.
The phase separation agents of this invention are gases at atmosphere pressure and 25° C, and include H 2 , N 2 and its oxides, He, Ne, CO, CO 2 , C 1 -C 4 alkanes, C 2 -C 4 alkenes, C 2 -C 4 alkynes and mixtures thereof. Halogenated C 1 -C 3 hydrocarbons which are normally gases at atmospheric pressure and 25° C. may also be used as phase separation agents The preferred halogenated compounds are fluorinated hydrocarbons. Naturally occurring mixtures of gases, e.g., natural gas, petroleum gas, etc. may also be used as the PSA.
Illustrative examples of hydrocarbons suitable for use as phase separation agents in the practice of this invention are methane, isobutane, ethylene, ethane, propane, propylene, butane, 1-butene, 2-butene, isobutylene, acetylene, propadiene, 1,4-butadiene, dichloro-difluromethane, monochlorotrifluoromethane, trifluoromethane, methylchloride, monochloropentafluoroethane, hexafluoroethane, trifluoroethane, pentafluoroethane, monochlorotrifluoroethylene, tetrafluoroethylene, vinylidene fluoride and vinyl fluoride. For the production of ethylenepropylene or ethylene-propylene-non-conjugated diene copolymers, methane, ethane, propane, ethylene and propylene are the preferred hydrocarbon PSA's.
In terms of solution thermodynamics, the essence of this invention lies in the discovery that for certain PSA-polymer-solvent systems, the LCST and UCST coincide at or above a particular critical concentration of PSA. Further, in polymer solution, in the region of this coincidence, phase separation of the system into a polymer rich phase and a solvent rich phase occurs rapidly over a broad temperature range when the pressure is below a particular value for the system in question. As a result, no energy input for heating or cooling the solution is required to recover the polymer.
Unlike the teachings of Irani, et al; U.S. Pat. No. 4,319,021, heating of the solution is not a necessary part of this invention. However, heating may be advantageously used to increase the extent of separation of polymer from solvent; that is, to achieve a solvent rich phase essentially free of polymer when the minimum critical concentration of PSA is being used. Where heating is to be utilized, it is preferred that only the solvent rich phase be heated and that during the heating step the solvent rich phase pressure be above the phase separation pressure for the solvent-polymer-PSA system in order to avoid fouling of heat transfer surfaces. The solvent rich polymer solution can be heated to a temperature of about 0° F. to about 150° F. above its initial temperature e.g., the polymerization reactor temperature.
When the critical level of PSA in a system is reached, there is a dramatic change in the phase relationships of the system. This is illustrated in FIG. 1B. For a given overall system composition with the components being polymer, solvent and PSA, there is a single liquid phase shown as `1 Phase` in the higher regions, there are two liquid phases in the cross hatched area designated `2 Phase` and three phases composed of two liquids and a vapor in the region designated `3 Phase`. The curve shown as line 12 separates the 1 Phase and 2 Phase regions. The curve line 13 separates the liquid/liquid of 2 Phase and the liquid/liquid/vapor or 3 Phase regions. The separation into solvent rich and polymer rich liquid phases over the broad temperature range is the outstanding feature of FIG. 1B.
Several additional noteworthy features of FIG. 1B deserve particular mention. First, the phase relationships are reversible in that changing operating conditions to slightly above or below the phase boundary curves and then returning to the original conditions will cause the respective single phase, two phase or three phase region to disappear and then reappear. Second, the `2 Phase` region is stable over the temperature regions extending below the LCST and down to the UCST. This means that stable, low temperature separations can be achieved. Third, there is now a continuous phase boundary between the liquid/liquid and the liquid/liquid/vapor region over temperature ranges of interest in polymer solvent separations. This means that either two phase or three phase separations near the boundary line can be practiced. It is also evident that the temperature sensitive phase relationships illustrated in FIG. 1A are overcome. The separations achieved with the invention are possible because of the new phase relations which have lower temperatures, wider stability regions and expanded two phase-three phase boundaries.
It can also be seen from FIG. 1B that curve 13 is the vapor pressure curve for the overall system composition. As pressure is slightly reduced below curve 13, the first bubble of vapor in the system will form. Hence, curve 13 is referred to as the bubble point line. Because the PSA is the most volatile component, the first bubble and the vapor phase in general will be predominantly PSA. In the three phase region, near the bubble point line, the system will separate into a solvent rich liquid, a polymer rich liquid phase and a vapor that is essentially PSA.
While the method of this invention will generally be carried out at a pressure which is at or above the bubble point line, it may also be advantageously carried out at lower pressures when a relatively small vapor phase can be present. For separation to occur, the pressure will be at ranges where either the liquid/liquid or liquid/liquid/ vapor phases are formed. As used in the specification and claims, the term "bubble point pressure" means the vapor pressure of the solvent/solute/PSA system at a particular temperature. The "bubble point line" is a plot of pressure vs. temperature, which is the locus of the bubble point pressures for such a system.
The amount of PSA required to reach the critical concentration is a function of the solvent, the type of polymer, the polymer molecular weight, molecular weight distribution, and composition, and the composition and purity of the PSA. Thus no specific value exists for all situations.
In order to determine the critical concentration, it is necessary to prepare compositions of polymer solution and PSA and measure the temperatures at which phase separation occurs These techniquires are well known in the art and readily accomplished by the experienced practitioner. For example, a small amount of PSA is dissolved in a polymer solution of given composition at a pressure just sufficient to prevent formation of a vapor phase. The solution is cooled until turbidity first appears. This temperature is the UCST. The solution is further cooled and the pressure increased until the turbidity disappears. This pressure/temperature combination defines a point on the one phase/two phase boundary shown by the upper curve, 11, in the left hand side of the phase diagram of FIG. 1A. Cooling in increments followed by pressure increases and decreases to cause the disappearance and appearance of turbidity will define the shape of the entire curve. The solution is now heated, while maintaining a pressure just sufficient to prevent formation of a vapor phase, until turbidity appears. This temperature is the LCST. Further heating is then carried out with pressure increases and decreases at each temperature to define the shape of the one phase/two phase boundary shown by the upper curve, 16, on the right hand side of figure in FIG. 1A.
These measurements are repeated with increasing concentrations of the PSA. A series of phase diagrams will result as shown schematically in FIG. 2, which indicates increasing UCST and decreasing LCST as the concentration of PSA increases. At or above the critical concentration, the USCT and LCST are equal and phase separation occurs at all temperatures provided the pressure is below that represented by the upper line, 21 of FIG. 2. Each of the parameters (C 1 , C 2 , C 3 and C 4 ) represents a different concentration of PSA, and the dashed curve, 22, is a plot of the LCST and UCST as a function of concentration.
The minimum critical concentration is obtained by plotting UCST and LCST versus PSA concentration as shown in FIG. 3. The point of coincidence, 31, of the UCST and LCST defines the minimum critical concentration.
The process of this invention may be applied to the separation of a broad range of polymers. Illustrative of solution polymerization processes to which the separation process of this invention may be applied are processes for preparing butyl rubber, polyisoprene, polychloroprene, polybutadiene, polybutene, ethylene-propylene rubber (EPM), ethylene propylene-nonconjugated dienes which may be utilized in preparing EPDM include methylene norbornene, ethylidene norbornene, 1-4 hexadiene, dicyclopentadiene, etc.
While polymer separation processes are generally considered in the context of solution polymerization processes, it is often necessary to affect such separations in processes other than polymerization processes For example, butyl rubber is halogenated by first dissolving the finished polymer in hexane, halogenating the polymer and subsequently recovering the polymer The separation process of this invention is equally applicable to such a separation.
Illustrative non-limiting examples of the solvents which can be used in the practice of this invention are linear, branched or cyclic C 5 -C 8 hydrocarbons. They include the isomers of pentane, hexane, heptane, octane, benzene, toluene, xylene, cyclohexane or mixtures thereof.
The process of this invention can be carried out in either a batch or continuous manner; however, a continuous process is generally preferred for economic reasons. The preferred procedure in obtaining polymer separation by utilizing this invention is as follows:
1. The critical concentration of PSA is dissolved in the polymer solution at a minimum pressure of at least the vapor pressure of the resulting solution. Agitation may be desirable to obtain rapid dissolution. Turbulence in a flowing stream can provide the necessary agitation. Furthermore, it may be desirable to prevent polymer phase separation during the dissolution step. In that case dissolution is carried out at a pressure high enough to maintain the system as a one phase system.
2. Phase separation is allowed to occur. Where elevated pressures are used to maintain a single phase, it is necessary to reduce the pressure in order to achieve the two phase condition. The polymer phase is recovered by gravity settling, centrifugation, or other suitable means.
3. The pressure is reduced on the light, solvent rich phase to vaporize the PSA. Heating or cooling of the solvent rich phase to assist in the recovery of the particular PSA may also be desirable. The recovered PSA and solvent, after purification, if needed, can now be reused in step 1.
The advantages of this invention may be more readily appreciated with reference to an ethylene-propylene rubber (EPM) process and the following examples.
Typical EPM processes are based on a solution polymerization process in an isomeric hexane diluent catalyzed by a Ziegler catalyst. The polymerization is carried out in a stirred tank reactor. The product stream contains about 5 to about 12 weight percent polymer in hexane. In order to obtain a stable product, it is desirable to remove catalyst residue from the polymer in a deashing step.
Solvent and unreacted monomers are steam stripped from the deashed polymer in coagulation drums to form an aqueous slurry of rubber particles. The rubber particles are separated from the slurry and then finished by extrusion drying. In this steam stripping step of the process, large energy requirements increase production costs. Application of the separation process of this invention greatly reduces these energy requirements.
For purpose of illustration, the separation method of this invention is described in terms of its utilization after the deashing step using methane as the PSA.
FIG. 4 is an illustrative process flow sheet of the separation method of this invention as applied to a solution of ethylene-propylene rubber in a hexane solvent. The solution is polymerization reactor effluent which has been subjected to deashing.
The polymerization effluent flows from a reactor by line 410 to a settler, 411. The settler is at 100° F., Water is discharged by line 413, the solution flows by line 412 to a pump, where it is pressurized to flow by line 414 into a separation vessel 415. In the vessel, the polymer solution and PSA, here methane, are mixed together; this is at a pressure of 1600-2600 psia and a temperature of 100° F. Methane is introduced as a recycle stream by line 439. Alternatively, it can be supplemented with PSA entering with the polymer solution.
The conditions in the vessel allow a heavy polymer rich phase to settle and leave by exit line 417. The lighter solvent rich phase leaves by the overhead line 416.
In this embodiment, the solvent rich phase is processed to recover the solvent and PSA separately. It goes to a first heat exchanger, 420, where it is cooled to 61° F. It goes by line 418 to a second heat exchanger, 421, where it is cooled to 44° F. It then flows by line 419 to a first flash drum, 422. It is flashed at 515 psia to an overhead vapor leaving by line 423 and a bottom liquid which flows by line 424 to a second flash drum, 425. There it is flashed at 215 psia and at 38° F. The overhead vapor leaves by line 426, while the bottom liquid flows by line 427 to the third flash drum, 428. The final flashing is at 65 psia and 32° F. The overhead vapor leaves by line 429 and joins line 429a for admission of make up methane to flow to the first compressor 432. The bottom liquid flows by line 430 to the heat exchanger 420 where it is heated and leaves by line 431. At this point, the bottom liquid is essentially hexane.
In the first compressor, 432, vapor is compressed to 215 psia and leaves by line 433 to flow to the second compressor, 434. In the second compressor, the vapors are raised to 515 psia and leave by line 435 for the third compressor, 436. There it is raised to 2015 psia and sent by line 437 to a heat exchanger, 438, where it is cooled. It leaves by line 439 for the separation vessel, 415. The recycle gas is primarily methane with small amounts of ethylene, propylene and hexane.
In the above illustration, the hexane can be purified and recycled to the polymerization vessel.
After phase separation occurs, some polymer can remain in the solvent phase. It is usually desirable to minimize this quantity for maximum product recovery. However, in the situation where the dissolved polymer represents an undesirable low molecular weight portion of the product, some product quality benefits may be obtainable by retaining this portion of the polymer in the solvent rich phase for later disposal. The amount of polymer left in the solvent phase is a complex function of polymer molecular weight, molecular weight distribution and composition, solvent composition, and amount and composition of the PSA. For this reason the conditions that give maximum amount of polymer separation cannot be quantified with precision. In general, the polymer separation will be enhanced by raising the quantity of PSA added to the solution, raising the temperature, or reducing the pressure to the solution vapor pressure. Also, in a series of homologous hydrocarbon PSA's, selecting the one with the lowest molecular weight will usually produce the lowest amount of polymer in the solvent phase, all other things being equal.
The concentration of PSA in the polymer solution required to reach the "critical concentration" to cause coincidence of the LCST and the UCST is a function of factors such as polymer type, polymer molecular weight and its distribution, polymer concentration and solvent composition as well as the composition and purity of the PSA.
Although there is, in all probability, a specific value which can be assigned to the critical concentration, its precise determination is not practical in view of the complex system which is being analyzed. The term "critical concentration" as used in the specification and claims refers to the minimum concentration which results in the LCST-UCST coincidence.
In order to determine the critical concentration, it is necessary to prepare composition of polymer solution and PSA and measure the temperature at which phase separation occurs. These techniques are well known in the art, and readily accomplished by the experienced practitioner in the manner described above.
It will be evident from this disclosure that after the lower limit of the critical concentration is achieved, further increases in PSA concentration do not minimize the advantageous results obtained by the practice of this invention. Hence, in describing the critical concentration in the specification and claims, it is designated as being "at least" a particular concentration for a particular system.
FIG. 5 is a graphic representation of the effect of concentration of PSA on the LCST and UCST. The parameter for the three different curves is the PSA used. It is evident that methane is advantageously used at a lower concentration than either ethylene or propylene. As carbon number increases, the critical concentration increases. A similar curve showing the LCST-UCST coincidence may be generated for any of the other aforementioned PSA. The curves of FIG. 5 are intended as being illustrative of the phenomenon upon which this invention is based.
The following examples utilizing methane and a hexane solution of EPM are illustrative of the invention. Since the greatest difficulty in achieving phase separation is experienced with lower molecular weight polymers, the polymer used was Vistalon grade V-457 (Exxon Chemical Company) which is an elastomeric EPM polymer having a low average molecular weight. This polymer comprises 42.8 weight percent ethylene, has a weight average molecular weight (M w ) of 140,000 and a M w /M n weight average molecular weight/number average molecular weight ratio of 2.2.
The hexane solvent used comprised about 87 weight percent n-hexane, about 9.4 weight percent methyl cyclopentane, about 2.3 weight percent 3-methyl pentane and trace amounts of other C 5 -C 6 hydrocarbons.
EXAMPLE I
A polymer solution was prepared having an EPM concentration of 5.2 weight percent. In a variable-volume pressure cell, methane was introduced into the polymer solution to give total system concentrations of 11.5 and 13.4 weight percent.
The pressures were increased and decreased repeatedly to determine the liquid/liquid-liquid phase transition and the liquid-liquid/liquid-liquid-vapor phase transitions. At 11.5 weight percent, the upper pressure, shown in FIG. 6 by line 62, was about 2600 psia; the lower pressure, shown by line 62a, was about 1600 psia. Phase separation in the liquid-liquid phase region was extremely rapid; the single liquid phase could be re-established by increasing pressure.
At 13.4 weight percent, the upper pressure, shown by line 61, was about 4200 psia, while the lower pressure, shown by line 61a, was about 1800 psia. The single liquid to liquid-liquid phase transition (line 61) was repeatedly observed. It can also be seen that the temperature over which the two liquid phase region exists encompasses those between the UCST and LCST of the polymer-solvent system and thus is in the broad temperature range. As shown in FIG. 6, at 11.5 weight percent methane, phase separation occurred over a broad temperature range when the methane pressure was reduced to below about 2600 psia. Similarly at 13.4 weight percent methane, phase separation occurs over a broad temperature range when the pressure is reduced below about 4200 psis.
The two phases constituted a hexane-rich substantially polymer free lighter, upper phase and a heavier polymer rich lower phase. The solvent rich phase comprised about 80-90 percent by volume of the test cell. The polymer rich phase comprised sticky strands which stuck to the wall of the cell at pressures in the proximity of the lower transition line, 61a, of FIG. 6. As is seen from FIG. 6 for both 11.5 weight percent and 13.4 weight percent methane, the merged LCST/UCST line is approximately parallel to the bubble point line.
EXAMPLE II
Since, after polymerization, the EPM polymer solution typically contains unreacted propylene, the experiment of Example I was repeated with 7 wt. % propylene included in the solvent system to determine what effect propylene has on the phase separation achieved by the technique of this invention.
The sample cell was loaded with the polymer solution, injected with the desired amount of methane and then injected with the desired amount of propylene.
The initial methane concentrations used were 10.8 and 14.4 weight percent on a total system basis After introduction of about 8.7 weight percent propylene and 7 weight percent propylene respectively, the methane concentration was reduced, as a result of dilution, to 9.8 weight percent and 13.4 percent, respectively.
Evaluation of these systems before and after injection of propylene confirmed that propylene does not have an adverse effect on the observed phase separation. Hence, mixtures of methane and propylene may be used as the PSA.
The phase volumes after separation were 60-70% by volume solvent rich phase and 30-40 percent by volume polymer rich phase. Again, the critical methane concentration was confirmed to be at least 11 weight percent on the total polymer solvent-PSA system.
Referring now to FIG. 7, where 10.8 wt. % methane is used as the PSA, the phase diagram is the classical prior art phase diagram wherein the LCST line, 72b, intersects the bubble point line formed by segments 72 and 72a The area between the LCST line, 72b, and the bubble point line segment 72a, represents the region in which there exists a two phase liquid-liquid (L-L) system; one liquid phase is polymer rich, the other is solvent rich. Above (to the left) of the LCST line the system is homogeneous (L). Below the bubble point line and to the right cf the intersection of the LCST and bubble point line segment 72a, a liquid-liquid-vapor phase (LLV) exits; while below the bubble point line and to the left of the intersection of the LCST line and bubble point line segment 72, a homogenous liquid phase exists in equilibrium with a vapor phase (LV). As used in the specification and claims, the term "phase separation pressure" means a pressure below which phase separation will occur for a particular system.
Where the PSA is a combination of 9.8 wt. % methane and 8.7 wt. % propylene, the phase diagram is similar but the bubble point line segments 71 and 71a are about 100 psia lower and the intersection of the bubble point line and LCST line, 71b, has been shifted about 30° C. lower
Where the solvent system includes 7.0 wt. % propylene and 13.4 wt. % methane, the bubble point line, 73, has been lowered by about 100 psi below the bubble point line, shown in FIG. 6 for 13.4 wt. % methane used alone Hence, it is evident that propylene is acting as a PSA in combination with methane
As discussed above in connection with FIG. 6, the siginificance of the general parallelism in the region bounded by the phase boundary lines 61 and 61a is that twophase separation occurs over a broad temperature range. As can be seen from these data, this unique and unexpected result occurs for methane in this system if polymer and solvent is at a critical concentration of at least 11.0 weight percent based on the total weight of the solvent-polymerPSA system. Preferably at least 11.5 weight percent methane is used; more preferably at least 13 weight percent, e.g., at least 13.4 weight percent; most preferably at least 14 percent methane is used.
When similar experiments are conducted for the EPM/hexane system using ethylene, propylene or CO 2 as the phase separation agent, the same separation phenomenon as that observed for methane would be achieved. Where the phase separation agent is CO 2 , the critical concentration is at least about 25 weight percent based on the PSAsolvent-polymer system, preferably at least 35 weight percent. CO 2 is used, more preferably at least about 45 weight percent. Where the PSA is ethylene, the critical concentration is at least about 22 weight percent based on the PSA-solvent-polymer system; preferably at least 26 weight percent is used; more preferably at least 28 weight percent; most preferably at least 30 weight percent, e.g., 35 weight percent. Where propylene is the PSA, the critical concentration is at least about 40 weight percent based on the PSA-solvent-polymer system; preferably at least 50 weight percent is used; more preferably at least 60 weight percent; most preferably 65 weight percent, e.g., 70 weight percent.
While the separation process of this invention may be carried out at any pressure at which two phase separation is achieved, preferably the separation is conducted at about the bubble point pressure of the system. The term "at about the bubble point pressure" as used in the specification and claims means a pressure range from about 10 psia below the bubble point pressure to about 300 psia above the bubble point pressure, e.g., 100-200 psia above the bubble point pressure. Those skilled in the art will appreciate from the foregoing disclosure that the bubble point pressure will be dependent on PSA concentration as well as system temperature. The particular bubble point pressure for a system is readily determined in the manner described above. The Table below presents typical bubble point pressures for a hexane-PSA system.
TABLE______________________________________Bubble Point Pressure for Hexane-PSA SystemConcentration Bubble Point Pressure (PSIA)PSA Wt. % 250° C. (77° F.) 115° C. (240° F.)______________________________________CO.sub.2 25 250 780 35 346 1072 45 435 1310C.sub.2 H.sub.4 22 368 920 26 420 1010 28 450 1060 30 460 1070 32 470 1080 35 480 --C.sub.3 H.sub.7 40 95 447 50 125 520 60 150 610 65 160 655 70 175 710CH.sub.4 12 1438 16 1526 20 2520______________________________________
For methane, the preferred operating pressure range is about 1450 psia to about 4300 psia; more preferably about 1600 psia to about 2600 psia; e.g., 2000 psia. For ethylene, the preferred operating pressure range is about 360 psia to about 1300 psia; more preferably about 500 psia to about 1100 psia, e.g., 800 psia. For propylene, the preferred operating pressure range is about 90 psia to about 1000 psia; more preferably about 125 psia to about 700 psia, e.g., 650 psia. For CO 2 the preferred operating pressure range is preferably about 240 psia to about 1600 psia; more preferably about 350 psia to about 1000 psia; most preferably about 400 psia to about 850 psia; e.g., 600 psia.
In general, separation will occur rapidly except for the very narrow region in the proximity of the liquid/ liquid-liquid transition lines, where the densities of the respective liquid phases are nearly equal to one another. It is thus preferred to operate at pressures where the density differences between the phases is at a maximum so that phase separation rates are at a maximum. In the two inch diameter test cell used, the two phases will generally fully separate in about five seconds. It is significant that the phase separation can be caused to occur in temperature ranges which include the EPM polymerization temperature (i.e. about 20° -70° C.). Hence, unlike prior art phase separation processes, no additional heat input is required to cause separation. Furthermore, since phase separation results in a low volume of polymer rich phase (10-40%), the energy requirements for polymer finishing are greatly reduced.
Utilizing the method of this invention, the phase separation which occurs results in at least 66% by volume of solvent rich phase as compared to about 50% for prior art techniques. This is so even at about 10.8 wt. % methane in the region where the phase diagram is the classical diagram as shown in FIG. 6. Where methane is used as the sole PSA, at a loading of at least 13.4 wt. %, the phase split is about 80/20 solvent rich phase to polymer rich phase.
While the above invention has been described in terms of specific examples, it is intended that the invention will include steps and techniques that are deemed by those in the art as equivalents. For example, this invention can be practiced directly in the polymerization process as well as in post polymerization treatments or in polymer solvent solutions apart from polymerization processes.
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A separation process has been found in which a polymer-solvent solution separates into phases of highly different composition which are in equilibrium over a broad temperature range. Upon addition of the phase separating agent, which is near or above its supercritical conditions, rapid disengagement into two phases occurs. The relative volume of solvent rich phase is substantially larger than the polymer rich phase. The process can be practiced at relatively low temperatures such as those employed in polymerization or post-polymerization processes. The separation is accomplished by adding or elevating the concentration of a phase separation agent to or above a minimum effective concentration, which causes the UCST and LCST lines to merge. Suitable phase separating agents are organic and inorganic compounds that are gases at 1 atm pressure and 25° C. Due to the gaseous nature of the phase separating agent, it is easily removed from the solvent phase for reuse in the process.
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RELATED APPLICATIONS
This application is a continuation in part of provisional application No. 60/073,707 filed on Feb. 4, 1998.
FIELD OF THE INVENTION
The invention relates to anti-inflammatory drugs and in particular, to a new and improved carrier formulation for delivery of phenylbutazone and functional homologues thereof. More specifically the carrier is palatable to horses, provides improved absorption into the horse's blood stream, and facilities new methods of preparing and administering phenylbutazone to horses.
PROBLEM
Phenylbutazone, is one of the most popular and useful nonsteroidal anti-inflammatory veterinary pharmaceuticals. It is typically the drug of choice for equine treatment modalities when an illness or injury necessitates the use of a painkiller or anti-inflammatory medication. Phenylbutazone treats joint deterioration, swelling and inflammation from injuries, founder, fevers, and various other pains experienced by horses.
While phenylbutazone has been used to treat horses for more than thirty years, the administration of phenylbutazone persists in being the source of many problems. Despite its bitter taste, phenylbutazone is most often administered orally. The horses often reject the bitter drug, which leads to inconsistent dosages and extreme inconvenience suffered by those administering the drug.
Phenylbutazone is typically available to horse owners and veterinarians in one-gram tablets for oral administration. Horses do not willingly eat phenylbutazone tablets. Absent physical force, most horses will not swallow phenylbutazone tablets due to their bitterness. Thus, administration involves first catching the horse and, depending on the individual personality and training of the horse, applying various degrees of restraints. Restraints range from a halter to prevent bobbing and weaving of the head, to more extreme measures that prevent rearing and kicking.
Horse owners and veterinarians have developed several means for the actual delivery of phenylbutazone to horses. In simple cases the tablets are crushed and mixed with the horse's food. This method is problematic because the crushed tablets do not adhere to the horse's food. Powder or granules sift to the bottom of the feeder as the horse eats. The amount of sifting varies with each administration and results in inconsistent dosages or diet problems due to the addition of feed to administer the remaining medication.
Some horses reject the grain and drug mixture altogether, requiring the additional step of mixing the crushed tablet with syrup or molasses before adding the bitter drug to the horse's feed. This method is problematic for several reasons. Syrup and molasses are very sticky, and the mixing process leaves a mess in the surrounding area as well as in the mixing container and feed trough or dish. In addition, the phenylbutazone is insoluble in syrup and molasses making it impossible to obtain a homogeneous mixture. If the mixture is not immediately administered to the horse, the phenylbutazone settles resulting in an inconsistent dosage or additional mixing requirements. Encapsulation of the crushed tablet matter by the syrup or molasses also hinders the speed at which digestive fluids can interact with the phenylbutazone and, consequently, blood absorption of phenylbutazone is delayed through the digestive process.
In other cases the delivery means includes mixing the crushed tablets with water in a slurried form for oral administration with a syringe. This method of delivery often requires the person administering the dosage to reach into the horse's mouth and exert pressure at certain points as inducement for the horse to open its mouth for direct delivery of the drug to the horse's throat by syringe. This activity is unpleasant for the horse and the person, and can result in injury as the person administering the drug is bitten, pawed or stepped on by a stubborn horse. Because the slurry is still bitter, a horse will continue to reject the slurry with efforts that increase in intensity over time. Ultimately, it becomes difficult or impossible to catch the horse three times a day for delivery of the drug and, if caught, the horse attempts to spit out the slurry after it is delivered.
Paste and granulized formulations of phenylbutazone are available to prevent those administering the drug from having to crush tablets, but the granulized and past formulations still sustain the same problems associated with tablets, namely, rejection, inconvenience, and inconsistent dosages. For example, The paste is squeezed from a tube into the rear of the oral cavity under the horse's tongue. Most horses make a valiant effort to spit the paste out. Thus, the horse's mouth must be empty during delivery so the paste adheres to the oral cavity to prevent it from being spit out. If, as often is the case, the horse has hay or grain residue in its mouth at the time of delivery, the paste will adhere to it and is easily spit out along with the hay or grain. Some horses even learn to rinse their mouth out after delivery causing owners to limit access to water for approximately 15 minutes.
The described administration problems with phenylbutazone would be merely inconvenient, except that they, in turn, cause serious problems, which are related to effective dosages. The drug is intended to control potentially chronic inflammation and pain, which can result in permanent soft tissue lesions, such as scarring of other fibroid tissue growth, as a consequence of long term chronic inflammation cycles. The drug provides relief from chronic cycles of inflammation and pain, and eventually facilitates increased range of motion without permanent loss of function. Thus, it is important to provide a method of administration that avoids peaks and valleys in the blood concentration levels of phenylbutazone arising from inconsistent dosage due to rejection or an inability to catch the horse for administration of the drug.
An important factor to consider in the delivery of phenylbutazone, in addition to methods for oral administration of the drug, is the speed at which the drug is absorbed into the horse's blood. Inflammation and pain are more easily relieved when effective treatment concentrations are attained more quickly. This is especially true when the inflammation is potentially associated with hemorrhaging due to soft tissue injury. Maintaining the proper blood concentration level, timing, and diet are critical to the effectiveness of the drug. Even so, it is commonly understood that mixing a drug with a carrier, such as a nutritional base for delivery of the drug, has the disadvantage of slowing down the blood absorption rate.
While a veterinarian should make the determination on an individual basis, a moderate dose for a 1000 pound horse is 1-2 grams or 5-10 cc per administration. Oral administration of phenylbutazone is slow to take effect, requiring 3-5 hours to achieve an effective concentration level. Three dosages per day should be administered to maintain the proper blood concentration level. However, due to the problems with oral administration, most horse owners and veterinarians settle for a double or sometimes only a single dosage per day, as opposed to the ideal triple dosage.
Another problem related to dosage is measuring the proper amount of medication for the horse. Where the paste formulation is used, the person administering it must pre-measure the paste or guess at the appropriate amount as it is squeezed into the horse's mouth. Both techniques result in an inconsistent dosage either from guesswork or due to loss of medication from residue left behind as the paste is transferred from the measuring device to administering device. In the tablet form, an odd dosage requires splitting the tablet, which results in inconsistent dosages due to crumbling of the tablets.
Administration and dosage problems are compounded where prolonged treatments are required for treatment of chronic soft tissue injuries, and these problems can result in significant health effects to the horse and cost burden on the owner. Therefore, there is a need for an improved carrier formulation of phenylbutazone that is palatable to horses, easily administered in a proper dosages without special skills or alteration from its manufactured state, and provides quicker absorption into the bloodstream.
SOLUTION
The present invention overcomes the problems that are outlined above and advances the art by providing an improved carrier formulation for administering phenylbutazone in a palatable medium to horses. The carrier formulation comprises a powdered carrier base including at least one flavoring agent and at least one anti-caking agent mixed to substantial homogeneity with a therapeutically effective amount of phenylbutazone. The powder carrier base and phenylbutazone mixture is palatable to horses providing owners and veterinarians with confidence that their horse will consume the full dosage of medication.
Phenylbutazone is commonly known in the art and is described in U.S. Pat. No. 2,562,830. Phenylbutazone is also known as 4-butyl-diphenyl-3,5-pyrazoidinedione, benzone, butadione, intrabutazone, and numerous other common names. Phenylbutazone is widely understood to be an effective veterinary anti-inflammatory and analgesic agent in treating inflammation in horses and other animals. A review of the hematological effects of phenylbutazone has been published by G. A. Faich in 7 Pharmacotherapy 25 (1987). There are numerous commercial suppliers of phenylbutazone including, by way of example, Sigma Corporation located in St. Louis, Mo.
The flavoring agent is an inactive ingredient comprising a flavoring agent and an anticaking agent. The flavoring agent is a plurality of sweeteners and flavor additives that make the powdered carrier formulation palatable to horses as a food supplement and in its raw form. Horses consider that phenylbutazone delivered with the carrier formulation as a treat, and they aggressively ingest it
Sweeteners used in the flavoring agent may be any type of compatible sweetener, either from a natural material or an artificially produced sweetener. Artificial sweeteners such as saccharine and aspartame are preferred for cost reasons, and because unlike natural sugars, they do not promote significant tooth decay and contribute few if any calories to the foods they sweeten. Commercial suppliers of Saccharine and aspartame include Monsanto Corporation and its subsidiaries, such as Kelco Corporation. In addition, because horses have preferred tastes, combinations of sweeteners may be employed to ensure palatability in a broader range of horses. Examples of sweeteners include but are not limited to, sucrose, glucose, fructose, lactose, acesulfame-K, dextrose, sucralose, saccharin, and aspartame.
Flavor additives used in the flavoring agent may also be products from a natural material or synthetically produced products. Any flavor additive palatable to horses including but not limited to, cinnamon, orange, or apple, may be employed. Preferably, however, inventors have found artificial green apple flavoring, such as that which is commercially available from Professional Compounders Center of America, to be the most palatable to the broadest range of horses. Additional examples of flavor additives include but are not limited to cinnamon, cherry, strawberry, and carrot.
The anti-caking agent is not a necessary ingredient to the carrier formulation of the present invention, and is utilized for the practical requirement of improving the manufacturing process. The preferred anti-caking agent is silica dioxide sold under the trade name Flogard, an example of which can be purchased from Pharmatech Inc. The anti-caking agent improves the manufacturing process by preventing clotting and balling of the product caused by the inherently tacky nature of the flavoring ingredients. It should also be noted that, while the anti-caking agent silica dioxide is added to the carrier formulation to improve manufacturing, additional anti-caking agents are present as sub-ingredients in some of the flavoring ingredients. For example, calcium silicate is a sub-ingredient of the Fresh Green Apple flavoring ingredient.
Despite common knowledge that dilution of a drug with a carrier for delivery has the disadvantage of slowing down the blood absorption rate, the dilution of the phenylbutazone active agent with the carrier formulation of the present invention substantially improves blood absorption during the initial hours after administration. Not only is the initial delivery speed faster with the carrier formulation, but absorption and metabolization of the phenylbutazone over subsequent intervals is approximately equivalent to that of delivery of pure phenylbutazone.
The respective ingredients of the carrier formulation are provided as a solid, powder, or particulate at room temperature, so that mixing of the materials results in a finely divided powder. The powder has an electrostatic affinity for the cellulosic substances that horses eat.
The carrier formulation is produced by causing particles of the at least one flavoring agent and the at least one anti-caking agent to come into high speed contact with particles of the therapeutically effective amount of phenylbutazone by collision. During collision of the particles there is a partial melting and fusion with each other to form an agglomerate of all the particles in a substantial homogenous mixture of fine powder at room temperature. Various apparatuses can be utilized to realize contact of the ingredients, including but not limited to V shaped blenders, slant load blenders, high efficiency powder mixers, and pneumatic high vortex apparatuses and so on. It is possible to effect the colliding contact of the ingredients by subjecting them to a single blending process. Nevertheless, multiple blending obtains an increase in the melting, fusion, and homogeneity performance yielding an overall better mixture.
Care must be paid here to determine the proper blending time, as the blending times will vary depending on the device and its efficiency. Blending is performed until the phenylbutazone is distributed to substantial homogeneity in the carrier base. A suitable weight proportion of phenylbutazone to achieve the advantages of the invention may be in the range of 50% to 90% and preferably in the range of 70% to 90% of the total formulation weight. An even more preferable weight is in the range of 75% and 90% with an even more preferable range being 85% to 90%. A suitable weight proportion of anti-caking agent is in the range of 0% to 10% but preferably 4%, depending upon the type of anticaking agent that is used. A suitable weight proportion of the flavoring ingredient may be in the range of 10% to 50% but preferably ranges from 10% to 20%.
The carrier formulation of the present invention is administered to horse orally in its raw form or as a feed supplement by spreading it over conventional feed components, including but not limited to, grain, hay, oats, barley, corn and so on. Advantageously, the sweetener ingredients provide the carrier formulation with an inherently tacky property, such that the carrier formulation adheres to feed when the it is administered as a feed supplement. Thus, product is not lost due to sifting as the horse eats.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 presents data from a comparative test study showing phenylbutazone blood concentrations over time between a group of horses that were fed phenylbutazone with the carrier formulation according to the present invention versus a group of horses that were fed phenylbutazone from a prior art formulation; and
FIG. 2 illustrates examples of sweetener combinations by percentage of total weight of the carrier formulation of the present invention.
DETAILED DESCRIPTION
The following non-limiting examples set forth preferred methods and materials for making the phenylbutazone carrier formulation according to the present invention. In addition, the phraseology and terminology employed herein is for the purpose of description, and not of limitation.
EXAMPLE 1
A PREFERRED PRODUCT FORMULATION
During the first stage of preparation, seven individual batches of product were mixed, each having a total weight of 124 kilograms. A 200 kilogram stainless steel blending mixer, commonly known in the art as a V-shaped blender, was used to mix each batch. Before each batch was mixed the blending mixer was sterilized by thoroughly wiping with a sterile cloth soaked in rubbing alcohol. During the second stage of preparation, the seven individual batches were combined and mixed in a 1000 kilogram stainless steel V-shaped blending mixer to produce the finished product.
Each of the seven batches produced during the first stage of preparation consisted of: 100 kilograms of phenylbutazone, 10 kilograms of saccharine, 6 kilograms of Fresh Green Apple Flavor, 4 kilograms of Aspartame, and 4 kilograms of Flogard. The ingredients for a single batch were weighed and placed in the 200 kilogram blending mixer and blended for a period of 40 minutes. After 40 minutes of blending, the batch was removed from the 200 kilogram blending mixer and weighed to confirm that no product was lost. After weighing the batch was placed into a 1000 kilogram blending mixer, but was not mixed until all seven batches from the first stage of preparation were added to the 1000 kilogram mixer.
During the second stage of production the seven batches were blended in the 1000 kilogram blender for a period of 20 minutes to produce 868 kilograms of finished product. After blending, the finished product was removed and weighed to confirm that substantially no product was lost. After weighing, the product was tested for bacteria and potency before packaging in individual doses. The packaged product contained 1 gram of phenylbutazone, 0.1 gram of Saccharine, 0.06 gram of Fresh Green Apple Flavor, 0.04 gram of Aspartame, and 0.04 gram of Flogard, per 3.5 cc spoonful of packed powder.
EXAMPLE 2
BIOEQUIVALENCE TEST
In example two, three healthy mature geldings and a non-pregnant mare aged 3-10 years with similar weights were chosen for a bioequivalence test. The bioequivalence test was designed to determine the difference in blood plasma absorption between commercially available phenylbutazone tablets and the product of example one.
Two weeks prior to the test, the horses did not receive any form of medication. At five o'clock p.m. the evening before the test, each horse was fed a normal meal consisting of 1 gallon of grain with twelve percent protein, and ten pounds of alfalfa hay. During the test each horse was stabled separately and had access to drinking water at all times. On test day, each horse was fasted until five hours after administration of the test product, and then given a normal meal consisting of one gallon of grain with twelve percent protein and ten pounds of alfalfa hay. Each horse was again given a normal meal consisting of one gallon of grain with twelve percent protein and ten pounds of alfalfa hay at five hours and at twelve and one-half hours after administration.
The morning of the test, 4.96 grams of the product from example one containing a total of four grams of phenylbutazone, was dissolved in one quart of water. The dissolved mixture of product and water was then tubed directly into the horse's stomach. Without removing the tube, a follow up quart of water was also tubed directly into the horse's stomach to flush out the tube and mixing bucket. Each of the three horses followed this procedure.
Two hours following administration a 4.5 cc blood sample was taken from each of the three horses. Thereafter, additional 4.5 cc blood samples were taken at half-hour intervals until the sixth hour. After the sixth hour 4.5 cc blood samples were taken hourly until the eighth hour. After the eighth hour 4.5 cc blood samples were taken at twelve and one-half hours, sixteen hours, and eighteen hours. The blood samples were taken with a 20 gauge needle and promptly put into a green CST Lithium Heparin tube and refrigerated at 40 degrees F. After all of the samples were collected, the blood samples were spun to separate the blood plasma from each sample. The separated blood plasma was placed in a freezer for twenty-four hours.
After twenty-four hours, the blood plasma was thawed to room temperature and phenylbutazone levels were quantified for each sample by a validated HPLC method. The average phenylbutazone level for the three horses at each of the sampling time intervals are given in Table 1.
COMPARISON TO PHENYLBUTAZONE TABLETS
The same test population of horses was used to monitor phenylbutazone blood plasma levels from commercially available phenylbutazone tablets. Subsequent to the first test and before the comparison test using prior art phenylbutazone tablets was performed, approximately fifteen half lives of phenylbutazone, or seventy five hours, passed. The half-life of phenylbutazone is four to five hours. After seventy five hours the steps of the prior test were repeated exactly, except that four 1 gram tablets of phenylbutazone (4 grams of pure phenylbutazone) were substituted for the 4.96 grams of product from example one. Thus, both tests administered a total of four grams of phenylbutazone per horse. The average phenylbutazone level for the three horses in the second test are also given in table 1.
TABLE 1______________________________________BLOOD PLASMA CONCENTRATIONS OF PHENYLBUTAZONE Average Average phenylbutazone phenylbutazone concentration concentration for PercentNumber of for product of pure Difference inHours after example one phenylbutazone Intestinaladministration (ppm) Absorption______________________________________2 15.75 11.72 34%2.5 19.14 14.63 31%3 16.90 37%3.5 23.81 20.59 16%4 22.59 3%4.5 21.46 24.91 -14%5 20.59 0%5.5 20.02 19.57 2%6 20.98 -20%7 19.30 -7%8 17.39 3%10 13.80 14.25 -3%12.5 9.24 11.26 -18%16 5.73 6.84 -16%18 4.23 4.79 -12%______________________________________
FIG. 1 illustrates a graphical representation of the data contained in Table 1. From FIG. 1 and Table 1, it follows that phenylbutazone administered with the carrier formulation exhibited superior bloodstream absorption during the initial hours following administration. Specifically, the phenylbutazone delivered with the carrier formulation was absorbed on average 34% faster during the first three hours and 24.2% faster during the first four hours. During subsequent intervals, the phenylbutazone levels remained approximately equivalent to those of the pure phenylbutazone delivery.
The time that is required for a drug to enter the bloodstream corresponds to the time required for pharmacological efficacy. Presently, oral doses of pure phenylbutazone require approximately three to five hours to take effect. This is verified by Example 2 showing the average peak concentration of 24.91 ppm occurring at four and a half hours for the phenylbutazone tablets.
This example shows that the initial time for phenylbutazone to take effect is shortened when the phenylbutazone is delivered by the carrier formulation, yet metabolization over extended periods remains substantially the same. In addition, the average peak concentration of 23.81 ppm for phenylbutazone delivered by the carrier formulation occurs at three and a half hours, which closely corresponds to the recognized therapeutic dosage interval of four hours. Thus, consistent blood concentration levels are maintained throughout a treatment period because subsequent dosages are administered as the metabolization of absorbed phenylbutazone begins.
Inventors also believe that additional advantages will be realized by quicker absorption of the phenylbutazone. Phenylbutazone is an irritant with known side effects such as stomach and/or intestinal ulceration. Inventors believe that faster absorption of the phenylbutazone across the stomach lining following administration will reduce known side effects by lessening contact with body tissue.
EXAMPLE 3
PALATABILITY TEST
In example 3, two hundred and fifty racehorses were randomly selected for a palatability test of phenylbutazone delivered by the carrier formulation of example one. The test was conducted over three days while the horses were undergoing race training.
During the test, a single dosage of 2.48 grams of the product from example one, containing two grams of phenylbutazone, was mixed with each horse's evening feed. The evening feed consisted of two gallons of grain mixed with one ounce of liquid vitamin.
The result for all two hundred and fifty horses over the course of the three day study was a 0.75% rejection rate. This compares to a 100% rejection rate for pure phenylbutazone. A rejection for purpose of this test was defined as an individual horse's refusal to voluntarily finish eating its entire evening feed.
EXAMPLE 4
Example 4 illustrates a plurality of formulations, for the carrier formulation of the present invention. The formulations were all prepared according to the method of example 1 and comprise 4% silica dioxide anti-caking agent, 6% green apple flavor additive, and a therapeutically effective amount of phenylbutazone. Although various weight percentages will be apparent to one skilled in the art based on the description given herein, the formulations of this example were mixed so that the sweetener ingredient or combination of sweetener ingredients was 10% of the total formulation weight. FIG. 2 illustrates the examples of sweetener combinations for the carrier formulation prepared in example 4.
It is apparent that there has been described, an improved carrier formulation for the delivery of phenylbutazone, that fully satisfies the objects, aims, and advantages set forth above. While the carrier formulation has been described in conjunction with a specific embodiment thereof, it is evident that many alternatives, modifications, and/or variations can be devised by those skilled in the art in light of the foregoing description. Accordingly, this description is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.
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A powdered carrier formulation for delivery of phenylbutazone to animals contains phenylbutazone in combination with a flavoring agent and an anticaking agent.
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CROSS REFERENCE TO RELATED APPLICATIONS/REFERENCES CITED
Prior Application filed is a provisional patent
Application number: 60/634,059
Filing date: Dec. 7, 2004
Title: Automatic Garage Door Closing Device
Inventor: Steven Nigel Dario Brundula
PATENTS CONTAINING PRIOR ART FOR REFERENCE ONLY
U.S. Pat. No. 4,386,398 May, 1983 Matsuoka et al. 700/90.
U.S. Pat. No. 4,463,292 July, 1984 Engelmann 318/283.
U.S. Pat. No. 4,939,434 July, 1990 Elson 318/285.
U.S. Pat. No. 5,752,343 May, 1998 Quintus.
U.S. Pat. No. 6,046,562 April, 2000 Emil 318/484.
U.S. Pat. No. 6,437,527 August, 2002 Rhodes et al. 318/280.
U.S. Pat. No. 6,563,278 May, 2003 Roman 318/282.
U.S. Pat. No. 6,819,071 January, 2003 Graham; Kenneth B. 318/442
TECHNICAL FIELD
The technical field of this device is in electronics. The more specific areas of electrical expertise needed for this product is digital electronics for the control and timing circuitry, analog electronic knowledge for the alarm and device powering considerations (the whole design can be done in analog circuitry if preferred), and wireless RF electronic experience (although if a universal garage door design is purchased and interfaced no RF experience is necessary).
BACKGROUND
Most people who have a garage door have accidentally left it open. Leaving the garage door open can have consequences such as; having belongings stolen from the garage or even the house, animals such as snakes can enter the garage to live, and in colder climates pipes can freeze and break. Prior art has come up with devices to fix this issue but are too cumbersome to use. Wires need to be connected, sensors need to be mounted, usually expensive, complicated and time consuming. This led to the idea of creating a device that can be mounted on a garage door, powered off of a battery, work with existing garage door openers, provide a warning before closing the door, and be very simple to install.
SUMMARY OF INVENTION
The Background has led to two most probable and different devices, 1) the first and the simplest is a device that mounts to the inside of a garage door and detects the tilt of the garage door. When the garage door is not perpendicular to the ground for greater than a certain amount of time, the module sets off an alarm. A certain amount of time after that if the garage door is still not perpendicular to the ground and the device has not been turned off, a signal is sent to the garage door opener to close the garage door or to a wall mounted module that presses the garage door open/close button to close the garage. 2) The second device is almost the same as the first except that instead of setting off an alarm, it sends a phone call or text message to a specified phone number. Replying by pressing a touch-tone button on the phone or a text message with a specific message will tell the device to try and close the garage door.
DETAILED DESCRIPTION
Device 1 (see FIG. 3 ) consists of a sensor such as a tilt sensor, a universal garage door remote or wall-mounted device to press the garage door open close button (see FIG. 2 and FIG. 4 ), control inputs/switches, a system controller, and an alarm device(s).
Device 2 would be the same as Device 1 , as it would contain a sensor a universal garage door remote or wall mounted device to press the garage door open/close button, control inputs/switches, a system controller, and an alarm device; in addition however it would also contain a telephone module to make the module contain a cell phone, or it would talk to another module that is plugged into a phone line.
The sensor could be one or more of many different devices, such as measurement sensors to measure the distance the garage door is off the floor, or tilt sensors to measure the tilt of the garage door. Due to simplicity the tilt sensor would be preferable.
The universal garage door remote is what stores all the codes to all the different garage doors; this allows one product capable of working on thousands of different garage doors. When the universal garage door remote is signaled, the universal garage door remote transmitter sends an RF signal to the garage door opener to close the garage door. An alternative to using the universal garage door remote would be to send a wireless signal to a module that would press the garage door open/close button (see FIG. 2 ).
The alarm device(s) are audible and/or visual; the purpose is to warn anyone around the garage door that the door is going to soon close. Most probably a flashing light and a siren or beep would be the preferable alarm method. Another probable alarm device is a device that calls a phone number if the garage door is open too long. The additional device can be a module that plugs into a standard phone line, or a separate mobile phone built into the automatic garage door closing device.
The control inputs/switches control a) turning on and off the device, b) programming the universal remote for a specific garage door type, c) changing the values of how long the garage door can be open before the alarm goes off, d) change how long the alarm goes off before the signal is sent to close the garage door, and e) to change the phone number to send a text message to warning that the garage door is open. The device would also need to have a method to show the current settings so a simple to complex display can be used to show setting values.
The system controller regulates the operation of the device; the operation it performs is the following. If the door is sensed to be open, the controller waits a specified amount of time for the garage door to close. If after this variable time the garage door is still not closed and the phone module is not part of this system then the controller starts the alarm(s). The alarm will continue for another specified amount of time and if by the end of that time the garage door is still open, the controller then sends an appropriate signal to close the garage door. If the phone module is part of the system then a phone call or text message is sent to a specified phone number. The phone module then waits for a response such as the press of a specific touch-tone button, or to receive a text message. Pressing different options can do different things, returning/pressing 1 closes the garage door, 2 leaves the garage door open and doesn't warn you anymore, 3 leaves the garage door open and will warn you again after a specified amount of time if the garage door has still not been closed.
The controller also checks the status of the input switches/sensors to see if any of the system parameters such as delay time until sending off an alarm is to be changed. A potentiometer or switch that rotates adjusts the amount of time delay from when the door is opened until an alarm goes off, a toggle switch turns the system on and off. The phone module includes a display to show the phone number to call when the garage door is open. All systems have indicator lights to show if any of the batteries are going low, when the batteries are low alarms also go off but with different intensities to warn the user to change the system batteries.
All the sensors and features built into a garage door opener continue to work and are not inhibited with this device. Likewise if a car or a person blocks a door sensor, this device will try but will not be able to close the garage door.
DESCRIPTION OF DRAWINGS
FIG. 1 : An illustration of how one of the devices may look mounted to a garage door.
FIG. 2 . Illustration of a device that can press a garage door button and close a garage door.
FIG. 3 : High-level block diagram of an automatic garage door closer with an RF transmitter that sends the same signal as a garage door remote to close the garage door.
FIG. 4 : High-level block diagram of an automatic garage door closer that presses the garage door open/close button on the wall to close the garage door.
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A detector that resides inside of a garage with a working wireless electric garage door opener, the detector detects when the garage door is open for too long and when the garage door is open too long the detector sends out warnings, then after the appropriate conditions occur the detector can close the garage door. The detector additionally requires no special installation of sensors or wires.
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BACKGROUND OF THE INVENTION
The present invention relates to an openable roof capable of opening and closing a central portion thereof. The openable roof is typically used in a temporary structure for an event site or the like, though the applicational field is not limited to them.
Applicants of this invention have already filed a patent application relating to a roof capable of being opened and closed. The prior patent application is related to an openable roof for creating a so-called closed space when the top is closed by a movable roof section and creating an open space when the top is open.
FIGS. 13 through 15 of the attached drawings show an example of the openable roof which is disclosed in Japanese Patent Application No. Sho 61-81858 entitled "Movable Roof".
As shown in FIGS. 13 and 14, the movable roof or the openable roof 1 comprises a movable roof section which is composed of a plurality of roof units 2 formed into a sectorial shape. The roof units 2 are angularly movable about a center of rotation of the sectorial shape, whereby the movable roof section can open and close the roof building subject or a site L. The roof units 2 jointly use the common center of rotation. As shown in FIG. 15, a first support leg 3 and a second support leg 4 supporting each roof unit 2 are arranged respectively adjacent an arc of the sectorial shape forming the roof unit 2 and adjacent the center of rotation. The first and second legs 3 and 4 are provided respectively with slide mechanisms which are movable respectively along arcuate tracks 5 and 6.
An upper space above seats 8 is closed by a stationary roof section 7. In addition, although illustration is omitted, the first support leg 3 has its lower end which is provided with a drive device. By the drive device, wheels engaged with the track 5 travel along the same.
According to the openable roof 1, it is possible to angularly move the roof units 2 about the center of rotation that is the center of the sectorial shape. For instance, as illustrated in FIG. 14, in case where the openable roof 1 comprises four roof units 2, these four roof units 2 can be arranged in adjacent relation to each other to uniformly close or cover the upper portion of the roof building subject L. On the other hand, the adjacent four roof units 2 can be spaced two by two away from each other toward the stationary roof section 7, thereby opening the upper portion of the roof building subject L.
By the way, the openable roof 1 has such superior advantages that the movable roof section can be built and withdrawn with respect to the roof building subject L optionally and easily, whereby it is possible to freely cope with the weather and so on. However, the openable roof 1 has the following drawback.
That is, particularly, in the circular or sectorial roof, in case where the movable roof section is divided into a plurality of sectorial roof units which are angularly movable about the center of rotation to open and close the roof building subject L, a post 9 is required to be provided at the center of rotation, that is, at the center of the roof building subject L. The post 9 is an obstacle to effective utilization of the vast roof building subject L.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an openable roof which has a superior function of forming a closed space and an open space, which can completely open the space in an open position, and in which it is unnecessary to arrange a post o the like at a roof building subject.
According to the invention, there is provided an openable roof capable of opening and closing a central space having a certain point, the openable roof comprising;
a stationary roof section arranged in spaced relation to the certain point of the central space by a predetermined distance, the stationary roof section having an inner periphery which defines the central space;
a movable roof section arranged on the stationary roof section and radially movable relatively thereto toward and away from the certain point of the central space between an open position where the central space is open and a closed position where the central space is closed, the movable roof section being divided into a plurality of movable roof units having their respective apexes which are substantially identical in central angle with each other, wherein, in the closed position, the apexes of the respective movable roof units are abutted against each other and the movable roof units cooperate with each other to close the central space, and wherein, in the open position, the movable roof units are spaced from each other and are spaced from the certain point of the central space to open the latter; and
drive means for drivingly moving the movable roof units between the open and closed positions.
With the arrangement, the following superior advantages are obtained. That is, the movable roof units are moved toward and away from the certain point of the central space to open and close the latter, whereby it is possible to secure formation of the completely open space having no obstacles such as a post or the like at the point of the central space. Thus, the open space can effectively be utilized. Further, the drive means for the movable roof section can be made simple in construction, and the post or the like can be dispensed with. Thus, it is possible to contribute a reduction of the execution cost of the openable roof.
Preferably, the drive means comprises wire-like fastening means for connecting the apexes of the respective roof units to each other in the form of a ring to simultaneously move the movable roof units between the open and closed positions, and winding means mounted on at least one of the stationary roof section and the movable roof section for winding and unwinding the wire-like fastening means to move the movable roof units between the open and closed positions.
In this case, the wire-like fastening means can easily and quickly wound and unwound to simultaneously move the movable roof units between the open and closed positions, whereby it is possible to cope with a change in the weather and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1(a) through 1(d) are somewhat diagrammatic top plan views showing a manner in which a plurality of movable sectorial roof units of an openable roof according to an embodiment of the invention from a fully open position to a closed position;
FIGS. 2(a) through 2(d) are somewhat diagrammatic bottom views showing movement, from the fully open position to the fully closed position, of a plurality of movable roofstructural supports of the respective movable roof units illustrated in FIGS. 1(a) through 1(d);
FIGS. 3 through 5 are enlarged schematic crosssectional, side elevational views showing movement, from the fully open position to the fully closed position, of the movable roof-structural support and a movable roof finish which form one of the movable roof units illustrated in FIGS. 1(a) through 1(d).
FIG. 6 is a somewhat diagrammatic cross-sectional view taken the line VI--VI in FIG. 2(a);
FIGS. 7(a) and 7(b) are partially broken-away, enlarged schematic side elevational views showing one of a plurality of stationary structural supports;
FIG. 8(a) is a top plan view of the openable roof illustrated in (a) through 1(d);
FIG. 9(b) is an enlarged cross-sectional view taken along the line VIIIb--VIIIb in FIG. 8(a), showing a starling section;
FIG. 9(a) is a view similar to FIG. 8(a), but showing the movable roof units which move toward the fully closed position;
FIG. 9(b) is an enlarged cross-sectional view taken along the line IXb --IXb inn FIG. 9(a);
FIG. 10(a) is a view similar to FIG. 8(a), but showing the movable of units in the fully closed position;
FIG. 10(b) is an enlarged cross-sectional view taken along the line Xb--Xb in FIG. 10(a);
FIG. 11 is a cross-sectional view taken along the line XI--XI in 10(b);
FIG. 12 is a cross-sectional view showing an openable roof according to another embodiment of the invention;
FIG. 13 is a cross-sectional, side elevational view showing the conventional openable roof;
FIG. 14 is a top plan view of the openable roof illustrated in FIG. 13; and
FIG. 15 a side elevational view showing a building construction of a movable-roof truss beam of the openable roof shown in FIGS. 13 and 14.
DETAILED DESCRIPTION
Referring to FIGS. 1(a) through 1(d) and FIGS. 2(a) through 2(d), there is shown a manner in which a movable roof section 12 (refer to FIG. 1(d)) of an openable roof 10 according to an embodiment of the invention moves from a fully open position illustrated in FIGS. 1(a) and 2(a) toward a fully closed position shown in FIGS. 1(d) and 2(d). Specifically, FIGS. 1(a) through 1(d) illustrate a manner in which a plurality of movable roof finishes 24 of respective movable sectorial roof units 11 forming the movable roof section 12 move from the fully open position to the fully closed position. FIG. 2(a) through 2(d) illustrate a plurality of movable roof-structural supports 23 of the respective movable sectorial roof units 11 from the fully open position to the fully closed position.
In FIG. 1(d), the openable roof 10 comprises the aforesaid movable roof section 12 and a stationary roof section 13. In the closed position, the movable roof section 12 is arranged at a circular central space 61 (refer to FIGS. 1(a) through 1(c)) of the openable roof 10 which is sectioned by a predetermined radius from a certain point or a circular center 0. The stationary roof section 13 is arranged in spaced relation to the circular center 0 by a radius of the central space 61. The stationary roof section 13 has its inner periphery which is circular to define &he circular central space 61.
In the illustrated embodiment, the openable roof 10 is in the form of a circle in plan as a whole. Specifically, the central space 61 is in the form of a circle in plan, and the stationary roof section 13 is in the form of an annulus in plan. It will be understood, however, that the invention is not limited to this specific openable roof, but is applicable to any openable roof in the form of a sector or a rectangle. Specifically, the central space 61, that is, the inner periphery of the stationary roof section 13 may be in the form of a sector or a rectangle in plan, and the stationary roof section 13 may itself be in the form of a sector or a rectangle in plan.
The movable roof section 12 is divided into the aforementioned plurality of, eight in the illustrated embodiment, movable sectorial roof units 11 which are the same in their central angle as each other. The openable roof 10 according to the embodiment is such that the movable roof units 11 are radially moved toward and away from the central point 0 to open and close the central space 61 as shown in FIGS. 1(a) through 1(d).
As illustrated in FIGS. 3 through 5, the stationary roof section 13 is formed with outer and inner inclined surfaces which gradually rise from an outer peripheral portion toward an inner peripheral portion of the stationary roof section 13. The inner and outer inclined surfaces are slightly convex upwardly. The stationary roof section 13 is composed of a plurality of stationary structural supports 14 formed by a stereoscopic truss construction and a plurality of stationary roof finishes 15 mounted respectively on the stationary structural supports 14.
As illustrated in FIGS. 2(a) through 2(d), the stationary roof section 13 in the form of a ring or an annulus comprises a plurality of, or eight, stationary truss boxes 16 which extend radially and which are arranged in equidistantly and circumferentially spaced relation to each other. As shown in FIG. 6 which is a cross-sectional view taken along the line VI--VI in FIG. 2(a), each of the truss boxes 16 is hollow by surrounding of four main members, i.e., a pair of upper chord members 17a and 17a and a pair of lower chord members 17b and 17b, which all extend radially. In FIG. 6, the aforesaid movable roof-structural supports 23 form the movable sectorial roof units 11, respectively. A plurality of pairs of bearings 20 and 20 are arranged, at their predetermined positions, outside of the upper and lower chord members 17a and 17b forming each truss box 6 and a pair of tying members 18 and 18 such as lattices, braces or the like to slidably support the roof-structural support 23. Each pair of bearings 20 and 20 are spaced a predetermined distance from each other.
On the other hand, as shown in FIGS. 1(a) through 1(d), a plurality of pairs of rails 21 and 21 are laid on the roof finishes 15 of the stationary roof section 13 (refer to FIGS. 3 through 5). Each pair of rails 21 and 21 extend parallel to each other with the truss box 16 clamped centrally between them. The pairs of rails 21 and 21 and the truss boxes 16 serve as guides along which the movable sectorial roof units 11 move slidably.
As illustrated in FIG. 3, each of the movable sectorial roof units 11, which form the movable roof section 12, is composed of one of the aforesaid movable roof-structural supports 23 and one of the aforementioned plurality of movable roof supports or sectorial roof finishes 24 mounted respectively on the roof-structural supports 23. Similarly to each truss box 16, each of the roof-structural supports 23 has a pair of upper chord members 22a and 22a and a pair of lower chord members 22b and 22b to form a telescopic truss in the form of an elongated box. The same radius of curvature as the stationary structural supports 14 are given to the movable roof-structural supports 23. As shown in FIG. 4, each of the movable roof-structural supports 23 has its outer periphery which is supported by the pairs of bearings 20 and 20 (refer to FIG. 6) arranged inside of a corresponding one of the truss boxes 16, so that the movable roof-structural support 23 is longitudinally slidable along the truss box 16.
As shown in FIGS. 2(a) through 2(d), each of the movable roof-structural supports 23 is tapered or narrowed in lateral width at its forward end. The forward end of the movable roof-structural support 23 has an apex angle "α" which is substantially 45° . As illustrated in FIGS. 3 through 5, each of the movable sectorial roof finishes 24, which are mounted respectively on the movable roof-structural supports 23, has a wheel 25 at the apex-angle portion of the sectorial roof finish 24 and a pair of wheels 26 (only one shown in FIGS. 3 through 5) at respective apex portions of a rearward end of the roof-structural support 23 which is formed into a sectorial arc. The pair of wheels 26 are in engagement respectively with the pair of rails 21 and 21 shown in FIGS. 1(a) through 1(d). That is, the movable roof finish 24 and the movable roof-structural support 23 are vertically spaced from each other by a gap or a clearance. The stationary roof finish 15 gets into the gap.
As shown in FIGS. 7(a) and 7(b), a PC steel wire 30 is incorporated in the pair of the upper chord members 17a and 17a of each of the stationary structural supports 15 which form the stationary roof section 13. Likewise, a PC steel wire 30 is incorporated in the pair of the upper chord members 22a and 22a of each of the movable roof-structural supports 233 which form the movable roof section 12. As will be understood from FIGS. 7(a) and 7(b), portions except for the radially extending eight truss boxes 16 of the stationary roof section 13, that is, portions of the stationary roof section 13 among the truss boxes 16 are formed also by telescopic trusses, and the PC steel wire 30 is incorporated in an upper chord member of each of the trusses. The PC steel wire 30 has one end or an upper end thereof which is fixed or fastened to the forward end of the structural support 14 or 23 by a fastener 31. The other end or a lower end of the PC steel wire 30 is fixed or fastened to the rearward end of the structural support 14 or 23 by a fastener 32 through a hydraulic tightening jack 62 for applying tightening force to the PC steel wire 30. Thus, pre-stress is given to the upper and lower chord members 22a and 22b of the respective roof-structural supports 23 forming the movable roof section 12, the upper and lower chord members 17a and 17b of the respective structural supports 14 forming the stationary roof section 13, and the portions of the stationary roof section 13 among the truss boxes 16.
As shown in FIGS. 2(b) and 2(c), opening and closing drive means comprises fastening means or a wire member 36 by which the tapered forward ends of the respective movable roof-structural supports 23 arranged in eight locations are connected to each other in the form of a ring. In this case, as illustrated in FIGS. 3 through 5, the forward ends of the upper chord members 22a of the respective roof-structural supports 23 are formed respectively with insertion bores 37 through which the wire member 36 extends. A plurality of pairs of pulleys 38 and 38 are provided respectively adjacent the insertion bores 37, with each insertion bore 37 located between the corresponding pair of pulleys 38 and 38, for holding the wire member 36 against disengagement from the insertion bores 37. The wire member 36, by which the forward ends of the respective movable roofstructural supports 23 are connected to each other in the form of a ring, has one end which is guided by a pulley 39 mounted to the lower chord member 22b of one of the movable roof-structural supports 23. The wire member 36 extends toward the truss box 16 associated with the movable roof-structural support 23, along the lower chord member 22b, and is wound around a winder 40 which is mounted to the truss box 16. The other end of the wire member 36 is fixed to the movable roof-structural support 23 or the truss box 16.
Likewise, as shown in FIGS. 1(b) and 1(c), the aforesaid opening and closing drive means further comprises fastening means or a wire member 41 by which tapered or narrowed forward ends the respective movable roof finishes 24 provided at eight locations ar connected to each other in the form of a ring. The wire member 41 has one end thereof which extends from the forward end of one of the movable roof finishes 24 to the rearward portion of the roof finish 24 through an insertion bore and a pulley (both not shown), similarly to the wire member 36 for the movable roof-structural supports 23. As shown in FIGS. 3 through 5, the one end of the wire member 41 is wound about a winder 42 which is mounted to an inner surface of the roof finish 24. The other end of the wire member 41 is fixedly connected to the same roof finish 24.
In connection with the above, the construction of the movable roof units 11, that is, the construction of the the movable roof-structural supports 23 is not limited to the telescopic truss beams into which pre-stress is introduced. That is, if the movable roof units 11 are not so long in their longitudinal length, the movable roof units 11 may be formed by a general truss construction into which no pre-stress is introduced, or may be formed by a lamella construction.
FIGS. 8(a) through 10(b) show a construction of a starling section for the movable roof section 12 of the openable roof 10 according to the embodiment of the invention. The starling section is provided to prevent water from entering the central space 61 when the movable roof section 12 is in the closed position.
FIG. 8(b) is a cross-sectional view along the line VIIIb--VIIIb in FIG. 8(a). In FIG. 8(b), each of the sectorial roof finishes 24 constituting the movable roof section 12 is formed such that both sides of the movable sectorial roof finish 24, which extend radially, stand on different levels. Accordingly, as shown in FIG. 8(b), one of both sides of one of the adjacent movable sectorial roof finishes 24 and 24, and one of both sides of the other movable sectorial roof finish 24, which are abutted against each other, stand on different levels. Of the sides standing on different levels, the higher side is formed with a tapered portion 50 in its inner surface such that the tapered portion 50 tapers off toward a side edge 24a of the roof finish 24. Further, an engaging member 51 is mounted on the tapered portion 50 so as to be slidable therealong. As shown in FIG. 11, the engaging member 51 is formed at its inclined upper face with a dovetail joint 51a which is dovetail-joined with that of the tapered portion 50.
Referring again to FIGS. 8(b), 9(b) and 10(b), a first projection 52 slightly rising upwardly is formed on a side edge 24b of the adjacent roof finish 24, which is located at the low level. As shown in FIGS. 9(b) and 10(b), a second projection 53 is formed at a location on the roof finish 24, which is positioned slightly inwardly from the first projection 52. The second projection 53 has its projecting height which is higher than that of the first projection 52. The first and second projections 52 and 53 are formed parallel to each other and are spaced from each other by a distance which is equal to or slightly larger than the width of the movable engaging member 51.
The operation of the openable roof constructed as above will next be described.
Under the condition shown in FIG. 1(a), the movable sectorial roof units 11 are spread radially and are overlapped with the ring-like or annular stationary roof unit 13. Thus, the sectorial roof units 11 are spaced from each other circumferentially and equidistantly. That is, as shown in FIGS. 2(a) and 3, the movable roof-structural supports 23 are accommodated respectively in the truss boxes 16 of the respective stationary structural supports 14. The movable sectorial roof finishes 24 supported respectively by the movable roof-structural supports 23 are overlapped with the upper surfaces of the respective stationary roof finishes 15. Under this condition, the central space 61 of the circular openable roof 10 is open. Thus, the open central space 61 is given to the subject site such as an event site and the like on which the openable roof 10 is erected, so that people can sufficiently enjoy sunlight, fresh air and so on. In this connection, under this condition or stage, no tightening force is given to the PC steel wires 30 for both the stationary structural supports 14 and the movable roof-structural supports 23.
In order to close the central space 61 from this condition, as shown in FIGS. 2(a) through 2(d), the movable roof-structural supports 23 are first closed. That is, the winder 40 illustrated in FIGS. 3 through 5 is driven to wind the wire member 36 gently or slowly. As described previously, since the wire member 36 passes through the pulleys 38 and connects all the forward ends of the respective eight movable roof-structural supports 23 to each other in the form of a ring, winding of the wire member 36 reduces the ring diameter gradually. Accompanied with this, as shown in FIG. 4, the forward ends of the respective movable roof-structural supports 23 simultaneously approach each other toward the circular center 0 of the central space 61 while the movable roof-structural supports 23 slide respectively within the truss boxes 16. In a short time, the forward ends of the respective movable roof-structural supports 23 are all abutted against each other. In this manner, the movable roof-structural supports 23 are radially assembled together on the central space 61 of the openable roof 10 in the form of a dome. Under this condition, tightening force is given too the PC steel wires 30 by the hydraulic tightening jacks 62. Thus, pre-stress is introduced into the movable roof-structural supports 23.
Subsequently, as shown in FIGS. 1(a) through 1(d), the movable roof finishes 24 are moved toward the circular center 0 of the central space 61. That is, the winder 41 is driven slowly to wind the wire member 41. As mentioned previously, the wire member 41 passes through the pulleys (not shown) and connects all the forward ends of the respective eight movable roof finishes 24 to each other in the form of a ring, winding of the wire member 41 reduces the ring diameter gradually. Accompanied with this, as shown in FIG. 5, the forward ends of the respective movable roof finishes 24 simultaneously approach each other toward the circular center 0 of the central space 61. In a short time, as shown in FIG. 1(d), the forward ends of the respective movable roof finishes 24 are all abutted against each other. In this manner, the movable roof finishes 24 are radially assembled together on the central space 61 of the openable roof 10 in the form of a dome, and the central space 61 is closed by the movable roof finishes 24. Under this condition, tightening force is given to the PC steel wires 30 by the hydraulic tightening jacks 62. Thus, pre-stress is introduced into the movable roof finishes 24.
The operation of the starling section for the openable roof 10 accompanied with the closing operation of the movable roof finishes 24 will be described with reference to FIGS. 8(a) through 10 (b).
When the movable roof finishes 24 under the condition shown in FIGS. 8(a) and 8(b) approach each other toward the circular center 0 of the central space 61 as shown in FIGS. 9(a) and 9(b), the side edge 24a of one of the adjacent roof finishes 24 and 24, which is located at the high level, approaches the side edge 24b of the other roof finish 24, which is located at the low level. As shown in FIG. 9(b), the engaging member 51 of the one roof finish 24 moves beyond the first projection 52 on the other roof finish 24, and is abutted against and engaged with the second projection 53 on the other roof finish 24. When the movable roof finishes 24 approach each other from this condition as illustrated in FIGS. 10(a) and 10(b), the interaction between the tapered portion 50 and the engaging member 51 engaged with the second projection 53 causes the engaging member 51 to slide downwardly along the tapered portion 50. Thus, as shown in FIG. 10(b), the engaging member 51 is accommodated in a groove between the first and second projections 52 and 53. In this manner, the starling section is completed. Moreover, although the engaging member 51 is abutted against the first projection 52 at the opening operation of the roof finishes 24, the tapered portion 50 slides upwardly. Accordingly, the engaging member 51 is disengaged from the first projection 52, so that the opening operation of the movable roof finishes 24 is made possible.
In connection with above, if it is desired that the movable sectorial roof units 11 are moved from the open position toward the closed position, the above-described steps of procedure are done in reverse order.
According to the embodiment of the invention, there are provided the following superior advantages:
(1) Since pre-stress is given to the movable roof-structural supports 23 by the PC steel wires 30, it is possible to reduce deflection of the movable roof units 11. Further, the introduced pre-stress enables parts of the tension loads applied to the upper and lower chord members 22a and 22b of the respective movable roof-structural supports 23, to be born by the PC steel wires 30. Lightening of the roof units 11 can correspondingly be realized. By doing so, it is particularly possible to bring the movable roof units 11 to a long span construction. The above is also applicable to the stationary roof section 13.
(2) When the roof units 11 are moved between the open and closed positions toward and away from the circular center 0 of the central space 61, the wire members 36 and 41 passing through the forward ends of the respective movable roof-structural supports 23 and the respective movable roof finishes 24 of the roof units 11 are merely wound and unwound by the winders 40 and 42, respectively. Winding and unwinding of the wires 36 and 41 by the winders 40 and 42 cause the roof units 11 to be simultaneously moved toward and away from the circular center 0 of the central space 61. In this manner, troublesome or cumbersome operation can be dispensed with such as driving of each of the movable roof units 11. Thus, it is possible to do the opening and closing operation of the movable roof section 12 quickly, and it is possible to sufficiently cope with a sudden change in the weather and so on.
(3) In the construction of the starling section for the movable roof sectioon 12, the side edges 24a and 24b oof the respective adjacent movable roof finishes 24 and 24 stand in different levels from each other. Accordingly, it is possible to permit or allow slight divergence or gap between the side edges 24a and 24b due to the use of the movable roof section 12 for a long period of time. Further, under the closed condition between the side edges 24a and 24b, the engaging member 51 of one of the side edges 24a is engaged with the groove between the first and second projections 52 and 53 of the other side edge 24b by the action of the tapered portion 50. Thus, it is possible to always secure constant starling effects.
Referring to FIG. 12, there is shown an openable roof according to another embodiment of the invention. In FIG. 12, components and parts like or similar to those of the embodiment illustrated in FIGS. 1(a) through 11 are designated by the same reference numerals to avoid repetition.
The openable roof 10 according to the another embodiment utilizes hydraulic jacks 150 in substitution for the winders 40 illustrated in FIGS. 3 through 5, as opening and closing drive means for the movable roof section 12.
As shown in FIG. 12, each of the hydraulic jacks 150 has its base end 150a which is fixedly mounted on the roof building subject L so as to move angularly in a vertical plane. The hydraulic jack 150 has a rod 151 which extends and contracts with respect to a jack body 152 by hydraulic force. The rod 151 has its forward end 151a which is connected substantially to a center of the movable roof-structural support 23 so as to move angularly in the vertical plane. Extension and contraction of the rod 151 cause the movable roof-structural support 23 supported by the rod 151 to be moved between the open and closed positions.
Similarly to the movable roof finishes 24 of the aforesaid first embodiment, each of the movable roof finishes 24 is formed separately from the corresponding one of the movable roof-structural supports 23. Moreover, forward ends of the respective movable roof finishes 24 are connected to each other in the form of a ring by fastening means or a wire member 41 which forms the opening and closing drive means. The wire member 41 has one end thereof wound about a winder 42 which is fixedly mounted to an inner surface of the movable roof finish 24. The other end of the wire member 41 is fixedly connected to the same movable roof finish 24.
According to the another embodiment shown in FIG. 12, a part of the load of the movable roof-structural support 23 is born by the rod 151 of the hydraulic jack 150. Thus, it is possible to lengthen the span of the movable roof-structural support 23 without introduction of pre-stress into the movable roof-structural support 23.
Further, the wire member 41 may be dispensed with. That is, the movable roof finish 24 and the movable roofstructural support 23 may be united together such that they are simultaneously moved between the open and closed positions while the load of the movable roof finish 24 and the movable roof-structural support 23 is sufficiently supported by the hydraulic jack 150.
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In an openable roof capable of opening and closing a central space having a certain point, a stationary roof section is arranged in spaced relation to the certain point of the central space. The stationary roof section has an inner periphery which defines the central space. A movable roof section is arranged on the stationary roof section and is radially movable relatively thereto toward and away from the certain point of the central space. The movable roof section is divided into a plurality of movable roof units having their respective apexes which are substantially identical in central angle with each other. In a closed position where the central space is closed by the movable roof section, the apexes of the respective movable roof units are abutted against each other and the movable roof units cooperate with each other to close the central space. In an open position where the central space is open, the movable roof units are spaced from each other and are spaced from the certain point of the central space to open the latter. A drive unit is provided for drivingly moving the movable roof units between the open and closed positions.
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BACKGROUND OF THE INVENTION
The invention concerns an apparatus for remote control of electrical power units, which consists of a transmitter having an astable multivibrator and a receiver which transforms the light impulses into electrical impulses which are conducted as control signals to a continuous electronic recording circuit.
Wireless remote control devices have been in use for many years to remote control movable objects, as for example cranes, locomotives, model airplanes or toy automobiles. such devices are also used with entertainment devices, such as televisions, to control the same. Even with entertainment instruments, the various continually adjustable kinds of adjustments, as for example volume, brightness, and contrast, and the adjustments which take place in distinct stages, such as the special search action and the station selection, are even controlled by wireless remote control. In this type of device, an ultrasonic signal emitted from a transmitter is often used. This ultrasonic signal is converted in a receiver aerial into a control signal corresponding to the frequency selected. A special remote control channel is assigned to each kind of adjustment to be made, with the frequency belonging to it defining the type of adjustment value. In the case of the continually adjustable adjustments, usually two frequencies are chosen for values such as louder-softer, brighter-darker, etc. The amount of the desired change of the adjustment value is usually determined by different lengths of pressure on a key of the transmitter.
Various procedures for the ultrasonic remote control are known. In the case of the impulse-code-procedure, coded impulse sequences are radiated from the transmitter and decoded by the receiver. This procedure has the disadvantage that the sender and receiver are complex and expensive. Another already mentioned procedure provides that a frequency is assigned to each function. For recognition of the various frequencies, a number corresponding to the number of frequencies of resonating circuits is used. This technique, however, requires a time-consuming balancing process imperative before the putting into operation of the receiver.
One problem with using ultrasonic frequencies is that numerous extraneous noises, as for example rattling of keys, clapping of hands, the ringing of a telephone, etc., can cause malfunctions by varying ultrasonic wave components. There is the further disadvantage where several receivers are used in that a special frequency for each receiver must be provided, since reflected ultrasonics can still control receivers at substantial distances from the transmitter. Moreover, domestic animals whose range of hearing extends to the supersonic frequencies can be disturbed by ultrasonic signals.
SUMMARY OF THE INVENTION
The problem of the invention is to avoid the disadvantages enumerated in the case of optical remote control and to create a remote control, of which the circuit wiring expense is less and which can partly be manufactured in integrated technology. Further, several receivers with the same transmitter are to be switched off or on at every position of the adjustment value when the adjustment values can be changed continually. The remote control is not to be influenced by stray light.
The problem is solved according to this invention by providing in the transmitter an astable multivibrator which has several elements determining frequency which are present in pairs. For the duration of the activation of the respective type key these pairs are switched on, so that in this time an impulse series is produced with the same keying ratio. In the receiver, the electrical impulses, after the latter have passed through a selective filter circuit and a following signal converter circuit, are conducted over a frequency divider to a recorder, the outputs of which are connected with a 1 from n decoder, on the outputs of which comparator circuit is connected, which compares the outputs of the decoder with the output of a time circuit during a periodically recurrent measurement time and in the case of the presence of an impulse of the same polarity on both outputs, transmits a control signal to the following control circuits of the electrical power unit.
Since the invention comprises the off and on switching as well as a continual adjustment of the electrical power unit, the invention can be used with power units which are merely switched on or off and/or with which a phasechannel circuit, null point regulation or the like is possible. Power units can for example be motor-driven in house installation, for room lamps, curtains, blinds or garage door control.
The advantages of this invention consist especially in that for example in the case of room lamps, the adjusted brightness does not change even over an extended period of time. Besides upon switching on the system voltage after system failure, the lamps are still in the off-position independent of their previous operational condition.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made to the figures in which:
FIG. 1 shows a circuit diagram of a transmitter,
FIG. 2 shows a circuit diagram of a part of a receiver,
FIG. 3 shows a circuit diagram of the other part of the receiver, and
FIGS. 4 and 5 show a waveform chart.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The transmitter circuit diagram shown in FIG. 1 indicates three frequency information channels, one of which switches the power unit on and off, and the other two of which change the adjustment value up or down. If necessary, the transmitter can have fewer or more information channels. The supply voltage U B1 for the transmitter is preferably supplied from batteries, but alternatively, the transmitter can include a rectifying circuit for utilizing available AC power.
The transmitter produces light signals by means of a Ga-As-luminescence diode 1, which emits infrared light in the form of near monochromatic light with a wave length of 950 nm. The anode of diode 1 is connected to the collector of a transistor 2, the emitter of which is connected via resistor 3 to supply voltage U B1 . On the cathode side diode 1 is grounded. The base-emitter path of transistor 4 is connected in parallel with resistor 3, so that a constant current can flow through transistor 2 and diode 1, which can be calculated from the relationship of the base-emitter-voltage of the transistor 4 to the value of resistor 3. The current supplied to diode 1 is via the collector-emitter path of transistor 2, so that should the voltage supply U B1 vary the current remains approximately constant through diode 1 to maintain the radiated power of the diode constant.
The circuit includes a conventional astable multivibrator, consisting of the transistors 5 and 6, capacitors 7 and 8 and fixed resistors 9, 10 and 11. The pair of resistors 20 and 21 or 19 and 22 or 18 and 23, respectively, are added to the circuit for the duration of activation of touch or sliding keys 12, 13, 14, 15, 16 and 17, so that the constant current is supplied to diode 1 with varying frequency as square pulses with a pulse-pause ratio of 1:1. A frequency range between 19 to 38 KHz is usually selected for transmission.
To transform the transmitted infrared light signals into electrical signals, preferably a photodiode 24 is operated in a high resistance circuit with a large light leak angle in FIG. 2. The cathode of diode 24 is connected via resistor 25 to supply voltage U B2 and to ground via resistor 26. On the anode side, the signal voltage is coupled via condensor 27 to the positive input of operational amplifier 28. Operational amplifiers 28 and 29 are connected in series and function as band pass filters with the resistors 30, 31 as well as 32, 33 and the condensors 34, 35 and 36 having values such that the two outer band limits are roughly 19 and 38 kHz. Since for the operation of the filter only a positive supply voltage U B2 is available, the negative input is grounded. The positive input of the operational amplifier 28 is connected to U B2 via the voltage divider formed by resistors 38, 39 and 40. Resistor 40 and condensors 41 and 42 serve as ground for the supply voltage. Resistors 43, 44 and the condensors 45, 46, 49, 50, 47 and 48, suppress oscillation of operational amplifiers 28 and 29.
In direct proximity to the photodiode 24 a light source emitting a visible light is mounted, which preferably is a light diode 49. This light diode is connected to U B2 via a resistance 50 and lights continually, as long as transistor 51 is kept non-conductive. If now a signal is received by the photodiode 24, then the increased signal b from the output of operational amplifier 29 is applied via the direct voltage grounding condensor 52 with band resistance 53 to a rectifying circuit consisting of a diode 54 and a condensor 55 and from there via resistor 56 to the base of transistor 51, which short circuits the diode 49 so that it goes out only for the duration of the transmission.
The alternating-current voltage b at the output of the operational amplifier 29 is shaped by conventional circuit 57 and transformed into noiseless square wave impulses c with steep flanks.
The recording circuit consists of conventional 16 impulse dividers 58 and 59, which divide down the transmitted impulses in the ratio 1:128. The 4-bit binary counter 60 counts the subdivided impulses only during a measuring interval of 20 ms which interval is repeated. In the 1 from n decoder 137 the binary output of counter 60 is decoded. The decimal output signals of decoder 137 are inverted by inverters 61, 62 and 63 and connected respectively with an input to NAND-gates 64, 65 and 66. The input of the monostable flip-flop 67 is a system-synchronized impulse e, as shown in FIG. 4, with a 20 ms repeat duration. The output impulse f of monostable flip-flop 67 with pulse duration t q67 = R 68 .C 67 .C 7 is applied to the other inputs of each of NAND-gates 64, 65 and 66. If a low-signal is produced at one of the decimal outlets of decoder 137 during the pulse duration t q67 of the flip-flop 67, and consequently a high signal at the inverter outlet, then the corresponding output of the NAND-gate switches to low during the duration of the pulse. As long as the same frequency is transmitted, a pulse train g with 20 ms repeating duration is provided at the outlet of the respective NAND gate associated with that frequency. With output impulses f of flip-flop 67 a further flip-flop 70 is controlled, of which the output impulses h are delayed by the time t q70 = R 71 .C 72 . 0,7. The outlet impulses h reset divders 58 and 59, as well as the counter 60, after the outputs of the decoder 137 have been interrogated with the outlet signal f of flip-flop 67.
The transmission frequencies have been selected in such a way that the 4-bit-binary counter 60 in 20 ms counts to 3, 4 or 5. After 128 impulses at the input of the divider 58 the counter 60 counts one more. Consequently, the following table results:
______________________________________ Duration of theCounter- Number of periods t everyposition the impulses impulse n Frequency f =Z every 20 ms t = 20/n μs 1/t kHz______________________________________1 128 - 255 156,25 - 78,43 6,4 - 13,752 256 - 383 78,125 - 52,219 12,8 - 19,153 384 - 511 52,083 - 39,138 19,3 - 25,554 512 - 639 39,062 - 31,29 25,6 - 31,955 640 - 767 31,25 - 26,075 32,0 - 38,34______________________________________
The transmission frequencies are consequently
f 1 = 22,375 ± 3,175 kHz
f 2 = 28,775 ± 3,175 kHz
f 3 35,17 ± 3,175 kHz
The output signal g of the NAND-gate 66 is inverted by inverter 73 (FIG. 2) and rectified by diode 74 (FIG. 3). Trigger 77 circuit is supplied slowly by the delay circuit comprising elements 78, 79, 80, 81 and 82, 83. The output signal of the trigger circuit 77 switches a masterslave flip-flop 84, the output signal of which changes with every renewed trigger from high to low or low to high. On the low-signal from flip-flop 84 the base of the circuit transistor 85 is connected via diode 86 through the internal circuit of flip-flop 84 with ground. Consequently, transistor 85 is non-conductive, so that triac 87 is not controlled and the power unit 88 remains switched off. With renewed transmission signal the output of flip-flop 84 is switched to high, so that by means of the circuit transistor 85 and of triac 87 the power unit is switched on.
The circuit consisting of the resistors 89 and 90 and the condensor 91, ensures that on return of the supply voltage -- for example after a system breakdown -- the low signal is produced briefly on the reset input of flip-flop 84, so that the output is switched low and consequently the power unit 88 remains switched off.
For control of the triac 87, a circuit transistor 85 is used. Resistors 92 and 93 connect operational amplifier 94 as a comparator which, with the wiring resistors 95, 96, 97 and 98, produce control impulses k to be applied to transistor 85 via base resistor 99 and diode 100. Signals k can be displaced synchronized by power supply with a direct voltage with a phase angle x between 0° and 180° and 180° and 360°. The displacement of the control impulses takes place in such a way that, at positive input of the operational amplifier 94 is applied a saw-toothed voltage 1 synchronized by the power supply with a frequency of 100 Hz. A variable reference voltage m is applied to the positive input so that the output of comparator 94 then switches to the highsignal, when the value of the saw-tooth voltage 1 is the same as variable reference voltage m. The saw tooth voltage 1 is applied via a load resistor 101 and condensor 102. The discharge of the condensor 102 takes place at low resistance over the collector-emitter portion of the transistor 103 in synchronism with the system voltage. For production of the system synchronized control impulses n for transistor 103, the positive half-waves of diode 105 with the breakdown diode are limited as waveform p by the system voltage o over a resistor 104. Signal q is formed by differentiating elements 107, 108 and 109 from which the negative pulses r switch through transistor 13 in a reversal stage, consisting of the transistors 110 and 111 and the resistors 112, 113, 114, 115 over the diode 116 and base resistor 117. For the rest negative half-waves are rectified by diode 118 with the breakdown diode 119 and formed over a differentiating element 120, 121 and 122 into impulses t, from which the positive pulses u likewise connect through the transistor 103, so that the transistor unloads all 10 ms before the null passage of the system voltage to the condensor 102.
The reference voltage m is shifted by phase angle x by means of two consecutively-connected 4-bit, reversing counters 124 and 125.
For brightness control of the power unit 88 the reference voltage m for comparator 94 must become smaller, so that the increasing saw tooth voltage 1 will switch the comparator at the smaller phase angle x and the triac 87 consequently is fired earlier; for darker adjustment the reference voltage m must become greater.
The outlet of the NAND-gate 64 is connected via gate 126 to the forward count input and that of the NAND-gate 65 via gate 127 to the reversing count input of the updown counter 124. If now for example a transmitted signal is sent with the frequency for darkness control, then at the outlet of the NAND-gate 64 a pulse sequence g with 20 ms for the duration of the signal appears, so that the counter 124 counts for 20 ms periods. Using both 8-bit counters up to 255 can be counted, so that a control time of 20 ms × 255 = 5.1 seconds results for darkness regulation and 5.1 seconds for brightness regulation.
The binary outputs with the value W = 1, 2, 4, 8, 16, 32, 64 and 128 are wired with resistors, whereby at the outlet with W = 1, a resistance with the resistance value R = 1 and at the outlets W = 2 R = 1/2, W = 4 R = 1/4, W = 8 R = 1/8, etc, is required. The resistors 128 to 135 are grounded together via a resistor. At the intersection now stands a reference voltage m, which varies according to each counter position between about OV and for example + 2V. On the basis of the 255 counter steps for the regulation during 5.1 seconds, a delicate, continuous regulation is possible.
The two input of the NAND-gates 126 and 127 are connected with the output of master-slave-flip-flop 84. Thereby it is ensured that only when the outlet has the high signal, and thus the power unit 88 is switched on, a bright-darker-regulation is possible.
The wiring is constructed in this form of construction from single elements and integrated circuits. However, several separate elements and/or integrated circuits can, if desired, be combined in a single integrated circuit.
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An apparatus for remotely controlling one or more power units including a transmitter which produces an optical pulse train having a frequency varied by an astable multivibrator controlled by keys which connect different resistances into the astable circuit, and one or more receivers. Each receiver receives the optical pulses, converts them to electrical pulses, divides the frequency, counts the electrical pulses, provides an analog output from the counter and compares that analog output with a saw tooth periodic waveform to control circuit elements which in turn control conduction through the power unit.
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This is a divisional of application Ser. No. 08/911,524, filed on Aug. 14, 1997 now U.S. Pat. No. 5,947,552 issued Sep. 7, 1999.
FIELD OF THE INVENTION
This invention relates to a convertible infant product and, more particularly, to a collapsible bassinet/infant seat having a canopy.
BACKGROUND OF THE INVENTION
Sleep products are generally tailored to the age and size of the user. Infants generally start out sleeping in a bassinet or cradle. Toddlers use cribs up until they are ready to sleep in a conventional bed.
Bassinets and cradles are generally small and can be kept in a parent's room so that the infant is close to the parents during its first few months. Known bassinets and cradles are not collapsible into a compact configuration and only function as sleep products. Moreover, bassinets and cradles have a limited life and use because they are quickly outgrown by infants. However, cribs are generally too large to fit into a parent's room. Thus, there is a need for a smaller sleep product for use in a parent's room that has a sleep surface and sufficient depth to laterally restrain the infant during use, but that overcomes the limited life and use associated with known bassinets and cradles.
U.S. Pat. No. 4,967,432 to Kujawski et al., which is assigned to the assignee of this invention, discloses a multi-use product including a bassinet and playpen in one product. The playpen is of the type including a frame covered by playpen fabric. The flat bassinet/diaper changing surface is inset into the open end of the playpen to make it more accessible for naps and diaper changing. The bassinet/diaper changing surface is a fabric enclosure with a rigid floor mat. The fabric is draped over the upper edge of the playpen and rigid hook-shaped clips sewn to the fabric are secured to the upper edge of the playpen. As this product is on the scale of a playpen, it is larger than a bassinet.
In the vein of portability, but apart from sleep products, infant seats are available that are usually formed from rigid shells that are portable but not collapsible into a compact configuration. In one type of infant seat proposed in U.S. Pat. Nos. 5,115,523; 5,092,004; and 4,998,307 all to Cone, the infant seat includes a rigid shell assembly having upper and lower shell portions pivotally coupled together so as to be convertible between a flat configuration and a seated configuration. Although this seat is portable it is cumbersome and is not collapsible into a compact configuration.
Known bouncer seats of the type disclosed, for example, in U.S. Pat. No. 5,207,478 to Freese et al. include a portable infant seat where the back is convertible between an upright and a tilted position. Although these bouncer seats can be collapsed for portability, they are not intended for use as a sleep product, for example, they are not convertible into a horizontal position.
Accordingly, what is needed is a small, lightweight, collapsible infant product that has a range of utilities including a sleep product and a seating product.
SUMMARY OF THE INVENTION
The invention is generally directed to an infant product. An aspect of the invention is directed to the combination bassinet/infant seat feature. In particular, the infant product includes a frame having an infant receptacle suspended from the frame. The infant receptacle is convertible between a bassinet configuration and an infant seat configuration. This conversion between the reclined and upright configurations may be accomplished using only parts of the soft goods. In the bassinet configuration, the support surface of the infant receptacle is substantially planar, such that the infant is positioned in a reclined or flat position. In the infant seat configuration, the back portion of the infant support surface may be tilted or disposed at an angle whereby the infant can be supported in an elevated or seated position. In one aspect of the invention, this conversion is accomplished through the use of a support strap assembly. In yet another aspect of the invention, the support strap assembly and infant support surface cooperate to provide improved lateral head support for the infant.
In another aspect of the invention, the infant product is foldable or collapsible, such that the infant product is convertible between an assembled configuration for use with the infant in either of the reclined or upright positions just described and a compact collapsed configuration for travel and storage. In one aspect of the invention, a simple three-step folding method may be used to convert the infant product between the assembled erect position and compact folded configurations. The suspended soft goods are folded-up along with the frame. Moreover, part of the frame that is used to support the infant product in the assembled erect position serves the dual purpose as a handle in the compact configuration. A lightweight carrying case may be provided to cover the main portion of the compact infant product.
In yet another aspect of the invention, the infant product may include a canopy. The canopy is of the type made of a fabric having floating ribs or stays disposed in tunnels sewn into the fabric of the canopy. With the use of a quick connect system, the canopy can be easily converted between an expanded open position and a closed position.
Other features and advantages of this invention will be apparent from the following description, the accompanying drawings and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 are side, front end, back end, and top front perspective views, respectively, of the infant product in accordance with the invention in the assembled bassinet position.
FIGS. 5-9 are is a perspective, side, back end, top and bottom views, respectively, of the infant product in accordance with the invention in the infant seat position.
FIGS. 10-12 are perspective front end, perspective back end, and side views, respectively, of the frame for the infant product in accordance with the invention.
FIG. 13 is a side view of one of the structural hubs which forms part of the frame of FIGS. 10-12.
FIG. 14 is a side view of a leg bracket used in the frame of FIGS. 10-12.
FIG. 15 is a top view of the infant product in accordance with the invention where the removable pad has been removed.
FIG. 16 is a partial top view of the infant product shown in FIG. 15 .
FIG. 16A is an exploded view of the bottom wall of the infant product in accordance with the invention.
FIG. 17 is a back end view of the infant product in accordance with the invention showing the support strap system for the infant recline/seat feature.
FIG. 18 is a partial view of the support strap system shown in FIG. 17 .
FIG. 18A is a cross-sectional view taken along line 18 A- 18 A in FIG. 9 .
FIG. 18B is a cross-sectional view taken along line 18 B- 18 B in FIG. 1 .
FIG. 18C is a partial cross-sectional view taking along line 18 C- 18 C in FIG. 9 .
FIG. 19 is a perspective view of the canopy in accordance with the invention.
FIG. 19A is a partial view of the canopy in accordance with the invention in the expanded and secured position.
FIG. 20 is a partial view of the canopy in accordance with the invention in the unsecured position.
FIG. 21 is a side view of the canopy in accordance with the invention in the closed position.
FIGS. 21A-B are front views of an alternate embodiment of an infant product incorporating the canopy in accordance with the invention where the canopy is in the closed and open positions, respectively.
FIG. 22 is a side view of the conversion of the front leg of the frame from the assembled position to the compact position.
FIG. 23 is a side view of the conversion of the rear leg from the assembled position to the compact position.
FIG. 24 is a side view of the conversion of the front arcuate member from the assembled position to the compact position such that the frame is in its compact configuration.
FIG. 25 is a perspective view of the frame in the compact configuration.
FIG. 26 is a side view of the infant product in accordance with the invention where only the front leg is disposed in the compact configuration.
FIG. 27 is a side view of the infant product in accordance with the invention where both the front and rear legs are in the compact position.
FIGS. 28-30 are side, top and back views, respectively, of the infant product in the compact configuration.
FIG. 31 is a top view of the infant product in the compact configuration with the main portion disposed in a carrying case in accordance with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. In particular, the invention is directed to an infant product, the presently preferred embodiments of which are shown generally in FIGS. 1, 5 and 31 , for example. More particularly, the infant product in accordance with the invention is directed to: 1) a collapsible infant product that is configurable between: a) an in-use, deployed or unfolded configuration, shown generally at 11 in FIGS. 1-9 and b) a storage, stowed or folded configuration shown generally at 16 in FIGS. 27-31; and 2) deployed infant product 11 , which may be disposed in either of two configurations: a) a deployed bassinet configuration shown generally at 12 in FIGS. 1-4, and b) an deployed infant seat configuration shown generally at 14 in FIGS. 5-9.
Regardless of the respective configuration, however, the infant product in accordance with the invention includes a foldable frame shown generally 100 in FIGS. 10-14 and soft goods shown generally at 200 in FIGS. 1-9 which are suspended from frame 100 . Accordingly, a detailed discussion of frame 100 and soft goods 200 follows. Then, the method of converting the infant product between deployed bassinet configuration 12 and deployed infant seat configuration 14 will be described, as well as, the conversion between deployed configuration 11 and compact folded configuration 16 .
The Foldable Frame
Referring now to FIGS. 10-14, frame 100 will be described. Frame 100 has a construction that suspends soft goods 200 and is convertible between deployed configuration 11 as shown in FIGS. 10-12, for example, and compact folded configuration 16 as shown, for example, in FIG. 27 . Frame 100 is preferably converted by folding frame 100 along with soft goods 200 . Therefore, the frame is not limited to a particular configuration so long as it can suspend soft goods 200 and can be easily converted between a compact configuration and a deployed configuration in accordance with the invention.
Frame 100 has a longitudinal axis L (FIG. 12) and a transverse axis T substantially perpendicular to longitudinal axis L. As shown, frame 100 generally includes an annular upper rim frame 102 , a front leg 104 , a back leg 106 , structural hubs 108 , 110 and back leg brackets 112 , 114 .
Annular upper rim frame 102 , front leg 104 and back leg 106 may be made of any lightweight rigid and durable material. In the illustrated embodiment, these members are 18-gauge, powder-coated, hollow, cylindrical steel tubing. Upper rim frame 102 may have a 0.5″ (1.2 cm) outer diameter and front and back legs 104 , 106 may have ⅝″ ( 1.7 cm.) outer diameter. However, other types of materials may be used in accordance with the invention, such as rectangular tubing, aluminum, wood, or plastic tubing or channel, etc.
Annular upper rim frame 102 provides the support from which soft goods are suspended. Annular upper rim frame 102 as shown includes a front rim tube 116 and a back rim tube 122 , both of which have a generally U-shaped configuration. Front rim tube 116 has two ends 118 , 120 pivotally coupled to structural hubs 108 , 110 , respectively, such that front rim tube 116 is pivotal relative to back rim tube 122 as discussed in more detail below. Back rim tube 122 has two ends 124 , 126 non-pivotally secured to structural hubs 108 , 110 as discussed in more detail below. As illustrated in FIG. 12, in the deployed position front rim tube 116 is disposed substantially parallel to transverse axis T, while back rim tube 122 is disposed at an angle relative to front rim tube 116 . Back rim tube 122 is disposed at a slight angle such that infant recline/seat feature 222 (see, e.g. FIGS. 17 and 18) can be positioned high enough to form deployed infant seat configuration 14 , as discussed in more detail below. However, other configurations are within the scope of the invention to accommodate infant recline/seat feature 222 , and if the recline/seat feature 222 is not used, back rim tube 122 may also be parallel to transverse axis T.
Front leg 104 and back leg 106 are disposed to support annular upper rim frame 102 in deployed configuration 11 at a suitable height above a supporting surface to suspend soft goods 200 above the supporting surface. For example, front and back legs 104 , 106 are disposed at angles opposing each other, with their upper ends relatively close together and their lower, support-surface engaging ends relatively far apart to provide a broad, stable base. Front leg 104 has a generally U-shaped configuration including a base 128 and two side legs 130 , 132 extending substantially perpendicular from base 128 . Side legs 130 , 132 have ends 134 , 136 respectively, which are pivotally attached to structural hubs 108 , 110 , respectively, as discussed in more detail below. Back leg 106 is also of a generally U-shaped configuration and includes a base 138 including two side legs 140 , 142 extending substantially perpendicular from base 138 . Side legs 140 , 142 have two ends 144 , 146 respectively, pivotally attached to back leg brackets 112 , 114 , respectively, as discussed in more detail below. Side legs 140 , 142 of back leg 106 include transition portions 148 , 150 in the vicinity of ends 144 , 146 whereby the lateral spacing or distance between side legs 140 , 142 is increased such that back leg 106 does not interfere with the folding movement of front leg 104 (front leg 104 pivots inside of back leg 106 ) and such that back leg 106 can detent against the outside of structural hubs 108 , 110 in compact folded configuration 16 as discussed later. Although front and back legs 104 , 106 have been described as being pivotally coupled relative to upper rim frame 102 , any type of releasable connection may be used.
To increase resistance to sliding of the legs with respect to the support surface in deployed configuration 11 , rubber feet 152 may be disposed, two each, on bases 128 , 138 of back leg 106 and front leg 104 , respectively. Rubber feet 152 may be formed of any rubber material including, for example, a synthetic rubber such as a thermoplastic elastomers (TPE). Rubber feet 152 also prevent the infant product in its deployed configuration 11 from shifting or “walking,” for example, when a vibration unit is used, as discussed below.
Annular upper rim frame 102 , front leg 104 and back leg 106 just described are deployed and interconnected using structural hubs 108 , 110 and back leg brackets 112 , 114 . Accordingly, structural hubs 108 , 110 and back leg brackets 112 , 114 will now be discussed in detail along with the assembly of frame 100 . Structural hubs 108 , 110 and back leg brackets 112 , 114 may be made of a lightweight plastic material, such as, structural nylon.
Referring now to FIG. 13 in combination with FIGS. 10-12, structural hubs 108 , 110 will be discussed in detail. Structural hubs 108 , 110 include hollow box-shaped housings 154 , 156 . One of structural hubs 108 , 110 may include a vibration unit integrated into its housing 154 , 156 to sooth the infant. Such a vibration unit may include, for example, a motor, a weight, an on/off switch, battery contacts and wiring. It is preferable to place the vibration unit on one of structural hubs 108 , 110 because structural hubs 108 , 110 are in structural communication with the entire frame 100 and therefore distribute the vibration most effectively, however, other configurations may be used in accordance with the invention.
As structural hubs 108 , 110 are laterally disposed on frame 100 , they are mirror images of each other. Accordingly, the following discussion only describes structural hub 108 in detail, because the construction of structural hub 110 is readily apparent from the detailed description of structural hub 108 .
Housing 154 of structural hub 108 includes an interior side wall 158 and an exterior side wall 160 (FIG. 12) opposing and substantially parallel to interior side wall 158 . Housing 154 further includes an upper side 162 substantially parallel to transverse axis T, a lower side 164 disposed at an angle relative to transverse axis T, front side 166 and back side 168 . Other configurations are within the scope of the invention.
Exterior side wall 160 includes a carrying handle 170 formed integrally therewith and extending outwardly therefrom. Carrying handle 170 includes a recess on its lower side for being gripped by the hand such that the infant product in deployed configuration 11 may be moved. Carrying handle 170 is preferably positioned such that it is at or near the center of gravity of deployed configuration 11 when the infant is in the infant product. Exterior side wall 160 further includes a detent 171 , formed as, for example, a slightly raised surface area, and an abutment portion 172 (FIG. 12) to position and releasably hold back leg 106 in compact folded configuration 16 , as discussed in more detail below.
The upper end of back side 168 of housing 154 is adapted to fixedly mount end 124 of back rim tube 122 . For example, housing 154 may include hollow tubular projection 174 having a hollow tubular opening 175 to receive end 124 of back rim tube 122 . Hollow tubular opening 175 extends though projection 174 and into the interior of housing 154 for a distance sufficient to adequately support back rim tube 122 , and has an inner diameter substantially equal to the outer diameter of end 124 of back rim tube 122 . End 124 of back rim tube 122 is slidably disposed within hollow tubular projection 174 and may be secured by a screw (not shown), for example.
At upper side 162 of housing 154 is formed a channel 176 extending substantially parallel to transverse axis T and between front side 166 and back side 168 . End 118 of front rim tube 116 is pivotally secured to housing 154 within channel 176 by a known pivotal connector, such as, a pin. This pivotal attachment is represented in FIG. 13 by pivot point P 1 . In deployed configuration 11 of the infant product, front rim tube 116 is positioned within channel 176 as shown so as to extend substantially parallel to transverse axis T. As discussed in greater detail below, to collapse the deployed infant product, front rim tube 116 is rotated about pivot point P 1 in the direction illustrated by the directional arrow D 1 . Accordingly, to deploy the infant product, front rim tube 116 would be rotated from its compact folded configuration 16 in a direction opposite to directional arrow D 1 into deployed configuration 11 as shown.
Lower side 164 of housing 154 includes another channel 178 extending between front side 166 and back side 168 of housing 154 . Channel 178 extends at an angle relative to transverse axis T. For example, this angle may be approximately 35° from transverse axis T. End 134 of front leg 104 is pivotally attached to housing 154 within channel 178 using any known pivotal connector. This pivotal attachment is illustrated by pivot point P 2 . To collapse the deployed infant product, front leg 104 is pivoted about pivot point P 2 in the direction illustrated by directional arrow D 2 until front leg 104 is disposed in a position opposing the position shown in FIG. 13 (i.e. 180°), as will be discussed in greater detail below.
Referring now to FIG. 14, back leg brackets 112 , 114 will be discussed. Back leg brackets 112 , 114 are disposed laterally on frame 100 and are mirror images of each other. Accordingly, only back leg bracket 112 will be discussed in detail as the construction of back leg bracket 114 will be readily apparent from the discussion of back leg bracket 112 .
Back leg bracket 112 includes an exterior side wall 180 , an interior side wall 181 (see also FIG. 11 ), an upper end 182 , a lower end 184 , a front end 186 and a back end 188 . At upper end 182 it is formed a hollow tubular sleeve through which back rim tube 122 is slidably disposed. In corner 192 between lower end 184 and front end 186 is formed a channel 194 disposed at an angle, for example, 45°, relative to transverse axis T to support back rim tube 122 . End 144 of back leg 106 is pivotally attached to back leg bracket 112 and is disposed within channel 194 when back leg 106 is disposed in deployed configuration 11 of the infant product. End 144 of back leg 106 is pivotally attached to back leg bracket 112 by any known pivotal connector. This pivotal connection is represented in FIG. 14 by pivot point P 3 .
As discussed in detail below, when deployed configuration 11 is collapsed, back leg 106 is pivoted about pivot point P 3 in the direction represented by directional arrow D 3 . Accordingly, to position back leg 106 in deployed configuration 11 from compact folded configuration 16 , back leg 106 is moved in a direction opposite to the direction represented by directional arrow D 3 until its detents on detent 171 on exterior sidewall 160 of housing 154 . As discussed below, in compact folded configuration 16 , back leg 106 is disposed substantially parallel to back rim tube 122 .
A detent 198 (FIG. 11) is also formed on interior side wall 181 of back leg bracket 112 to releasably secure front leg 104 in compact folded configuration 16 . For example, detent 198 may include a raised surface or a raised surface with a depression corresponding to the shape of front leg 104 .
To properly and releasably position back leg 106 relative to back rim tube 122 in the deployed configuration, a spring or Valco button connection 196 may be used. In particular, spring button connection 196 includes spring button 195 formed on end 144 of rear leg 106 that is spring biased in an extended position, and a hole 197 formed in exterior side wall 180 of back leg bracket 112 . As back leg 106 is rotated into its assembly configuration, spring button 195 will become aligned with hole 197 and engage or lock into hole 197 . Therefore, rear leg 106 can be easily locked into its proper deployed position, yet is easily unlocked by simply depressing spring button 195 . Although illustrated with a Valco button, any suitable latching or locking mechanism can be used.
The Soft Goods
Referring now to FIGS. 1-9 and 15 - 21 , soft goods 200 in accordance with the invention will be discussed in detail. Soft goods 200 generally include a bassinet shell 202 , a canopy 212 , and a removable pad 216 .
Referring to FIGS. 1-9, bassinet shell 202 is constructed such that, in deployed configuration 11 , it is suspended from frame 100 and naturally falls into deployed bassinet configuration 12 due to its own weight and gravity as shown in FIG. 1, for example. Thus, bassinet shell 202 is preferably formed of pliable and/or foldable construction such that bassinet shell 202 is conveniently collapsed and folded into deployed bassinet configuration 12 . Bassinet shell 202 is constructed such that infant recline/seat feature 222 can be incorporated into soft goods 200 and operated independently of frame 100 , as discussed in more detail later. By minimizing the connections between frame 100 and soft goods 200 , bassinet shell 202 can be folded-up into compact folded configuration 14 without having to disassemble or disconnect any parts, which is time consuming and inconvenient.
Bassinet shell 202 generally includes a front end 203 , a back end 201 , a bottom wall 204 , an annular side wall 206 , and structure to suspend bassinet shell 202 from frame 100 which may include a front tunnel 208 formed on upper annular edge 220 of annular side wall 206 at front end 203 of bassinet shell 202 , and a back tunnel 210 formed on upper annular edge 220 of annular side wall 206 at back end 201 of bassinet shell 202 .
Referring to FIGS. 9, 15 and 16 , bottom wall 204 of bassinet shell 202 has a generally elliptical shape with an outer perimeter 218 , a front end 224 , a back end 226 , a top surface 228 and a bottom surface 230 . Top surface 228 of bottom wall 240 as illustrated in FIGS. 15 and 16, is shown with removable pad 216 removed. As discussed later, removable pad 216 is disposed on top surface 228 of bottom wall 240 .
Bottom wall 204 has a jointed rigid construction whereby a substantially rigid flat surface can be maintained in deployed bassinet configuration 12 (FIGS. 1 - 4 ), however, which also can be repositioned into deployed infant seat configuration 14 (FIGS. 5 - 9 ).
In particular, with reference to FIG. 16A, bottom wall 204 is a multi-layer construction including flexible upper cover 232 , flexible lower cover 234 and front, intermediate, and back rigid panels 236 , 238 , 240 interposed between upper cover 232 and lower cover 234 . This rigid panel construction also has the advantage of providing a minimal weight bias (relative to lightweight annular side wall 206 ) in bottom wall 204 which will help bassinet shell 202 naturally fall into deployed bassinet configuration 12 and provide a slight tension on annular side wall 206 . Of course, this tension on annular side wall 206 is increased when the infant is placed in bassinet shell 202 .
Upper cover 232 is preferably made of an easily cleanable material such as vinyl. It includes a pair of laterally disposed V-shaped notches 246 , 248 of elastic material at back end 226 . Lower cover 232 is made of a generally non-elastic cloth material and also has a pair of laterally disposed V-shaped notches 242 , 244 of elastic material at back end 226 . Notches 242 , 244 , 246 , 248 are provided for purposes of infant recline/seat feature 222 , discussed in more detail below.
Front, intermediate, and back rigid panels 236 , 238 , 240 are flat, thin, rigid panels made of any type of rigid relatively lightweight material, such as, hardboard. Front rigid panel 236 is semi-circular in shape, intermediate rigid panel 238 is rectangular in shape and back rigid panel 240 is a partial elliptical shape with laterally disposed V-shaped notches 258 , 260 . Front, intermediate, and back rigid panels 236 , 238 and 240 are disposed in spaced relationship such that they may be rotated and folded unencumbered. Also, seams 260 , 262 (FIG. 15) may be provided to separate rigid panels 236 , 238 , 240 to prevent displacement of rigid panels 236 , 238 , 240 . For example, back panel 240 in back end 226 of bottom wall 204 can be pivoted from deployed bassinet configuration 12 substantially parallel to transverse axis T, to deployed infant seat configuration, which is angled relative to transverse axis T, for example, 30-35° from transverse axis T. Back rigid panel 240 is held in deployed infant seat configuration 14 by infant recline/seat feature 222 , as discussed in more detail below.
Annular sidewall 206 is attached to outer perimeter 218 of bottom wall 204 by, for example, stitching. Annular sidewall 206 forms a lateral restraint for the infant in addition to contributing to suspending bottom wall 204 . Annular sidewall 206 is formed of soft flexible material and may include a patchwork of solid cotton fabric panels 251 and breathable mesh fabric 252 . However, any type of material that will not scratch or injure an infant may be used. Panels 251 may be formed of a solid cotton fabric for durability. As discussed later, annular sidewall 206 can be folded and formed into compact folded configuration 16 , yet serves as a semi-rigid wall for providing lateral support when under tension in deployed configuration 11 .
Front and back tunnels 208 , 210 (FIG. 1) are formed to suspend bassinet shell 202 from annular upper rim frame 102 . Front and back tunnels 208 , 210 may be sewn onto upper annular edge 220 of annular side wall 206 or may be an extension of annular side wall 206 . Front and back tunnels 208 , 210 may be formed of a soft material padded with batting to cushion around front rim tube 116 and back rim tube 122 . Front and back tunnels 208 , 210 are constructed to form a front passageway in front tunnel 208 having open ends 264 , 266 and a back passageway in back tunnel 210 having open ends 268 , 270 (FIG. 4 ). Accordingly, front rim tube 116 is threaded through the front passageway in front tunnel 208 and back rim tube 122 is threaded through the back passageway in back tunnel 210 .
Removable pad 216 is disposed on top surface 228 of bottom wall 204 of bassinet shell 202 and may include any conventional pad having a substantially elliptical shape corresponding to the shape of bassinet shell 202 . Removable pad 216 may be made of a cloth material having a batting filling. Crease 292 (FIG. 4) may be formed in removable pad 216 , for example, using a seam to provide flexibility for lateral edges 288 , 290 as discussed below with reference to FIG. 18 A.
A known nylon webbing three-point restraint may be incorporated into bassinet shell 202 to support the infant in deployed infant seat configuration 14 .
Although a particular embodiment of bassinet shell 202 has been described above, other configurations and materials may be used so long as, for example, the bassinet shell is suspended from the frame in a manner appropriate to support the infant in either of the bassinet and infant seat configurations and the bassinet shell is easily folded into compact folded configuration 16 along with frame 100 .
Referring now to FIGS. 17-19, infant recline/seat feature 222 will now be described. In particular, FIG. 17, 18 and 18 A illustrate back end 226 of bottom wall 204 in deployed infant seat configuration 14 , whereas FIG. 1 and FIG. 18B illustrate the deployed bassinet configuration 12 . Infant recline/seat feature 222 includes a support strap assembly 214 of the type described for use with a stroller in U.S. Pat. No. 5,590,896 issued Jan. 7, 1997 to the same assignee as the instant application and the disclosure of which is incorporated herein by reference. Support strap assembly 214 includes straps 272 , 274 . Each strap 272 , 274 includes an end 276 , 278 , respectively, attached to upper annular edge 220 of annular side wall 206 by a seam, for example. In addition, each strap 272 , 274 has an end 280 , 282 to which a connector is attached. The connector may include any conventional easy connect connector such as a buckle as shown.
When straps 272 , 274 are connected to each other, they form a support raised above where bottom wall 204 of bassinet shell 202 would otherwise rest as illustrated by the comparison of FIGS. 18A and 18B, for example. In use, back end 201 of bottom wall 204 is raised to an angled position and straps 272 , 274 are interconnected to support back end 201 of bottom wall 204 in deployed infant seat configuration 14 . As illustrated in FIG. 1 and FIG. 18B, when straps 272 , 274 are not in use, they simply hang along side annular side wall 206 of bassinet shell 202 . Once straps 272 , 274 have been disconnected, the back end of bassinet shell 202 naturally returns to bassinet configuration 12 due to its own weight and gravity.
It is within the scope of the invention to raise and/or tilt bottom wall 204 of bassinet shell 202 in any manner desirable. For example, the front end of bassinet shell 202 may also include a strap and buckle connector that when joined will support front end 224 of bottom wall 204 of bassinet shell 202 in a raised position to provide an alternate seating position for the infant. A variety of known seat back recline mechanisms which could be adapted for use with the disclosed bassinet shell in ways apparent to the artisan.
Furthermore, in accordance with the invention and as also illustrated in FIGS. 15, 16 , 16 A, 17 , 18 A and 18 C, the infant product may also be constructed to provide additional lateral support at the back end of bassinet shell 202 to cradle the upper end of the infant in the deployed infant seat configuration 14 . This may be accomplished, for example, through the use of straps 272 , 274 , just described, in combination with the V-shaped notches 242 , 244 , 246 , 248 of elastic material formed in lower cover 234 and upper cover 232 , respectively, and V-shaped notches 258 , 260 in rigid panel 240 of bottom wall 204 . Accordingly, straps 272 , 274 can compress against and into bottom wall 204 to create lateral protuberances 271 , 273 (FIGS. 18A, 18 C) extending upwardly from otherwise planar back end 226 of bottom wall 204 . With protuberances 271 , 273 , the portion of bottom wall 204 corresponding to the upper body and head of an infant forms a V-shape or cradle (FIG. 18 A). When removable pad 216 is positioned on bottom wall 204 , removable pad 216 conforms to the shape of bottom wall 204 , thereby also forming a cradle shown generally at 217 in FIG. 18 A. Crease 292 facilitates the displacement of lateral edges 288 , 290 of removable pad 216 . As illustrated in FIG. 18B, when straps 272 , 274 are not connected, removable pad 216 is substantially flat.
This cradle feature may be implemented in variety of ways and is not limited to the structure described herein. For example, the back end 226 of bottom wall 204 may include a three-way fold, which may be implemented using a three-piece rigid back panel 240 . Another way to provide lateral support for an infant, which also may be used in accordance with the invention, is described in the context of a stroller in U.S. Pat. No. 5,441,328 issued Aug. 15, 1995, which has the same assignee as the instant invention and the disclosure of which is incorporated herein by reference.
Referring now to FIGS. 1 and 19 - 21 canopy 212 will be discussed in detail. Canopy 212 is attached to the back end of bassinet shell 202 and is convertible between an open tensioned position as shown, for example, in FIG. 1 and a closed relaxed position shown, for example, in FIG. 21 .
Canopy 212 generally includes fabric panel 300 , ribs or stays 302 , 304 and connectors 306 , 308 . Fabric panel 300 can be made of any lightweight material or cloth that is generally inelastic. Sewn into fabric panel 300 are sleeves 310 , 312 in spaced relationship into which stays 302 , 304 are threaded as illustrated in FIG. 19 . Accordingly, stays 302 , 304 are separated from each other. Stays 302 , 304 may be made of resilient material such as extruded plastic. Stays 302 , 304 , when inserted into sleeves 310 , 312 in fabric panel 300 hold the arcuate shape of canopy 212 . Connector 306 may include any suitable mechanism for releasably coupling front edge 320 of fabric panel 300 to a supporting structure so as to place fabric panel 300 in tension. Suitable connectors include buckles, hook-and-loop fasteners, zippers, magnetic catches, J-hooks, etc.
Canopy 212 is held in the open position by connectors 306 , 308 as illustrated in FIGS. 19A and 20. FIG. 19A shows connector 306 , for example, in a connected position and FIG. 20 shows connector 306 in a released position. Connectors 306 , 308 are identical, accordingly, only connector 306 is described in detail. Connector 306 includes tab 314 of cloth material sewn to front edge 320 of fabric panel 300 , a male snap 316 provided on tab 314 , and a female snap 318 provided on bassinet shell 202 . Accordingly, canopy 212 is held in the open tensioned position by engaging snaps 316 , 318 . When connectors 306 , 308 are released, canopy 212 is foldable into a flat configuration at back end 201 and rests along back rim tube 122 as illustrated in FIG. 21 .
Canopy 212 in accordance with the invention may be used on any type of infant product. For example, as illustrated in FIGS. 21A and 21B, canopy 212 may be provided on a conventional bouncer seat 400 . FIG. 21A shows canopy 412 in the flat closed position and FIG. 21B shows canopy 412 in the open expanded position. Accordingly, it is within the scope of the invention to use the canopy in a variety of infant products.
The Method of Folding and Unfolding the Infant Product
Referring now to FIGS. 22-25, the manner of converting frame 100 from deployed configuration 11 into compact folded configuration 16 will now be described. Of course, the steps would be performed in reverse to convert from compact folded configuration 16 into deployed configuration 11 .
To begin folding deployed configuration 11 , it does not matter whether bassinet shell 202 is in deployed bassinet configuration 12 or deployed infant seat configuration 14 . The method is a three-step folding process. First, front leg 104 is pivoted as illustrated by directional arrows in FIG. 22 about 180° to its folded position at which point front leg 104 detents against back leg brackets 112 , 114 .
Referring now to FIG. 23, secondly, back leg 106 is pivoted about 100° into its folded position at which point side legs 130 , 132 detent against the exterior side wall of housings 154 , 156 of structural hubs 108 , 110 .
Finally, thirdly, referring to FIGS. 24-25, front rim tube 116 is pivoted about 150° about structural hubs 108 , 110 until it is positioned substantially adjacent and rests on back rim tube 122 .
FIGS. 26-29 show the same conversion, but with the finished product, i.e., frame 100 and soft goods 200 .
In the compact folded configuration 16 , the infant product includes a generally flat configuration having an end 500 and a handle 504 which is formed by back leg 106 . End 500 may be slidably disposed within a carrying case 502 as illustrated in FIG. 31 . Accordingly, handle 504 which extends outwardly from carrying case 502 can be used for carrying the infant product in compact folded configuration 16 .
Carrying case 502 may be formed of nylon material and is used to protect and keep clean the folded infant device. When carrying case 502 is not in use, it may be stored on bassinet shell 202 . In particular, a pocket may be formed, for example, by sewing on bottom surface 230 of bottom wall 204 of bassinet shell 202 . Accordingly, carrying case 502 can be folded and slidably disposed within the pocket for storage during use of the infant product.
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The infant product of the invention is of the type having an infant receptacle suspended from a frame. The infant product is foldable between a deployed position for use and a compact configuration for shipping and storage. In the assembled configuration, the infant receptacle is convertible between a bassinet configuration in which the infant receptacle has a substantially planar support surface and an infant seat configuration in which the support surface of the infant receptacle is partially titled or disposed at an angle such that the infant can be supported in an elevated or seated position. The infant product may include a fabric canopy incorporating floating webs and a quick connect system for securing the canopy in an open position. When the canopy is closed, it is folded so as to lie flat against the infant receptacle. The infant receptacle may also include a lateral support assembly to cradle the infant.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Patent Application Ser. No. 60/130,916 filed on Apr. 23, 1999. The entire disclosure of the provisional application is considered to be part of the disclosure of the accompanying application and is hereby incorporated by reference.
GOVERNMENT GRANT
This invention was made with government support under a grant awarded by the National Heart, Lung, and Blood Institute, Grant No. PPGHL14985. The government has certain rights to this invention.
FIELD OF THE INVENTION
The present invention is directed to a method for treating pulmonary and systemic vascular diseases associated with cardiac hypertrophy, dysfunction, or failure, such method comprising administering effective amounts of a PKC antagonist to a patient suffering from one of such diseases. The methods may also be effective at directly treating airway and interstitial diseases of the lung that lead to the development of pulmonary hypertension. Other embodiments relate to particular formulations of bryostatin compounds formulated for particular diseases, as well as methods of using such compounds to treat patients having such diseases.
BACKGROUND OF THE INVENTION
Adult and neonatal pulmonary and systemic vascular disease is a common clinical problem. These vascular diseases include pulmonary and/or systemic hypertension, atherosclerosis, post-angioplasty re-stenosis, post-transplant vasculopathy, diabetic vasculopathy, peripheral vascular disease, vasculitis, and capillaritis. They are complicated by cardiac hypertrophy, dysfunction, or failure. These clinical problems characteristically include alterations in vascular structure, such as abnormalities in vessel wall thickness and/or vessel formation and/or obliteration, and alterations in vascular tone, such as abnormal contractile response to agonists. Myocardial hypertrophy, dysfunction, or failure are also often observed. These disease processes also cause important vascular cell responses in smooth muscle cells, adventitial fibroblasts, and endothelial cells that contribute to the disease process, including hypertrophy, proliferation, migration, matrix protein synthesis, permeability, and contraction. Inflammatory cell recruitment and activation is also though to be important in the pathogenesis of vascular disease.
Among these diseases is chronic hypoxic pulmonary hypertension (PHTN), which results from structural remodeling and abnormalities of vascular tone (Reeves and Herget, 1984; Haworth, 1993). The alteration in vascular structure results from changes in cellular hypertrophy, proliferation, apoptosis, differentiation, migration, permeability and matrix protein synthesis (Meyrick and Reid, 1979; Rabinovich, et al., 1981; Jones, et al., 1984; Stenmark, et al., 1987). The pulmonary hypertensive process has been observed in several species, including adult mice (Hales, et al., 1983; Klinger, et al., 1993; Steudel, et al., 1998; Fagan, et al., 1999).
The cellular and molecular mechanisms by which the pulmonary hypertensive process occurs are still poorly understood. However, it has been observed that protein kinase C (PKC) is involved in many of the vascular cell responses that contribute to the pulmonary hypertensive process (Komero, et al., 1991; Nishizuka, 1992; Haller, et al., 1994; Ways, et al., 1995). PKC is an important signal transduction pathway involving a family of at least 11 related intracellular kinases. One isozyme in particular, PKC-α, has been implicated in vascular cell responses to hypoxia (Goldberg, et al., 1997; Dempsey, et al., 1997, 1998; Xu, et al., 1997). On the basis of this assertion, as well as earlier studies, the PKC pathway has been presumed to be important in the pathogenesis of chronic hypoxic PHTN (Orton and McMurtry, 1990; Dempsey, et al., 1990, 1991; Xu, et al., 1997). Mechanisms that important here (like PKC) are also thought to play a critical role in other forms of PHTN, systemic vascular diseases, and various lung conditions like asthma, bronchiolitis, interstitial lung disease and lung injury.
It is, therefore, desirable to develop pharmacological strategies to attenuate chronic hypoxic pulmonary hypertension. One such strategy involves the PKC signal transduction pathway. One family of compounds that bind to PKC with high affinity is the bryostatins, a group of macrocyclic lactones isolated from marine bryozoans (Pettit et al., 1982; Kraft et al. 1986). In vitro, it has been found that bryostatin-1 inhibits cell growth and activity of isozymes of PKC, as well as inducing cell differentiation and apoptosis of a variety of transformed cell lines. Its effects on migration and contraction are unknown. Bryostatin-1 induces rapid inactivation and degradation of PKC in a cell-type-and isozyme-specific manner (Lee, et al., 1996, 1997; Blumberg, et al., 1997). In vivo, bryostatin-1 is known to accumulate in the lung in high concentrations. It is currently being tested in NCI-sponsored clinical trials for treatment of several types of malignancies (Zhang, et al., 1996; Caponigro, et al., 1997; Weitman et al., 1999).
SUMMARY OF THE INVENTION
In accordance with the present invention, bryostatin-1 has been tested in vitro in bovine pulmonary artery smooth muscle cells and in vivo in an adult murine model of vascular disease, specifically, chronic hypoxic pulmonary hypertension. The present invention relates to the discovery that bryostatin-1 can attenuate the development of chronic hypoxic pulmonary hypertension in adult ICR mice. The attenuating effects observed here on pulmonary vessels and the right ventricle of the heart are applicable to other types of pulmonary and systemic vascular and related disease. Other bryostatin derivatives could also have attenuating effects on these vascular disorders.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates abnormalities in vascular tone and structure that lead to chronic hypoxic pulmonary hypertension with representative slides of bovine lung tissue.
FIG. 2 is a diagram illustrating PA SMC proliferative response to hypoxia.
FIG. 3 is a bar graph illustrating pretreatment with bryostatin-1 attenuating hypoxic growth of adult bovine pulmonary artery (PA) smooth muscle cells (SMC) in vitro.
FIG. 4 is a bar graph illustrating that Go-6976, like bryostatin-1, inhibits hypoxia-induced PA SMC proliferation. Go-6076 inhibits activity of PKC-α and β in this preparation.
FIG. 5 is a bar graph illustrating that bryostatin-1 induced degradation of PKC-α is time dependent in bovine PA SMC.
FIG. 6 is a bar graph illustrating the dose-dependent effect of bryostatin-1 on degradation of PKC-α and hypoxic growth in bovine PA SMC.
FIG. 7 illustrates a gel showing that pretreatment with bryostatin-1 for 4 hours induces selective degradation of PKC-α in adult bovine PA SMC.
FIG. 8 illustrates chronic treatment of mice with bryostatin-1 decreases PKC-α protein levels in whole lung homogenates.
FIG. 9 illustrates a bar graph showing hematocrit levels in response to chronic hypoxia and bryostatin-1 administration.
FIG. 10 illustrates a bar graph showing the effect of hypoxia, vehicle and bryostatin-1 on right ventricular (RV) hypertrophy.
FIG. 11 illustrates a bar graph showing that subgroup analysis reveals a more marked attenuating effect of bryostatin-1 on hypoxia-induced right ventricular (RV) hypertrophy in a larger subgroup of adult ICR mice.
FIG. 12 is a bar graph illustrating preliminary data showing whole animal pre-treatment with bryostatin-1 blunts acute vasoconstrictor response to hypoxia.
FIG. 13 illustrates a bar graph showing the effect of hypoxia, vehicle and bryostatin-1 on initial right ventricular systolic pressure (RVSP) measurements.
FIG. 14 illustrates a bar graph showing the effect of chronic hypoxia and bryostatin-1 on right ventricular systolic pressure measurements made 0 vs. 48 hours after reintroduction to normoxia (Denver altitude).
FIG. 15 illustrates a bar graph showing the effect of bryostatin-1 attenuating early murine pulmonary vascular remodeling in response to chronic hypoxia.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
One aspect of the present invention relates to the specificity of bryostatin-like compounds with respect to cell type and PKC isozymes. In particular, bryostatin accumulates in lung tissue in high concentrations. It has been shown to inhibit cell growth and induces rapid inactivation and degradation of PKC. It binds to PKC with high affinity. The present inventor is the first to appreciate that bryostatin-1 will inhibit the hypoxic proliferative response in animals, and particularly mammals. For example, the inventor of the present invention is the first to appreciate that bryostatin-1 inhibits the hypoxic proliferative response of adult bovine PA SMC in vitro. Such inhibitory effect is mediated, at least in part, by inducing the degradation of PKC-α. The present inventor is also the first to appreciate that bryostatin-1 inhibits hypoxic growth and expression of selected PKC isozymes, in particular α-PKC, in vascular cells.
An effective agent for use in the present invention has one or more of the following characteristics: it upregulates growth, upregulates differentiation, upregulates apoptosis, down regulates contraction, down regulates migration and down regulates matrix protein synthesis. Agents having one or more of the above characteristics are potentially useful in decreasing vascular disease. Particularly preferred agents for use in the present invention include bryostatins which antagonize the signal transduction pathway important in vascular biology, such pathway including PKC.
Additional agents can be used in conjunction with the PKC antagonist described in the present invention, particularly bryostatin. In particular, combining PKC antagonists such as bryostatin with a second agent, such as tamoxifen, augments the results achieved using the PKC antagonist alone.
The method of the present invention can be used in any animal, and particularly, in any animal of the Vertebrate class, Mammalia, including, without limitation, primates, rodents, livestock and domestic pets. Preferred mammals to treat using the method of the present invention include humans.
The method of the present invention includes a step of administering an effective amount of a PKC antagonist, such as bryostatin or bryostatin derivatives (hereinafter collectively referred to as bryostatin, bryostatin-like compounds and/or PKC inhibitors or antagonists) to an animal that has, or is at risk of developing vascular diseases, including but not limited to chronic hypoxic pulmonary hypertension (CHPH), diabetes, ostheroscherosis, post-angioplasty, restenosis. According to the present invention, to inhibit vascular disease in an animal refers to inhibiting hypoxic growth and/or the expression of selected PKC isozymes, and in particular, α-PKC, due to the biological activity of bryostatin-like compounds. Inhibition of vascular disease according to the present invention can be accomplished by directly affecting the down-regulation of one or more CA 2+ -dependent isozymes by agents having bryostatin biological activity.
A further aspect of the present invention relates to the selective nature of bryostatin on inhibition of hypoxic growth. The down regulating effect of bryostatin is isozyme selective as evidenced by the fact that no degradation of other CA 2+ -dependent isozymes were expressed in adult cells nor were other CA 2+ -dependent isozymes detected (i.e.,δ,ε,ζ,ι,μ). Therefore, bryostatin inhibits hypoxic growth by a mechanism that is dependent upon PKC, and in particular, PKC-α. Reference to PKC-α should be understood to refer to all PKC. Bryostatin is therefore useful in attenuating abnormal SMC growth, both in vitro and in vivo.
As used herein, inhibition of vascular disease is defined herein as any measurable (detectable) reduction (i.e., decrease, down regulation, inhibition) of the biological activity of PKC. The biological activity or biological action of a bryostatin-like compound refers to any function(s) exhibited or performed by a naturally occurring form of a bryostatin compound as measured or observed in vivo (i.e., in the natural physiological environment of the compound) or in vitro (i.e., under laboratory conditions). According to the present invention, vascular disease is inhibited by directly inducing the proteolytic degradation of PKC. Preferably, vascular disease is inhibited by administering an agent including, but not limited to, an agent that binds to either and/or selectively degrades PKC and/or that interferes with the expression of PKC. Such an agent includes, but is not limited to bryostatin-like compounds, PKC antagonists and PKC antibodies.
Accordingly, the method of the present invention includes the use of a variety of agents (i.e., regulatory compounds) which, by acting to inhibit PKC activity, undesired hypoxic growth and vascular disease is reduced in an animal. Agents useful in the present invention include, for example, compounds, nucleic acid molecules, antibodies, and compounds that are products of rational drug design (i.e., drugs). Such agents are generally referred to herein as bryostatin-like compounds and include PKC degeneration compounds, bryostatin-1 and active moieties which form a portion of bryostatin that are effective in inhibiting, for example, the action of PKC-α. According to the present invention, a PKC inhibitor is any agent or mimetic which inhibits, either by direct inhibition or competitive inhibition, the expression and/or biological activity of PKC and includes agents which act similar to bryostatin.
As used herein, the term “mimetic” is used to refer to any peptide or non-peptide compound that is able to mimic the biological action of a naturally occurring PKC antagonist, such as bryostatin, often because the mimetic has a basic structure that mimics the basic structure of the naturally occurring compound and/or has the salient biological properties of the naturally occurring compound. Mimetics can include, but are not limited to: peptides that have substantial modifications from the prototype such as no side chain similarity with the naturally occurring compound (such modifications, for example, may decrease its susceptibility to degradation); anti-idiotypic and/or catalytic antibodies, or fragments thereof; non-proteinaceous portions of an isolated protein (e.g., carbohydrate structures); or synthetic or natural organic molecules, including nucleic acids and drugs identified through combinatorial chemistry, for example.
PKC inhibiting agents as referred to herein include, for example, compounds that are products of rational drug design, natural products, and compounds having partially defined PKC regulatory properties. A PKC regulatory agent can be a bryostatin-based compound, a carbohydrate-based compound, a lipid-based compound, a nucleic acid-based compound, a natural organic compound, a synthetically derived organic compound, an antibody, or fragments thereof. An effective PKC inhibitor of the present invention preferably has a structural configuration which enables biological associations with PKC that are effective to inhibit PKC activity. In one embodiment, PKC regulatory agents of the present invention include drugs, including peptides, oligonucleotides, carbohydrates and/or synthetic organic molecules which regulate the production and/or function of PKC. Such an agent can be obtained, for example, from molecular diversity strategies (a combination of related strategies allowing the rapid construction of large, chemically diverse molecule libraries), libraries of natural or synthetic compounds, in particular from chemical or combinatorial libraries (i.e., libraries of compounds that differ in sequence or size but that have the same building blocks) or by rational drug design. See for example, Maulik et al., 1997, Molecular Biotechnology: Therapeutic Applications and Strategies, Wiley-Liss, Inc., which is incorporated herein by reference in its entirety.
In a molecular diversity strategy, large compound libraries are synthesized, for example, from peptides, oligonucleotides, carbohydrates and/or synthetic organic molecules, using biological, enzymatic and/or chemical approaches. The critical parameters in developing a molecular diversity strategy include subunit diversity, molecular size, and library diversity. The general goal of screening such libraries is to utilize sequential application of combinatorial selection to obtain high-affinity ligands against a desired target, and then optimize the lead molecules by either random or directed design strategies. Methods of molecular diversity are described in detail in Maulik, et al., supra.
In a rational drug design procedure, the three-dimensional structure of a regulatory compound can be analyzed by, for example, nuclear magnetic resonance (NMR) or X-ray crystallography. This three-dimensional structure can then be used to predict structures of potential compounds, such as potential regulatory agents by, for example, computer modeling. The predicted compound structure can be used to optimize lead compounds derived, for example, by molecular diversity methods. In addition, the predicted compound structure can be produced by, for example, chemical synthesis, or by isolating a mimetope from a natural source (e.g., plants, animals, bacteria and fungi).
Various other methods of structure-based drug design are disclosed in Maulik et al., 1997, supra. Maulik et al. disclose, for example, methods of directed design, in which the user directs the process of creating novel molecules from a fragment library of appropriately selected fragments; random design, in which the user uses a genetic or other algorithm to randomly mutate fragments and their combinations while simultaneously applying a selection criterion to evaluate the fitness of candidate ligands; and a grid-based approach in which the user calculates the interaction energy between three dimensional receptor structures and small fragment probes, followed by linking together of favorable probe sites.
Another compound useful in the method of the present invention includes a fusion protein that includes at least one PKC antagonist (or a homologue or peptide mimetic thereof) attached to one or more fusion segments. Suitable fusion segments for use with the present invention include, but are not limited to, segments that can: enhance a protein's stability; act as an enhancer or inhibitor of the biological activity of a PKC antagonist; and/or assist with the purification of a PKC antagonist (e.g., by affinity chromatography). A suitable fusion segment can be a domain of any size that has the desired function (e.g., imparts increased stability, imparts increased biological activity to a protein, and/or simplifies purification of a protein). Fusion segments can be made susceptible to cleavage in order to facilitate recovery of an isolated protein comprising a PKC antagonist.
While the present invention, in one embodiment, is directed to the use of PKC antagonist compounds alone, it can also be used in combination with other agents, and particularly other vascular disease treating agents.
In accordance with the present invention, acceptable protocols to administer an agent including the route of administration and the effective amount of an agent to be administered to an animal can be accomplished by those skilled in the art. An agent (e.g., bryostatin-1) of the present invention can be administered in vivo or ex vivo. Suitable in vivo routes of administration can include, but are not limited to, oral, nasal, inhaled, topical, intratracheal, transdermal, rectal, and parenteral routes. Preferred parenteral routes can include, but are not limited to, subcutaneous, intradermal, intravenous, intramuscular, and intraperitoneal routes. Preferred topical routes include inhalation by aerosol (i.e., spraying) or topical surface administration to the skin of a mammal. An agent may be administered by nasal, inhaled, intratracheal, topical, or intravenous routes. Ex vivo refers to performing part of the administration step outside of the patient. Ex vivo methods are particularly suitable when the cell to which the agent is to be delivered can easily be removed from and returned to the patient.
According to the method of the present invention, an effective amount of a agent that inhibits PKC (also referred to herein simply as “an agent”) to administer to an animal comprises an amount that is capable of reducing vascular disease without being toxic to the mammal. An amount that is toxic to an animal comprises any amount that causes damage to the structure or function of an animal (i.e., poisonous).
A suitable single dose of a PKC inhibitory agent to administer to an animal is a dose that is capable of reducing or preventing vascular disease in an animal when administered one or more times over a suitable time period. For example, a suitable single dose of an agent comprises a dose that improves CHPH by a doubling dose of a provoking agent or improves the static respiratory function of an animal. A preferred single dose of an agent comprises between about 0.01 microgram×kilogram −1 and about 10 milligram×kilogram −1 body weight of an animal. A more preferred single dose of an agent comprises between about 1 microgram×kilogram −1 and about 10 milligram×kilogram −1 body weight of an animal. An even more preferred single dose of an agent comprises between about 5 microgram×kilogram −1 and about 7 milligram×kilogram −1 body weight of an animal. An even more preferred single dose of an agent comprises between about 10 microgram×kilogram −1 and about 5 milligram×kilogram −1 body weight of an animal. A particularly preferred single dose of an agent comprises between about 0.1 milligram×kilogram −1 and about 5 milligram×kilogram −1 body weight of an animal, if the an agent is delivered by aerosol. Another particularly preferred single dose of an agent comprises between about 0.1 microgram×kilogram −1 and about 10 microgram×kilogram −1 body weight of an animal, if the agent is delivered parenterally.
In one embodiment, the PKC-inhibitory agent is administered with a pharmaceutically acceptable carrier, which includes pharmaceutically acceptable excipients and/or delivery vehicles, for administering the agent to a patient (e.g., a liposome delivery vehicle). As used herein, a pharmaceutically acceptable carrier refers to any substance suitable for delivering a PKC-inhibitory agent useful in the method of the present invention to a suitable in vivo or ex vivo site. Preferred pharmaceutically acceptable carriers are capable of maintaining an agent of the present invention in a form that, upon arrival of the agent in the animal, the agent is capable of interacting with its target, such that vascular disease is reduced or prevented. Suitable excipients of the present invention include excipients or formularies that transport or help transport, but do not specifically target an agent to a cell (also referred to herein as non-targeting carriers). Examples of pharmaceutically acceptable excipients include, but are not limited to water, phosphate buffered saline, Ringer's solution, dextrose solution, serum-containing solutions, Hank's solution, other aqueous physiologically balanced solutions, oils, esters and glycols. Aqueous carriers can contain suitable auxiliary substances required to approximate the physiological conditions of the recipient, for example, by enhancing chemical stability and isotonicity.
Suitable auxiliary substances include, for example, sodium acetate, sodium chloride, sodium lactate, potassium chloride, calcium chloride, and other substances used to produce phosphate buffer, Tris buffer, and bicarbonate buffer. Auxiliary substances can also include preservatives, such as thimerosal, or o-cresol, formalin and benzol alcohol. Compositions of the present invention can be sterilized by conventional methods and/or lyophilized.
One type of pharmaceutically acceptable carrier includes a controlled release formulation that is capable of slowly releasing a composition of the present invention into an animal. As used herein, a controlled release formulation comprises an agent of the present invention in a controlled release vehicle. Suitable controlled release vehicles include, but are not limited to, biocompatible polymers, other polymeric matrices, capsules, microcapsules, microparticles, bolus preparations, osmotic pumps, diffusion devices, liposomes, lipospheres, and transdermal delivery systems. Suitable delivery vehicles have been previously described herein, and include, but are not limited to liposomes, viral vectors or other delivery vehicles, including ribozymes. Natural lipid-containing delivery vehicles include cells and cellular membranes. Artificial lipid-containing delivery vehicles include liposomes and micelles. As discussed above, a delivery vehicle of the present invention can be modified to target to a particular site in a patient, thereby targeting and making use of a PKC-inhibitory agent at that site. Suitable modifications include manipulating the chemical formula of the lipid portion of the delivery vehicle and/or introducing into the vehicle a targeting agent capable of specifically targeting a delivery vehicle to a preferred site, for example, a preferred cell type. Other suitable delivery vehicles include gold particles, poly-L-lysine/DNA-molecular conjugates, and artificial chromosomes.
A pharmaceutically acceptable carrier which is capable of targeting is herein referred to as a “delivery vehicle.” Delivery vehicles of the present invention are capable of delivering a formulation, including a PKC-inhibitory agent to a target site in a mammal. Additional delivery vehicles can include DMSO/phosphate buffered saline, PET diluent (for example, used by NCI for human trials), etc. A “target site” refers to a site in a mammal to which one desires to deliver a therapeutic formulation. For example, a target site can be any cell which is targeted by direct injection or delivery using liposomes, viral vectors or other delivery vehicles, including ribozymes. Examples of delivery vehicles include, but are not limited to, artificial and natural lipid-containing delivery vehicles, viral vectors, and ribozymes. Natural lipid-containing delivery vehicles include cells and cellular membranes. Artificial lipid-containing delivery vehicles include liposomes and micelles. A delivery vehicle of the present invention can be modified to target to a particular site in a mammal. Suitable modifications include manipulating the chemical formula of the lipid portion of the delivery vehicle and/or introducing into the vehicle a compound capable of specifically targeting a delivery vehicle to a preferred site, for example, a preferred cell type. Specifically, targeting refers to causing a delivery vehicle to bind to a particular cell by the interaction of the compound in the vehicle to a molecule on the surface of the cell. Suitable targeting compounds include ligands capable of selectively (i.e., specifically) binding another molecule at a particular site. Examples of such ligands include antibodies, antigens, receptors and receptor ligands. Manipulating the chemical formula of the lipid portion of the delivery vehicle can modulate the extracellular or intracellular targeting of the delivery vehicle. For example, a chemical can be added to the lipid formula of a liposome that alters the charge of the lipid bilayer of the liposome so that the liposome fuses with particular cells having particular charge characteristics.
One preferred delivery vehicle of the present invention is a liposome. A liposome is capable of remaining stable in an animal for a sufficient amount of time to deliver an agent described in the present invention to a preferred site in the animal. A liposome, according to the present invention, comprises a lipid composition that is capable of delivering an agent described in the present invention to a particular, or selected, site in a mammal. A liposome according to the present invention comprises a lipid composition that is capable of fusing with the plasma membrane of the targeted cell to deliver an agent into a cell. Suitable liposomes for use with the present invention include any liposome. Preferred liposomes comprise liposomes having a polycationic lipid composition and/or liposomes having a cholesterol backbone conjugated to polyethylene glycol. Also, the agents of the present can be delivered in a intra-dermal fashion.
In another embodiment, the method of the present invention is useful for treating any animal for the purposes of ameliorating vascular disease. The phrase, “to treat” a condition such as vascular disease in a patient refers to reducing, ameliorating or preventing the condition in a patient that suffers from the condition or is at risk of acquiring the condition. Therefore, in one embodiment of the present invention, “to treat” a disorder can also mean “to prevent” the disorder in a patient. Preferably, the condition, or the potential for developing the condition, is reduced, optimally, to an extent that the patient no longer suffers from the condition or to decrease the discomfort and/or altered functions and detrimental conditions associated with the disease. More particularly, “to treat” a condition associated with vascular disease includes the administration of PKC antagonist compounds as disclosed herein to prevent the onset of the symptoms or complications of such a condition, to alleviate the symptoms or complications, or to eliminate the condition.
The methods disclosed herein can also be used in conjunction with other methods related to the treatment of vascular disease or related conditions, including, but not limited to, coadministration of another vascular disease treating agent or compound.
The present invention also includes a formulation that reduces or prevents vascular disease in an animal. The formulation comprises: (a) an inhibitor of PKC selected from the group of: bryostatin, an agent which binds to a bryostatin receptor; a bryostatin-like compound having PKC (and particularly PKC-α) degradative capabilities, and an anti-inflammatory agent suitable for reducing CHPH in an animal that has, or is at risk of developing, CHPH.
Yet another embodiment of the present invention relates to a method to identify a compound that reduces or prevents vascular disease. Such a method includes the steps of: (a) contacting a putative regulatory compound with a cell that expresses PKC wherein in the absence of the putative regulatory compound, PKC can be expressed and is biologically active; (b) detecting whether the putative regulatory compound inhibits PKC expression or activity by the cell; and, (c) administering the putative regulatory compound to a non-human animal in which vascular disease can be induced and identifying animals in which vascular disease is reduced or prevented as compared to in the absence of the putative regulatory compound. A putative regulatory compound that inhibits PKC expression or activity and that reduces or prevents vascular disease in the non-human animal is indicated to be a compound for reducing or preventing vascular disease.
In this method, the step (b) of detecting can include, but is not limited to, a method selected from the group of measurement of PKC biological activity associated with the cell. Such methods of detecting an interaction of a ligand with a receptor, including the interaction of a ligand and PKC, are known in the art, and include immunoblots, phosphorylation assays, kinase assays, immunofluorescence microscopy, RNA assays, immunoprecipitation, and other biological assays.
As used herein, the term “putative” refers to compounds having an unknown or previously unappreciated regulatory activity in a particular process. As such, the term “identify” is intended to include all compounds, the usefulness of which as a regulatory compound of PKC expression or biological activity for the purposes of reducing vascular disease is determined by a method of the present invention.
The above-described methods for identifying a compound of the present invention include contacting a test cell or a cell lysate with a compound being tested for its ability to bind to and/or regulate the activity of PKC. For example, test cells can be grown in liquid culture medium or grown on solid medium in which the liquid medium or the solid medium contains the compound to be tested. In addition, as described above, the liquid or solid medium contains components necessary for cell growth, such as assimilable carbon, nitrogen and micro-nutrients.
The above described methods, in one aspect, involve contacting cells with the compound being tested for a sufficient time to allow for interaction of the putative regulatory compound with PKC. The period of contact with the compound being tested can be varied depending on the result being measured, and can be determined by one of skill in the art. For example, for binding assays, a shorter time of contact with the compound being tested is typically suitable, than when activation is assessed. As used herein, the term “contact period” refers to the time period during which cells are in contact with the compound being tested. The term “incubation period” refers to the entire time during which cells are allowed to grow prior to evaluation, and can be inclusive of the contact period. Thus, the incubation period includes all of the contact period and may include a further time period during which the compound being tested is not present but during which growth is continuing (in the case of a cell based assay) prior to scoring. It will be recognized that shorter incubation times are preferable because compounds can be more rapidly screened. A preferred incubation time is between about 1 minute to about 48 hours.
The conditions under which the cell or cell lysate of the present invention is contacted with a putative regulatory compound, such as by mixing, are any suitable culture or assay conditions and includes an effective medium in which the cell can be cultured or in which the cell lysate can be evaluated in the presence and absence of a putative regulatory compound. As may be appreciated, putative regulatory compounds preferably share structural characteristics with bryostatin and/or incorporate bryostatin as part of the compound.
Finally, a putative regulatory compound of the present invention can be evaluated by administering putative regulatory compounds to a non-human test animal and detecting whether the putative regulatory compound reduces vascular disease in the test animal. Animal models of disease are invaluable to provide evidence to support a hypothesis or justify human experiments. For example, mice have many proteins which share greater than 90% homology with corresponding human proteins. Preferred modes of administration, including dose, route and other aspects of the method are as previously described herein for the therapeutic methods of the present invention. The test animal can be any suitable non-human animal, including any test animal described in the art for evaluation of vascular disease.
Compounds identified by any of the above-described methods can be used in a method for the reduction or prevention of vascular disease as described herein.
It will be understood that the method and compounds as set forth in the present invention call for use in preventing, attenuating and reversing vascular disease. The present invention is therefore useful in ameliorating abnormalties of vessel formation for obliteration that may be the consequence of any particular vascular disease. It should also be appreciated that the agents used in the present invention, including not but not limited to bryostatin, and particularly bryostatin-1 and its derivatives, are useful to treat various pathogenesis of various forms of pulmonary hypertension, systemic vascular disease, and other forms of injury, inflammation and abnormal growth in the lung. The present invention is therefore useful for all forms of idiopathic primary and secondary (including hypoxic) pulmonary hypertension at rest or with exercise. In addition, the present invention is useful for treating earlier forms of vascular disease prior to the detectability of hypertension wherein only subtle structural changes or vascular disfunction may be apparent, resulting, for example, in hypoxemia out of proportion to pulmonary function testing. One particular use of the present invention is for the treatment of non-diabetic peripheral vascular disease. In addition to the above listed target cells to which the present invention relates, one will also understand that the present invention is useful in ailments involving inflammatory cell migration, recruitment, retention and activation in lung tissue. Various agents of the present invention, including bryostatin and bryostatin-1 in particular, are believed to have therapeutic effects on such cells. Such agents are also believed beneficial to affect various inflammatory states in view of the fact that inflammation is an important stimulus for vascular remodeling.
The PKC antagonist of the present invention, including bryostatin and in particular, bryostatin-1 and its analogs, are useful in the treatment of a variety of diseases including asthma and many forms of bronchiolitis, all forms of acute and chronic interstitial lung disease, injuries to lung tissues, and as a chemo-preventative agent for lung cancer (useful in the prevention of carcinogenisis as opposed to a treatment for transformed cells, such as lung cancer cells). While not bound by theory, the present inventor believes that because bryostatin-1 mimics and/or exceeds effects of heparin on the growth inhibition of vascular cells, and because heparin has been found in experimental systems to be useful in several of the above-referenced disease states and conditions, agents of the present invention are believed to have beneficial effects on the same or similar conditions as have been previously treated with heparin.
It should further be appreciated that the effects of the PKC antagonists as disclosed in the present invention have complex effects. As noted above, although the PKC antagonists, such as bryostatin, act as an initial activator of PKC, it can later inactivate and induce the degradation of various PKC isozymes. Thus, the effects of agents used in the present invention can be cell type specific, species specific and dose and time dependent. Due to the inter-relatedness and “cross talk” between PKC isozymes with other kinase cascades, and thus the regulation of various genes, the effects of bryostatin-like compounds in cells, organs and species are of significant breadth. Moreover, bryostatin compounds are believed to have effects that are not dependent upon PKC, but which are also believed to be clinically useful in treating one or more of the above-referenced disease states.
Bryostatin has various effects, as generally discussed above, on various isozymes of PKC. For example, PKC-α is very susceptible to degradation and is useful in testing the effects of bryostatin analogs in cell culture and in whole animal models. Bryostatin also induces degradation of PKC-β μ and given this isozymes importance in growth processes, bryostatin analogs can be used to effect such growth. PKC-β is less susceptible to degradation, but is also believed to be important in growth. At high doses of bryostatin, PKC-δ activates and protects such isozyme from degradation. At a low dose of bryostatin, however, it is believed that PKC-δ is degraded. The role of PKC-δ in vascular disease is believed to be growth inhibitory and pro-apoptotic and thus, the activation of such isozyme is believed to be beneficial. PKC-ε is believed to be important in contraction and growth and is susceptible to degradation by bryostatin in some cell systems.
With respect to various bryostatin analogs, one of skill in the art will understand that bryostatin analogs can be created in view of the structural analysis and rational design possibilities emanating from work directed to the binding properties of bryostatin-1, phorbol ester (PMC) and diacylglycerol to recombinant PKC-α. Indeed, PKC activation is believed to occur when one activator binds to a low affinity (DAG>phorbol>bryo) site alosterically promoting binding of a second activator to a high affinity (bryo>phorbol>DAG) site resulting in enhanced activity. Thus, an effective PKC antagonist of the present invention can be designed to bind to either one of the activator sites mentioned above in order to enhance and/or decrease activity, as desired. Other strategies for the design of novel ligands with bryostatin-like activities may be gleaned from the fact that bryostatin-1, at high doses, acts to protect PKC-δ from down-regulation induced by PMC. Site directed mutagenesis has been used to determine that the second cysteine-rich region of PKC-δ is important in binding phorbol esters and bryostatin-1. Site directed mutagenesis also evidences the importance of C1a and C1b phorbal esther binding domains of PKC-δ. Indeed, different selectivity of ligands has been found to have correlations with tumor promoting activities. Thus, the importance of C1a and C1b binding domains is that down-regulation by bryostatin is possible in a dose dependent protection fashion. C1 domain peptides that have been generated for all PKC isozymes can be used in the identification of desired bryostatin analogs. For example, preferred bryostatin analogs can be designed to retain putative recognition domains and can be simplified through deletions and/or modifications of C1-C14 spacer domains. The stereochemistry of C3 hydroxyl groups is believed to be important in the protection of bryostatin analogs having desired binding capabilities.
Finally, as one of ordinary skill in the art will appreciate, the various PKC antagonists and bryostatin analogs of the present invention can be used in combination with other agents to potentiate therapeutic effects, for example, by increasing apoptosis, decreasing growth, etc. Such other agents include estrogen-like derivatives like tamoxifen; chemotherapeutic agents like paclitaxel, vincristine and cisplatin; antitubulin agents like dolastatin 10 and amistatin PE; steroid hormones/vitamins like 1α, 25 dihydroxyvitamin D3; other PKC inhibitors like CGP41251 and staurosporine; immune modulators like interferon-γ; vasodilators like ACE inhibitors, calcium channel blockers, NEP inhibitors, ET antagonists and prostacyclin derivatives and other drugs that may exert attenuating effects on vascular (or airway or interstitial structure) structure like heparin.
Applicants incorporate by reference in their entireties the following U.S. patents to supplement the present written description of the present invention: U.S. Pat. Nos. 5,981,569; 5,886,195; 5,792,771; and 5,763,441. Additional patents are incorporated herein by reference which disclose various PKC modulators and inhibitors which, as one of ordinary skill in the art will recognize, could be used in the method of the present invention in place of and/or in conjunction with bryostatin compounds or bryostatin derivatives: U.S. Pat. Nos. 5,189,046; 5,744,460 and 5,648,238.
The following experimental results are provided for purposes of illustration and are not intended to limit the scope of the present invention.
Example 1
The effect of bryostatin-1 on hypoxic growth and PKC isozyme expression in adult bovine pulmonary artery smooth muscle cells was tested. Hypoxic growth was induced by priming with the PKC activator, 10 nM PMA. Proliferative response was measured by 3 H-thymidine incorporation and cell counts. Isozyme expression was measured by Western blot. Pretreatment with 10 to 100 nM bryostatin-1 for 4 or 24 hr inhibited the proliferative response to PMA and hypoxia (3% oxygen). Inhibitors of the Ca 2+ -dependent isozymes of PKC (1.0 μM GF1092203X and Go6976) had similar anti-proliferative effects. This data suggested that bryostatin-1 might be down-regulating one or more of the Ca 2+ -dependent isozymes in pulmonary artery smooth muscle cells. Therefore, the differential effects of bryostatin-1 on PKC isozyme expression were determined. bryostatin-1 (100 nM) rapidly induced the proteolytic degradation of PKC-α in smooth muscle cells, with degradation first detectable by 1 hour and complete by 24 hours. The threshold concentration to induce degradation was 10 nM, with a maximal effect at 50 to 100 nM. This same amount of bryostatin had been found to inhibit hypoxic growth. The down-regulating effect of bryostatin-1 was isozyme-selective. No degradation of the other Ca 2+ -dependent isozyme expressed in these adult cells (βI) or five other Ca 2+ -independent isozymes was detected (δ,ε,ζ,ι,μ). These results suggest that bryostatin-1 inhibits hypoxic growth of PA SMC by a mechanism that is dependent on PKC-α and may be useful in attenuating abnormal smooth muscle cell growth both in vitro and in vivo. See L. J. Ruff and E. C. Dempsey, “BRYOSTATIN-1 ATTENUATES HYPOXIC GROWTH OF BOVINE PULMONARY ARTERY SMOOTH MUSCLE CELLS IN VITRO,” FASEB J 12:A339, 1998.
Example 2
Bryostatin-1 was tested in a murine model of chronic hypoxic PHTN. Adult ICR mice were exposed to normoxia (N) (5,200 ft, Denver altitude) or hypoxia (H) (18,000 ft) for 4 weeks and received either no treatment (n=15-20), vehicle (DMSO; n=8), or bryostatin-1 at 11 or 33 μg/kg/d (n=13 and 7-10, respectively), delivered intraperitoneally. Hematocrit (Hct [%]), RV/LV+S, and RV systolic pressure (RVSP [mmHg]) were measured under normoxic conditions at 0 or 48 hr following removal from chamber. The results are shown in Table I. Chronic hypoxia caused an increase in Hct which was unchanged by vehicle or bryostatin-1. Hypoxia induced a rise in RV/LV+S and in RVSP. Initial (0 hour) measurements of RVSP following hypoxia in vehicle and drug treated groups were not different. However, when the measurements were made 48 hours later, an attenuating effect of bryostatin-1 on the hypoxia-induced increase in RVSP was detected. In conclusion, bryostatin-1 had attenuating effects in an adult murine model of chronic hypoxic pulmonary hypertension and is believed to be a useful pharmacological tool for the treatment this important clinical problem.
TABLE I
Effects of hypoxia on hematocrit, RV hypertrophy, and RVSP.
No
DMSO
bryostatin-1
bryostatin-1
treatment
vehicle
11 μg/kg/d
33 μg/kg/d
(n = 5-20)
(n = 8)
(n = 13)
(n = 6-10)
Hematocrit, %
39 ± 1
36 ± 2
35 ± 1
38 ± 4
N
51 ± 1
49 ± 1
48 ± 1
50 ± 3
H
RV hyper-
trophy (RV/
LV + S),
*p < .05
0.29 ± 0.02
0.25 ±
0.28 ± 0.01
0.26 ± 0.06
N
0.41 ± 0.02
0.02
0.36 ± 0.02
0.34 ± 0.05
H
0.40 ±
0.02
RVSP, 0 hours
N
31 ± 1
H
42 ± 2
RVSP, 48
hours,
*p < .05
31 ± 3
30 ± 2
N
40 ± 2
34 ± 2
H
See L Ruff, KE Grever, KA Fagan, IF McMurtry, AS Kraft, GR Pettit, and EC Dempsey, “ATTENUATING EFFECTS OF BRYOSTATIN-1 IN AN ADULT MURINE MODEL OF CHRONIC HYPOXIC PULMONARY HYPERTENSION,” Abstract from American journal of respiratory and critical care medicine, Vol. 159, A163, March, 1999.
Based on these results, bryostatin compounds are shown to be useful in preventing, attenuating, and/or reversing abnormalities in cardiovascular structure and function.
While various embodiments of the present invention have been described in detail, it is apparent that further modifications and adaptations of the invention will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention.
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A method for treating pulmonary and systemic vascular diseases associated with cardiac hypotrophy, dysfunction or failure that involves the administration of an effective amount of a PKC antagonist to a patient suffering from one of such diseases is disclosed. PKC antagonists are selected from bryostatin derivatives and more preferably from bryostatin-1. The disease states treatable in accordance with the present invention are characterized by alterations in vascular structure, vascular tone, myocardial hypotrophy, dysfunction or failure, idiopathic pulmonary hypertension and chronic hypoxic pulmonary hypertension. Particular formulations include bryostatin-1 in an effective amount to treat one or more of the above-referenced diseases.
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BACKGROUND OF THE INVENTION
1. Field Of The Invention
The present invention relates to gas turbine engines, notably for aeronautical applications, comprising a low-pressure spool and a high-pressure spool. It is aimed at the layout of the bearings which, within the engine casing, support the LP and HP shafts and, more particularly, at the downstream bearings.
2. Description Of The Related Art
A twin-spool or two-body gas turbine engine comprises a first rotary assembly, known as the low-pressure (BP) spool, formed of a shaft connecting an LP compressor at the upstream end, upstream and downstream being defined with respect to the flow of air through the machine, and an LP turbine at the downstream end. Each of the compressor and turbine elements may be made up of one or more stages. The two LP elements are spaced axially apart and leave a space for a second rotary assembly known as the high-pressure (HP) spool, formed of an HP compressor located downstream of the LP compressor, and of an HP turbine located upstream of the LP turbine. The HP compressor and the HP turbine are mechanically connected to one another by a connecting member in the form of a drum. The combustion chamber of the engine, which is stationary with respect to the two spools, is annular and housed circumferentially around said drum. It receives compressed air from the compressors of the LP stages and of the HP stages in turn, and delivers high-energy combustion gases to the HP and LP turbine stages in turn. The engine may comprise a fan rotor at the front, driven by the shaft of the LP spool. Other layouts are known.
A known engine such as the CFM56 comprises structural casing elements notably supporting the rotary assemblies via bearings. On the upstream side, a casing element, known as the intermediate casing, comprises a hub supporting the LP shaft via an upstream LP bearing. On the downstream side, a casing element known as the exhaust casing also comprises a hub supporting the LP shaft via a downstream LP bearing. The HP spool is supported by the LP shaft on the downstream side using an inter-shaft bearing.
An engine mounted on an aircraft experiences transverse dynamic loadings when the aircraft undertakes direction-change maneuvers. With such a bearing layout and for engine embodiments notably in which the length is great with respect to the slenderness of the shaft of the low pressure LP spool, the present applicant has analyzed the behavior of the HP and LP rotors when the engine is subjected to such maneuvering loadings. The transverse movement of the rotors along the engine axis is a critical parameter inasmuch as this movement has a direct influence on how the clearances between the tips of the blades and the stator rings are taken up. These clearances have to be kept at low values if optimum performance is to be maintained.
BRIEF SUMMARY OF THE INVENTION
The applicant has therefore set itself the objective of reducing the radial clearances at the tips of the compressor and turbine rotor blades under maneuvering loadings.
More particularly, the applicant has set itself the objective of improving the layout of the bearings that support the rotors in a twin-spool gas turbine engine with a view to reducing the transverse movements along the axis of the engine when the engine, mounted on an aircraft, is subjected to maneuvering loadings.
Such an objective is achieved, according to the invention, with a twin-spool gas turbine engine comprising a low-pressure LP spool and a high-pressure HP spool, which spools are mounted so that they can rotate about the same axis in a fixed casing of the engine, the low-pressure spool having an LP compressor and an LP turbine which are connected by a low-pressure LP shaft, said LP shaft being supported by an upstream LP bearing, and a first downstream LP bearing in structural casing elements, the HP spool being supported by an upstream HP bearing and a downstream HP bearing, said engine being characterized in that the LP shaft is supported downstream, in a structural casing element, by an additional downstream LP bearing.
The additional downstream LP bearing, in collaboration with the downstream LP bearing, allows better nesting of the LP shaft with respect to the downstream casing element.
According to another feature, the additional downstream LP bearing is located upstream of said downstream LP bearing. Thus, the additional downstream LP bearing is of a diameter greater than that of said downstream LP bearing.
It is notably also of a diameter greater than that of the downstream HP bearing, the downstream HP bearing being an inter-shaft bearing fitted between the LP shaft and the HP rotor, the HP spool being supported by the LP shaft.
According to one embodiment, the additional downstream LP bearing is positioned axially between the downstream HP bearing and the downstream LP bearing.
According to another embodiment, the downstream HP bearing and the additional downstream LP bearing are positioned in respective transverse planes that are close to one another.
Advantageously, with the downstream LP bearing and the additional downstream LP bearing being supported by the same structural casing element, said structural casing has radial-stiffening means. More particularly, said structural casing element forms the structural exhaust casing.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Other features and advantages of the invention will become apparent from reading the following description of one embodiment of the invention, given solely by way of nonlimiting example, with reference to the attached drawings in which:
FIG. 1 is a schematic axial half section of a gas turbine engine with a front fan, according to the prior art,
FIG. 2 depicts the downstream part of the engine of FIG. 1 in greater detail,
FIG. 3 is an axial half section of the rear part of the engine comprising an additional downstream LP bearing according to the invention,
FIG. 4 depicts the circulation of bearing chamber ventilation air according to the invention,
FIG. 5 depicts an alternative layout of the bearings according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The gas turbine engine 1 of FIG. 1 comprises, inside a casing and from upstream to downstream, a front fan 3 of which some of the air flow that it compresses is ejected into the atmosphere and a radially interior portion is guided through the engine. The latter comprises, in succession, a plurality of compressor stages forming the low-pressure (LP) compressor 4 , then the stages of the high-pressure (HP) compressor 5 . The air enters a diffuser via which it is admitted into the combustion chamber 6 . Downstream of the combustion chamber, the combustion gases are guided through the high-pressure HP turbine 7 then through the stages of the low-pressure LP turbine 8 ; finally, the gases are ejected into the atmosphere via a jet pipe nozzle not depicted.
Structurally, the rotor of the LP compressor 4 and that of the LP turbine 8 are mechanically connected by an LP shaft 9 thus forming the LP spool 9 C. The rotor of the HP compressor 5 and the rotor of the HP turbine 7 form, together with the drum 10 that mechanically connects them, the HP spool 10 C. The casing 2 , in which the two, LP and HP, spools 9 C and 10 C are mounted, comprises a plurality of elements including, as far as the present invention is concerned, an upstream casing element known as the intermediate casing 21 , and a downstream casing element known as the exhaust casing 2 E. These two casing elements are structural inasmuch as the forces between the engine and the structure of the aircraft pass through them. They are formed of a central hub and of radial arms crossing the gas duct that connects the hub to an outer shell ring.
The rotary assemblies are supported in the hubs by a set of bearings; the LP shaft 9 here is connected to the fan shaft which is supported by a bearing P 1 . The LP shaft 9 is supported on the upstream side by a bearing P 2 . These two bearings P 1 and P 2 are themselves supported by the intermediate casing 21 . The LP shaft is supported on the downstream side by a bearing denoted P 5 , itself mounted on the exhaust casing 2 E. The HP spool 10 C is supported by the LP shaft 9 via the inter-shaft bearing P 4 , on the downstream side. It is supported on the upstream side by the bearing P 3 mounted in the intermediate casing.
FIG. 2 shows the rear part of the engine in greater detail. The shaft 9 of the LP spool 9 C passes through the disk of the HP turbine 7 . It is supported by the bearing P 5 in an element 2 E 1 of frustoconical shape of the hub of the exhaust casing 2 E. It comprises a cage with rolling bearings held between an inner raceway secured to an end journal 9 C 1 of the LP shaft 9 and an outer raceway secured to the frustoconical hub element 2 E 1 . The rotor of the LP turbine 8 is secured to the LP shaft 9 .
Further upstream, the inter-shaft bearing P 4 comprises a cage with rolling bearings which is mounted between an inner raceway secured to the LP shaft 9 and an outer raceway secured to a journal 10 C 1 at the end of the HP spool 10 C and, more specifically, attached to a flange of the HP turbine disk 7 .
One embodiment of the invention, which is derived from the bearing arrangement of the prior art illustrated in FIG. 2 , will now be described with reference to FIG. 3 .
In this FIG. 3 , the HP and LP turbines 7 and 8 respectively are unchanged with respect to FIG. 2 . The LP shaft is referenced 19 . On its downstream end side it has a journal 19 C 1 which here is an attached journal but which could also be of one piece with the LP shaft. The journal comprises a part 19 C 1 A which is in the continuation of the LP shaft 19 and of substantially the same diameter. It comprises another part 19 C 1 B, of greater diameter, attached by a radial portion 19 C 1 C to the first part 19 C 1 A of the journal.
The hub of the exhaust casing 12 E comprises two frustoconical portions 12 E 1 and 12 E 2 forming supports for two bearings P 5 ′ and P 6 respectively. The bearing P 5 ′ is positioned between the part 19 C 1 A of the journal of the LP shaft 19 and the frustoconical portion 12 E 2 . It comprises a rolling-bearing cage mounted between an inner raceway or ring secured to the journal part 19 C 1 A and an outer raceway or ring secured to a cylindrical continuation 12 E 10 of the frustoconical portion 12 E 1 of the exhaust casing hub.
The bearing P 6 is mounted between the larger-diameter cylindrical part 19 C 1 B of the journal 19 C 1 and a cylindrical continuation 12 E 20 of the frustoconical portion 12 E 2 of the exhaust casing hub. Stiffening ribs, in radial longitudinal planes 12 E 3 and distributed about the axis of the engine, are formed between the two frustoconical portions to improve the resistance to the radial forces to which these two frustoconical portions are subjected at their upstream end. The hub also comprises longitudinal and radial ribs 12 E 4 distributed about the axis of the engine.
The journal 19 C 1 comprises a cylindrical portion 19 C 1 D extending the cylindrical portion 19 C 1 A upstream and slipped over exterior bearing surfaces of the shaft 19 . The inter-shaft bearing P 4 is housed in the annular space between the two cylindrical portions 19 C 1 B and 19 C 1 D. This bearing comprises a rolling-bearing cage mounted between a raceway or ring secured to the journal 1001 situated at the downstream end of the HP rotor 10 C and an outer raceway or ring secured to a ring 19 C 1 E, which is itself mounted on the journal 19 C 1 inside the cylindrical portion 19 C 1 B.
As can be seen in FIG. 3 , the journal 10 C 1 is fixed to a downstream flange of the HP turbine disk 7 . The journal 19 C 1 of the LP shaft 19 is bolted, by a radial flange external to the cylindrical portion 19 C 1 B, to a cone 8 C attached to one of the disks of the LP turbine rotor 8 . The LP turbine rotor here is made up of four turbine disks assembled into a single turbine unit.
The lubrication is shown in FIG. 4 . A chamber for lubrication oil is formed by labyrinth fields positioned between the parts that move relative to one another.
Thus, on the upstream side of the set of bearings P 4 , P 5 ′ and P 6 , there are labyrinth seals L 1 between the journal 10 C 1 of the HP rotor and the HP shaft 10 , L 2 between the journal 10 C 1 and the journal 19 C 1 of the LP shaft 19 , L 3 between the cone 8 C of the LP turbine rotor and the hub of the exhaust casing 12 E. On the downstream side, the labyrinth seal L 4 closes the chamber between the LP shaft 19 and the hub of the exhaust casing 12 E.
The arrows F 1 , F 2 , F 3 , F 4 and F 5 illustrate the flow of pressurizing air bled off upstream and by means of which the bearing chamber is kept pressurized in relation to the pressure obtaining in the low-pressure turbine stages. The oil admitted by appropriate ducts is sprayed over the rolling bearings in a way known per se and is removed via the inside of the LP shaft 19 which comprises an oil separator that has not been depicted.
This version seeks to keep the components that already exist in engines of the prior art so that the least possible amount of modification is needed. In particular, the inter-shaft bearing P 4 is mounted on the journal 10 C 1 which has not been modified. The bearing P 4 is thus upstream of the bearing P 6 .
According to an alternative form of embodiment depicted in FIG. 5 , the bearing P 4 is moved further downstream so that it lies substantially in the same transverse plane as the bearing P 6 . To do this, the journal at the end of the HP rotor is lengthened. This journal is referenced 110 C 1 in FIG. 5 . The journal of the LP shaft is also modified by comparison with the solution of FIG. 3 .
The solution of the invention is advantageous over the prior art in which the HP turbine journal is positioned externally with respect to the inter-shaft bearing.
In the latter instance, because the running speed of the HP turbine is greater than that of the LP turbine shaft mounted on the inside, this component is caused to expand.
In order to guarantee normal operating clearances for the inter-shaft rolling bearing, this bearing has to be mounted constrained between the LP turbine shaft and the HP turbine journal.
On assembly, as the LP turbine mates with its shaft on the HP spool module, the HP turbine journal fitted with the outer ring of the rolling bearing has to be heated to cause it to expand and allow the fitting of the LP turbine shaft fitted with the inner ring and with the rolling bodies of this same rolling bearing. Assembly is awkward.
With the solution of the invention, the HP turbine journal is positioned further toward the inside than the inter-shaft bearing and the LP turbine shaft further toward the outside of this same rolling bearing.
Thus, unlike an assembly of the type used in the prior art, the LP turbine fitted with its shaft, itself fitted with the outer ring of the inter-shaft rolling bearing, is mated with the HP turbine journal fitted with the inner ring and with the rolling bodies of the bearing, with clearance. There is therefore no need to heat the HP turbine journal. Assembly is thereby made easier. The clearance in the cold state is calculated to guarantee correct operation of the rolling bearing, according to the mechanical and thermal stresses of the whole and with due consideration to the fact that the running speed of the HP turbine journal is greater than that of the LP turbine shaft.
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A double-body gas turbine engine, including a low-pressure body LP and a high-pressure body HP, rotatably mounted about a single shaft in a stationary casing, the low-pressure body LP including a compressor and a turbine connected by a low-pressure shaft LP. The low-pressure shaft LP is supported by an upstream LP bearing, a first downstream LP bearing, and an additional downstream LP bearing by the stationary casing, the high-pressure body being supported by an upstream HP bearing and a downstream HP bearing which is an inter-shaft bearing including an inner track rigidly connected to the HP turbine rotor and an outer track rigidly connected to the LP shaft.
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FIELD OF THE INVENTION
The present invention relates to a dispenser cathode, and particularly to a cavity reservoir type dispenser cathode in which the activation aging time is shortened greatly.
BACKGROUND OF THE INVENTION
The reservoir type dispenser cathode comprises an electron emissive material made by press-molding tungsten and barium calcium aluminate, a porous metal base body positioned on the upper portion of the electron emissive material and provided with the diffusing cavity for diffuse Ba, a container storing the electron emissive material, and a sleeve supporting and fixing said container and enclosing the heater.
Some additives are added to the porous metal base body and the electron emissive material based on the above mentioned basic structure or material in order to lower the operating temperature of the cathode or enhance the current density. For example, as described in U.S. Pat. No. 4,823,044, issued to Ceradyne, Inc., suitable amount of Ir, Os, Ru, Re, etc., permeates into the porous metal base body. This cavity reservoir type dispenser cathode is inexpensive in manfacturing cost and has the current density of over 10 A/cm 2 .
But the aforesaid cavity reservoir type dispenser cathode is disadvantageous in that the time required for activation aging i.e., the time required for forming monatomic layer on the inner wall and the surface of the cavity of the porous metal base body is as long as approximately 10 to 30 hours, thereby decreasing the productivity of the product. The reason why the time required for the activation aging is lengthened is that diffuse Ba from the electron emissive material is diffused gradually through the cavity of the porous metal base body positioned on the electron emissive material and lastly it reaches the surface of the porous metal base body. In more detail, when diffuse Ba generated by thermal energy from the heater passes through the cavity and the monatomic layer is formed gradually on the surface of the porous metal body, the monatomic layer is not formed on the surface of the porous metal base body until Ba layer is sufficiently formed on the inner wall of the cavity (i.e. until the concentration thereof reaches the state of the saturation.).
To overcome these problems, there is a method to increase the produced amount of Ba. However, this method should increase the heat amount generated from the heater and therefore may shorten the lifetime of the heater and vaporize excessive amount of Ba. Thus, the lifetime of the cathode itself i.e. the time which can maintain the thermal electron emission for a long period may be short. Further, if vaporized Ba which does not contribute to form the monatomic layer is attached to a part of the periphery of the cathode, the lowering of the performance and the deterioration of the product itself are resulted.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a dispenser cathode which maintains an electron emission for a longer period and shortens the activation aging time greatly.
To accomplish the above object, the dispenser cathode according to the present invention comprises an electron emissive material and a porous metal base body, wherein said electron emissive material contains a suitable amount of BaAl 4 and Ni and includes barium calcium aluminate as base material.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and other advantages of the present invention will become more apparent by describing the preferred embodiment of the present invention with reference to the attached drawings, in which:
FIG. 1 is a cross-sectional view of the cavity reservoir type dispenser cathode.
FIG. 2A is an extracted cross sectional view of the porous metal base body positioned on the upper portion of the electron emissive material in the reservoir type dispenser cathode, wherein monatomic layers are not formed on the inner wall of the cavity of the porous metal base body and its surface.
FIG. 2B is an extracted cross sectional view of the porous metal base body positioned on the upper portion of the electron emissive material in the reservoir type dispenser cathode, wherein monatomic layer are formed on the inner wall of the cavity of the porous metal base body and its surface.
FIG. 3 illustrates the comparative line diagram of the current density versus time and temperature when the activation aging of a dispenser cathode of the present invention and the conventional dispenser cathode are carried out.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a cross-sectional view of the cavity reservoir type dispenser cathode of the present invention. In the drawing, the above dispenser cathode comprises an emissive material 2 stored in a reservoir 3, a porous tungsten metal base body 1 disposed on the top of the electron emissive material 2, and a sleeve 4 supporting and fixing these and enclosing a heater 5.
Said electron emission material 2 is prepared by mixing barium calcium aluminate, BaAl 4 powder, Ni powder and W powder and then press/molding the mixture into a predetermined shape, in which the amount of said BaAl 4 +Ni powder is preferably 5 to 30 wt % and within this range, the property of said material 2 does not vary. However, if the amount of said BaAl 4 +Ni powder is above 30 wt %, the characteristics of the cathode is lowered because Ba producing reaction proceeds suddenly at the beginning of the activation and a molten material is formed by a temperature rise caused by a reaction heat.
Said barium calcium aluminate is prepared by mixing BaCO 3 , CaCO 3 and Al 2 CO 3 powder at a mole ratio of 4:1:1 and baking them.
A metal powder mixture in said mixing ratio is shaped into an electron emissive material 2 contained in the reservoir 3 by using a press zig.
The porous metal base body 1 disposed at the top of the electron emissive material 2 is fabricated by press-molding and sintering heat resistant metal powder such as tungsten, and then is fixed to the reservoir 3 by welding.
The electron emissive material thus formed includes BaAl 4 and Ni powder, so it can produce a monatomic layer rapidly through activation aging.
FIG. 2A illustrates the porous metal base body prior to activation aging, in which the cavity 1a of porous metal base body 1 maintains its original state formed during fabricating process.
FIG. 2B illustrates the porous metal base body after activation aging, in which Ba layer 6a is formed in the inner wall of the cavity 1a and a monatomic layer 6 consisting of Ba--W--O is formed on its surface.
In more detail, BaAl 4 and Ni included in an electron emissive material during this activation aging are reacted suddenly at a temperature of about 700° C. and produces evaporated Ba and 4 AlNi. The reaction of barium calcium aluminate and tungsten which is a reducing agent by thermal energy generated from a heater and the reaction of BaAl 4 and Ni produce an evaporated Ba.
At this time the chemical reaction formula is as follows.
BaAl.sub.4 +4Ni→4AlNi+Ba↑
Thus, Ba layer 6a is formed by a sufficient evaporated Ba through the cavity 1a of porous metal base body 1 and a monatomic layer 6 is formed by evaporated Ba reacting the surface of porous metal base body 1.
FIG. 3 illustrates the comparative line diagram of the current density versus time and temperature, when the activation aging of a dispenser cathode of the present invention and the conventional dispenser cathode are carried out.
As can be seen from FIG. 3, the activation aging time of the conventional dispenser cathode, which is required for the current density to reach more then approximately 2.4 A/cm 2 , is 10 hours and that of the present invention is 2 hours.
As described above, the dispenser cathode according to the present invention can shorten aging time by promoting the activation aging function of BaAl 4 and Ni, in which production of the cathode per unit hour increases and also its lifetime is lengthened due to the increase of Ba production.
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A dispenser cathode comprises an electron emissive material containing BaAl 4 and Ni, the porous metal base body and a sleeve. The activation aging time of the dispenser cathode according to the present invention is shortened greatly as compared with the conventional dispenser cathode and therefore, the productivity can be increased.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method of increasing productivity and recovery of wells in oil and gas fields.
[0002] Method of the above-mentioned general type are known. A method of hydraulic fracture of underground layers for formation of horizontal slots is known, as disclosed for example in U.S. Pat. No. 3,965,982. In this method upper and lower packers are installed in a well opposite to the layer in contact with a surface of the layer.
[0003] Another method for increasing permeability of productive layers is based on introduction of clay wedging agent into a fluid, as disclosed in U.S. Pat. No. 3,976,138.
[0004] A further method is used for producing hydraulic fracture in productive layers with the use of viscous solutions of surface-active substances, as disclosed for example in U.S. Pat. No. 4,007,792. With this method a pressure in the well is increased to a value causing formation of cracks in the rock, and the pressure is maintained between 0.5 and 6 hours. The pressure is then reduced, and the material is removed from the well.
[0005] Also, a method of multiple fracturing of underground layers is known, in which in order to fracture the layer which is opened by a well, a working fluid is pumped through the well into the layer, and a particulate wedging material is introduced into the cracks. Then a working fluid is pumped through the well into the layer until the layer is fractured, and the particulate wedging material is introduced into the newly formed crack. This method is disclosed in U.S. Pat. No. 3,998,271.
[0006] A further method of “wedging” of cracks in productive layers includes introduction of a viscous fluid, so that the hardenable fluid penetrates into the cracks and is retained in them. Then the introduction of the viscous fluid is stopped so that the crack remains open until the hardenable fluid hardens and spreads the crack. This method is disclosed in U.S. Pat. No. 4,029,149.
[0007] Finally, a method for fracturing of productive layers by means of an acid foam is known as well. In accordance with this method a gel-like solution having a certain pressure and containing a surface active substance and an inert gas is introduced for forming slots in the layer. This method is disclosed in U.S. Pat. No. 4,044,833. Other methods are known as well.
[0008] The known methods are based on the concept of creating a hydraulic connection between a productive layer and a group of layers in a well through a low-permeable or practically impermeable near-well zone which is characterized by increased concentrations of stresses. Even if the near-well zone in the area of a productive layer does not have a poor permeability, the use of hydrofracturing not always leads to positive results. As a rule, the direction of the hydrofracturing changes along the layer, which leads to connection of the layer with water-carrying horizons and stops an industrial flow of oil/gas. In this case it is also not possible to connect simultaneously several wells for performing corresponding works.
SUMMARY OF THE INVENTION
[0009] Accordingly, it is an object of the present invention to provide a method of increasing productivity and recovery of wells in oil and gas fields, which is an improvement of the existing methods.
[0010] In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a method of increasing productivity and recovery of wells in oil and gas fields, comprising the steps of determining a direction of maximal horizontal stresses; producing at least two wells so that they are spaced from one another in a direction corresponding to the direction of the maximum horizontal stresses; forming in at least one of the wells at least one vertical slot oriented substantially from said at least one well toward the other of the wells; and introducing a hydrofracturing fluid at least into said least one well to produce a hydraulic fracture in direction from said at least one well toward said other well.
[0011] When the method is performed in accordance with the present invention, a significantly improved interaction of two wells is provided and therefore the productivity and recovery of the wells in gas and oil fields is increased.
[0012] In accordance with a further feature of the present invention, slots are formed in two wells and they are directed toward one another, and in particular in direction of the maximum horizontal stresses, and the hydrofracturing fluid is introduced in both wells, which further improves the efficiency of the method.
[0013] In accordance with still a further feature of the present invention, additional vertical slots are provided so as to extend substantially perpendicular to the first mentioned slots, with a length corresponding to a part of the length of the above mentioned first main slots, so as to increase a draining surface in the well without affecting the stress condition created by the first mentioned slots.
[0014] In accordance with still a further feature of the present invention the method further includes analyzing a plurality of layers; and performing the formation of the slots in a layer which is most efficient for compensating expenses for the slot formation. Therefore, all the expenses related to the process are compensated in the shortest possible time.
[0015] In accordance with still a further feature of the present invention, the method includes forming a slot with a slot forming medium; and supplying the slot-forming medium with a maximum pressure producible by an equipment located on a ground. It has been found that when the cutting of slots is performed, (contrary to a universally accepted principle using a pressure calculated in correspondence with the required criteria for cutting,) with a maximum pressure allowed by the equipment, it further increases the productivity.
[0016] The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a plan view schematically illustrating a method of increasing productivity and recovery of wells in oil and gas fields, in accordance with the present inventions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] In a method of increasing productivity and recovery of wells in oil and gas fields in accordance with the present invention, a hydraulic fracture in a corresponding layer is utilized. In the inventive method first a direction of maximum horizontal stresses is determined. For this purpose, for example, a well 1 is first drilled, and the direction of maximum horizontal stresses can be determined by detecting density of rock which surrounds the well around an axis of the well. The maximum horizontal stress is determined as
δmax=γmax. h,
wherein γmax is a maximum density of the rock determined in a corresponding point around the circumference of the well 1 , and h is a depth of the layer.
[0019] A second well 2 is then drilled. The second well 2 is made at the location such that the well 2 is spaced from the well 1 in a direction which correspond to the direction of the maximum horizontal stresses 3 .
[0020] In at least one of the wells, for example in the well 1 , a vertical slot 4 is then formed. The slot 4 is formed so that it is oriented toward the second well 2 , or in other words in a direction substantially corresponding to the direction of the maximum horizontal stress.
[0021] The slot 4 is cut by one of the known methods, for example by means of a hydraulic sand blasting perforation. A packer with a hydraulic anchor is then placed. A fluid for hydrofracturing is pumped in a space under the packer through corresponding pipes. The moment of the hydrofracture and occurrence of breaking with generation of cracks is determined by reduction of pressure in the system in condition of a constant supply of the pumping fluid. After the hydraulic fracturing, a fluid which carries sand with a binding material is pumped through the pipes, and then a pressing fluid with a volume equal to the volume of the pipes is pumped as well. The hydrofracturing fluid easily overpowers the destroyed zone of increased permeability.
[0022] With the inventive method, the work for breaking of the layer and formation of cracks starts beyond the limits of this zone, so that a distance between the wells can be increased. The pressure for the hydrofracturing can be significantly reduced, since the rock is additionally loaded by the maximum horizontal stresses, and in order to provide their extreme condition and their destruction a significantly lower additional action of pressure of the hydrofracturing fluid is needed.
[0023] In accordance with a further feature of the present invention, another slot 5 is formed in the second well 2 as well. It is formed so that it is directed toward the well 1 or in other words also in the direction of maximum horizontal stresses. The slot 5 can be produced similarly to the slot 4 . The formation of the second slot 5 additionally improves the orientation of the direction of the hydrofracturing exactly between the wells 1 and 2 . The supply of the fluids in the well 2 can be performed in the same manner as the supply of the corresponding fluids in the well 1 . The operations in the wells 1 and 2 can be performed successively one after the other. In accordance with a preferable embodiment of the present invention, however the operations for providing hydrofracturing in both wells 1 and 2 can be performed simultaneously.
[0024] In accordance with another feature of the present invention, when the hydrofracturing is performed from the well 1 , the pressure in the well 2 is depressed. This further increases the efficiency of the hydrofracturing.
[0025] In accordance with a further feature of the present invention a hydrofracturing is performed in a layer which is the most efficient for compensation of expenses required for the hydrofracturing. For example, first analysis is performed to evaluate the efficiency of the corresponding layers. Saturation of the layers with oil/gas and capacity of oil/gas in the layers is determined. Based on this determination a layer having a maximum saturation with oil/gas and a maximum oil/gas capacity is selected. Then, the above mentioned hydrofracturing works are performed in the thusly selected layer.
[0026] In the hydrofracturing process it has been a long standing concept to select a pressure of the fluid supplied for hydrofracturing in accordance with the parameters of the corresponding layer, in which hydrofracturing is to be performed. In accordance with the present invention, in departure from the long standing concept it, is proposed to supply the hydrofracturing fluid with the maximum pressure which can be achieved by the equipment located on the ground. Therefore, the efficiency of the hydrofracturing is significantly improved.
[0027] In the inventive method of increasing productivity and recovery of wells in oil and gas fields, in accordance with another embodiment, it is proposed to form additional slots. As shown in the drawings, one additional slot 6 is formed substantially transverse or perpendicular to at least the slot 4 of the well 1 . The slot 6 have a length substantially corresponding to 20-50% of the length of the slot 4 . The slot 6 is formed so as to increase a draining surface. The slot 6 can be formed in the same manner as the slot 4 .
[0028] Substantially similar slot 7 can be formed in the area of the slot 5 of the well 2 . It can have the same length as the slot 6 .
[0029] It should be mentioned that the slots 4 , 5 , 6 , 7 are cut over the depth corresponding to the efficient thickness of the corresponding layer.
[0030] In accordance with a further feature of the present invention, another well or other wells can be drilled in the same area, as identified with reference numeral 8 . A slot 9 can be then cut from the well 8 (with a slot 10 ), also in a direction corresponding to the direction of the maximum horizontal stresses. When the hydrofracturing fluid is then introduced into the well 8 , the hydrofracturing is also performed in a predetermined direction corresponding to the direction of maximum horizontal stresses. This hydrofracture from the well 8 can reach the area of influence of other wells, thus providing corresponding interactions of the wells.
[0031] It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of methods differing from the types described above.
[0032] While the invention has been illustrated and described as embodied in a method of increasing productivity and recovery of wells in gas and oil fields, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
[0033] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
[0034] What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.
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A method of increasing productivity and recovery of wells in oil and gas fields includes determining a direction of maximal horizontal stresses, producing at least two wells so that they are spaced from one another in a direction corresponding to the direction of the maximum horizontal stresses, forming in at least one of the wells at least one vertical slot oriented substantially from the at least one well to the other of the wells, and introducing a hydrofracturing fluid at least into the at least one well to produce a hydraulic fracture in direction from the at least one well to the other well.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application relates and claims priority to pending U.S. application Ser. No. 09/632,770 filed Aug. 4, 2000, and prior U.S. provisional patent applications No. 60/147,251 filed Aug. 5, 1999, and No. 60/155,454 filed Sep. 20, 1999.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field of the Invention
[0003] This invention relates to pressure vessels used in process operations requiring extreme cleanliness and operated at elevated pressures and temperatures, and in particular to pressure vessel design and shielded closure mechanisms that facilitate easier and cleaner loading and closing of pressure vessels used in automated wafer treatment processes in a production environment.
[0004] 2. Background Art
[0005] There is a general requirement in the semiconductor industry, and in other industries as well such as the medical industry, for conducting processes that require enclosures or pressure vessels that can be loaded with wafers or other objects to be processed, permit the admittance and removal of process fluids or materials necessary to the process after the enclosure is sealed, and be elevated and ranged in pressure and temperature. Some processes are much more critical as to contamination, and require quick and close control of temperature, pressure, and the volume and timing of the introduction of process fluids to the pressure vessel. Add to that the demand for conducting these processes in a production mode, and the growing sophistication of the processes themselves, and it is amply clear that improvements in pressure vessels are needed.
[0006] This disclosure relates in particular to pressure vessels used in operations requiring extreme cleanliness and operated at elevated or high pressures up to 10,000 psi (pounds per square inch) or more, and further, to pressure vessel design and isolated lid locking mechanisms that facilitate easier and cleaner loading and locking of pressure vessels used in automated wafer treatment processes in a production environment.
[0007] An example of a process to which these criteria apply, there is the manufacture of MEMS (Micro Electro Mechanical Systems) devices where the process agent is carbon dioxide, used in both liquid and supercritical form. Other actual and prospective process agents operated in supercritical phase conditions which require much higher temperature and pressure than does carbon dioxide. Other semiconductor related applications with strict cleanliness requirements, such as photoresist stripping, wafer cleaning, particulate removal, dry resist developing, and material deposition, all suffer from the same pressure vessel deficiencies, which include particle generation upon closing that causes contamination, closure mechanisms that are not suited for quick and automated closing, problems with automatically loading and unloading the vessel, and problems with the integration of the apparatus in a production line.
[0008] In many laboratory and production setups currently in use, the pressure vessel is loaded by vertical placement through an open top port of the same or larger diameter of the wafers being processed, and is unloaded by reverse action. The vessel is typically closed by manually bolting or mechanically clamping the process vessel flanges and its cover flanges together around the perimeter to form a pressure seal. This apparatus and methodology is both slow and prone to introducing particulate contamination due to the mechanical interface and constant wearing of mating surfaces. The particulate is generated immediately within the loading and processing environment, and inevitably contaminates the materials being processed to some degree.
[0009] These contaminants are of particular concern in the semiconductor industry, as even trace amounts are sufficient to plague product quality and production efficiencies. When these perimeter flange latching mechanisms are semi-automated for faster closure or production purposes, the contamination problem is simply placed in a free-running mode that gets progressively worse if unattended.
[0010] There are many examples in prior art. One such example is an autoclave with a quick opening door assembly. It typically consists of a chamber flange, a rotating locking ring and the door flange. The door and vessel are clamped and unclamped by the rotation of the locking ring only. As the ring rotates, surfaces of the mating wedges force the chamber flange tight against the gasket providing a leak proof static seal. Due to the contact of the wedges sliding across each other, particles are generated and debris put into motion that eventually contaminate the process beyond acceptable tolerances.
[0011] A further problem with traditional pressure vessels in a production environment is the difficulty in adapting them to the standard wafer handling robots of the semiconductor industry. Complex carriage systems are often necessary for automation of the loading and extracting of materials being processed, involving complex transitions between horizontal and vertical transport of the wafers between processing stations. Newer industry standards anticipate and provide for cluster tool arrangements, where rotary transport systems move wafers between connected wafer processing machines. It is this need and this environment to which the following disclosure is addressed.
SUMMARY OF THE INVENTION
[0012] It is an object of the invention to provide an inverted pressure vessel system with shielded closure mechanisms for conducting automated industrial processes under elevated pressure and temperatures. To that end, there is disclosed a pressure chamber with an underside loading port, a vertically movable pedestal arranged directly below the pressure chamber for opening and closing the loading port, the top of the pedestal functioning as the floor of the pressure chamber when the pedestal is raised to a closed position and as a loading platform when the pedestal is lowered to an open position.
[0013] There is included a motor and vertical drive system for moving the pedestal between open and closed positions, and a pedestal locking system consisting of another motor and lateral drive system for wedge locking the pedestal in a sealing relationship with the pressure chamber so as to define a process volume within which to conduct the processes.
[0014] It being another goal to avoid contamination of the processing environment by loosened particles and debris put in motion by the closing and locking systems, there is provided a shield between the loading and unloading area encompassing the pedestal top and pressure chamber, and the pedestal lateral support structure, and vertical drive and closed position locking mechanisms.
[0015] It being a further goal to provide for handling processes requiring control of pressure and temperature within the chamber, there is provided an inlet manifold and an outlet manifold communicating with the process volume within the chamber, the manifolds being connectable to a process fluid control source for delivering process fluids under controlled pressure to the process volume and removing byproducts therefrom. There is also provided a heat exchanging platen in the roof of the process volume which is connectible by fluid lines to an external fluid temperature control system, a heat exchanging platen incorporated onto the pedestal and likewise connectible by fluid lines to the external fluid temperature control system, and a thermocouple sensor configured for sensing temperature in the process volume and connectible for communicating with the external fluid temperature control system.
[0016] It is yet another goal of the invention to provide for optimal flow and distribution of the process fluids through the central processing cavity of the pressure chamber. To this end, there are provided divergent inflow channels connecting the inlet manifold to the central processing cavity, and convergent outflow channels connecting the cavity to the outlet manifold.
[0017] In further support of the goal of reducing contamination of the process, there is a horizontal shelf structure vertically positioned below the top of the pedestal and with a center hole through which the pedestal operates, with lateral support for the pedestal being attached thereto. There is a vertically collapsible bellows, the upper end thereof being attached by an upper bellows flange around the top of the pedestal and the lower end thereof being attached by a lower bellows flange to the perimeter of the hole in the shelf so as to encircle the pedestal and isolate the lateral support structure and drive and lock mechanisms from the loading and processing environment above.
[0018] Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description, wherein we have shown and described only a preferred embodiment of the invention, simply by way of illustration of the best mode contemplated by us on carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a side elevation cross section illustrating the principle components of the preferred embodiment with the pedestal and lock blocks in closed and locked positions, respectively.
[0020] [0020]FIG. 2 is a side elevation cross section of the preferred embodiment, with the pedestal and lock blocks in open and retracted positions, respectively.
[0021] [0021]FIG. 3 is a front elevation of the preferred embodiment, partially cut away to illustrate the pedestal in the open position.
[0022] [0022]FIG. 4 is a plan view of the preferred embodiment, illustrating the tie plate bolt heads, and the lock block drive screw motor and gearboxes on the backside of the machine.
[0023] [0023]FIG. 5 is a close up side elevation cross section view showing the upper compartment of the preferred embodiment, illustrating the process chamber with process fluid and heating fluid supply lines, with the pedestal and bellows in the mid range position between open and closed.
[0024] [0024]FIG. 6 is a plan view cross section through the process chamber of the preferred embodiment, illustrating the vanes and flow channels affecting the fluid flow through the process volume.
[0025] [0025]FIG. 7 is a plan view cross section view through the tie plates and pedestal column of the preferred embodiment, illustrating the pedestal guide bars and guide bar holders on each side of the column.
[0026] [0026]FIG. 8 is a plan view cross section through the tie plates and lock blocks of the preferred embodiment, illustrating the lock block drive system, LVDT sensor and pneumatic position sensor/interlock.
[0027] [0027]FIG. 9 is a side elevation close up cross section view of the lock blocks and base of the pedestal of the preferred embodiment.
[0028] [0028]FIG. 10 is a multi view illustration of the side elevation and plan view aspects of the pedestal locking wedge components of the preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] To those skilled in the art, the invention admits of many variations. What follows is a description of the preferred embodiment, and should not be construed as limiting the scope of the claims that follow.
[0030] The preferred embodiment described herein is a component of a cluster tool arrangement for the production processing of semiconductor wafers or pressure and temperature sensitive treatment of other small articles. It is an inverted pressure vessel with an isolated door closure mechanism, and a specially configured process volume for handling a through flow of processing fluids in a closely controlled temperature and pressure cycling environment. It conforms the cluster tool geometry SEMI/MESC (Semiconductor/Modular Equipment Standards Committee) standards. It contemplates a maximum operating pressure in the order of 4500 psi, (pounds per square inch), and in an embodiment with a cavity design size of 200 millimeters diameter and a total process volume of about three quarters of a liter, the structure is required to resist up to about 400,000 pounds of force from within the process volume. The temperature range of the preferred embodiment is −20 to +150 degrees centigrade. Higher pressures and temperatures may be desired for some processes, and are simply a function of design. No warranty is expressed or implied in this disclosure as to the actual degree of safety, security or support of any particular specimen of the invention in whole or in part, due to differences in actual production designs, materials and use of the invention.
[0031] The pressure vessel of the invention is assumed to be connected to a suitable dynamic process supply and control system that supplies process fluid under controlled pressure as required by the process, exerts temperature control via heat exchangers in the processing volume, excepts outflow byproducts of the process for recycling or other suitable disposition, and provides the necessary computer control and operator interface to be integrated into the production process. The pressure vessel and associated systems are configured with industry standard interlocks and safety features appropriate to the process conditions.
[0032] The preferred embodiment is configured for a cluster tool arrangement as part of an automated production system for processing semiconductor wafers, as it described below. It is adaptable to other systems for other elevated pressure/temperature processing in an automated system, incorporated into or combined with a horizontal, pass-through conveyor system, a wafer handling robot system, or any other handling system for delivering and loading articles to be processed under pressure, onto the open top of the pedestal. The vertically operated pedestal can carry a wafer cassette, a single wafer, or other object being processed into the pressure vessel for processing, and out again for pickup and further transport. The lift and lock mechanism for operating the pedestal is fully shielded so as to isolate any particulate matter generated and any debris put into motion by the lift and lock mechanism, from the loading and processing environment.
[0033] Referring to the figures, an inverted process chamber 10 with an underside loading port, is bolted to front tie plates 3 and rear tie plates 4 , which in turn are bolted to lower support plate 2 . This assemblage is supported by frame 1 . Within this assemblage is arranged a vertically movable pedestal 50 , a columnar structure the upper end of which terminates in a large, circular, flat top or loading platform, the same surface of which functions as the floor to inverted pressure chamber 10 when used to close the underside loading port. Pedestal 50 is vertically moveable between an upper closed, and a lower open position relative to process chamber 10 . Movement is effected by means of a pedestal drive motor and gearbox 52 mounted in frame 1 , which turns a vertically oriented pedestal drive screw 54 in a lift nut 59 in the base of pedestal 50 .
[0034] Process chamber 10 is machined and configured to provide a final wafer cavity 8 there within, generally sized to accommodate a single wafer diameter and thickness. Referring in particular to FIG. 6, flow channels 6 , divided by flow vanes 7 promote uniform distribution of process fluids into and out of wafer cavity 8 , between inlet and outlet manifolds 14 and 18 . The combination of inlet and outlet flow channels 6 and wafer cavity 8 make up the internal process volume of the pressure chamber.
[0035] Referring in particular to FIG. 7, pedestal 50 is configured with two opposing flats on its vertical wall, within each of which is machined a vertical channel or groove 55 . Lateral support and alignment is provided pedestal 50 throughout its vertical range of motion by opposing bronze pedestal guide bars 56 which closely conform to the cross section of grooves 55 , and which are attached to respective adjustable guide bar holders 58 that are in turn mounted on shelf 5 . The guide bars are lubricated for a sliding interface.
[0036] Shelf 5 divides the region between process chamber 10 and lower support plate 2 into upper and lower compartments, the upper compartment being the region where the loading and unloading of the process chamber occurs, and for which it is important to maintain the highest practical degree of cleanliness to avoid contamination of the process during loading and unloading of the chamber. To that end, bellows 60 is attached by bellows flanges 62 and 64 to shelf 5 and pedestal 50 so as to isolate pedestal and lock block drive systems from the upper compartment.
[0037] Referring back to FIGS. 1, 2 and 5 , a process fluid inlet line 12 is connected via inlet manifold 14 to the front of chamber 10 so as to provide an inflow path for process fluid into the process volume and wafer cavity 8 . A process fluid outlet line 16 is connected via outlet manifold 18 to the back side of process chamber 10 so as to provide an outflow path from the process volume and wafer cavity 8 for byproducts of the process. The fluid inlet and outlet lines are connected to a suitable process fluid supply source for the controlled supply of process fluids under very high pressures. Fluid lines 12 and 16 of the illustrated embodiment are one quarter inch inside diameter, but either or both lines may be larger or smaller, depending on the particular process requirements and the effects of line volume and control valve location with respect to the process volume within the pressure chamber. Either or both manifolds 14 and 18 may be modified to incorporate control valves, with their actuators connected to the process control system.
[0038] The preferred embodiment employs a motor and lateral drive mechanism for inserting a wedge structure in one form or another beneath the pedestal when it is in the closed position. Referring in particular to FIGS. 8 - 10 , a pair of lock blocks 90 are interlocked by lock block screws 92 for closure from opposing sides of the base of pedestal 50 . Lock block screws 92 are supported in screw blocks attached to lower support plate 2 at a height that permits lock blocks 90 to bear and slide on hardened support plates 2 A, let into lower support plate 2 . Lock blocks 90 are configured with hardened bottom plates 91 , which bear on and slide over hardened support plates 2 A when lock blocks 90 are operated for movement. As noted above, lock blocks 90 are interlocked by screws 92 , and are jointly movable between a retracted position clear of the pedestal's vertical motion, to a locking position beneath the base of pedestal 50 when the pedestal is raised up into a closed position against pressure chamber 10 .
[0039] Steel hardened locking wedge components 101 and 102 , having a two degree angle of ramp or wedge angle, are mounted on the top of the lock block 90 and the base of pedestal 50 respectively, so as to provide a sliding interface with a very high vertical component of force in response to the horizontal closing force applied to lock blocks 90 by the lock block screw motor 98 at low speed/high torque and gear boxes 96 . The sliding interface between wedge components 101 and 102 has about a three inch horizontal stroke, provided by the range of motion of locking blocks 90 between open and locked positions. A suitable lubricant can be applied to all sliding interfaces.
[0040] The resulting vertical range for the two degree slope wedge angle of wedge components 101 and 102 is in the order of {fraction (1/8)} inch, so pedestal 50 must be lifted on screw 54 by motor and gearbox 52 to within {fraction (1/8)} inch of full closure with chamber 10 before locking blocks 90 are actuated. A smaller slope angle can be used to obtain a greater locking force, the vertical component of motion of the locking mechanism being correspondingly smaller.
[0041] Upper and lower proximity sensors 57 and 58 , attached to a vertical rod mounted on shelf 5 adjacent pedestal 50 so as to sense the edge of the pedestal, control the range of pedestal 50 as driven by motor and gearbox 52 . Upon sensing pedestal 50 to be at the upper limit, motor and gearbox 52 are stopped and locking blocks 90 can be actuated for sealing pedestal 50 to process chamber 10 . Lift nut 59 is configured with some vertical play within the base of pedestal 50 , to avoid placing the pedestal drive screw in tension when locking blocks 90 are engaged.
[0042] Referring to FIG. 8, the control mechanism for lock blocks 90 includes an LVDT (linear variable displacement transducer) sensor 91 , which is configured to monitor the position of a lock block 90 within its normal range of motion. Lock block drive motor 98 is a two speed, brushless D.C. motor. Lock blocks 90 are driven at high speed/low torque to a predetermined position just short of where wedge components 101 and 102 come into engagement, as sensed by LVDT sensor 91 . Motor 98 is then switched to low speed/high torque and driven to the pre-determined final lock position, again as sensed by LVDT sensor 91 . Pneumatic interlock valve 93 is engaged when locking blocks 90 are filly closed into the locking position, permitting the process to be initiated within the closed and locked pressure chamber.
[0043] Referring to FIG. 5, a floating seal 51 embedded in the top of pedestal 50 provides a very high pressure sealing capability for the process volume when the pedestal is raised to the closed position and lock blocks 90 are placed in the locking position. Floating seals are known in the art for having compliant sealing characteristics suitable to the perimeter sealing problem of high pressure processing chambers.
[0044] In order to provide quick temperature control of the process volume when the pedestal is closed and locked, there is a heating platen 20 installed in the roof of wafer cavity 8 , and a similar heating platen 80 incorporated into pedestal 50 . Wafer crib 9 on platen 80 provides for receiving wafers delivered by an automated process, lifting and holding the wafer between the two platens when the chamber is closed for processing, and presenting the processed wafer for automated pickup when the process cycle is complete and the pedestal is lowered. The necessary thermal energy transfer to and from platens 20 and 80 for the temperature control and cycling according to the desired process is accomplished by the circulation of heating/cooling fluid through respective line sets 22 and 82 , which are connected to a suitable temperature control system. Process chamber thermocouple 30 is mounted on outlet manifold 18 , configured to sense temperature within the process volume of chamber 10 , and connects to the process control system.
[0045] As will be readily apparent to those skilled in the art, there are many useful embodiments within the scope of the invention. For example, the pedestal may be locked in the closed position by a rotate-to-actuate locking lug ring mounted on the lower support plate, that partially rotates so as to slidingly engage its internally extending wedge lugs with a uniformly spaced set of locking wedge lugs extending outward from around the column of the pedestal, instead of the linear slide block mechanism of the preferred embodiment. The ring and pedestal wedge lugs have a ramped or slightly sloping interface analogous to the lock block wedge components of the preferred embodiment. The rotate to lock mechanism is shielded from the loading and unloading compartment in the same manner as the preferred embodiment, by the shelf and bellows arrangement.
[0046] As another example, the pedestal may be of other and various cross sections, including square, channel, or I beam. The pedestal may be hollow or have a rigid skirt over a core element, where the skirt may be configured with a flexible rolling wall diaphragm-like structure with a flange that seals to the shelf to perform the isolating function of the bellows of the preferred embodiment. Another embodiment may have a vertically operable piston diaphragm, more accurately described here as a pedestal skirt diaphragm, sealing the top of the pedestal to the shelf so as to shield or isolate the lateral supports and the drive mechanisms in the same fashion. The shelf embodiment extends to a partial or full enclosure around the mouth or underside port of the pressure chamber, with a door or opening for allowing a transport mechanism to insert and remove articles or wafers being processed from on top of the open pedestal between processing cycles, with a center hole in the bottom of the enclosure through which the pedestal operates, and a pedestal skirt diaphragm sealed to the edge of the center hole to fully contain the loading and unloading environment within the enclosure.
[0047] The lateral support structure for the pedestal can be of various configurations so long as it provides continuous lateral support to the vertically movable pedestal structure. Guide bars, channels, and linear bearings are all within the scope of the invention, so long as they are excluded by the shield from exposure to the loading environment of the open pressure chamber along with the vertical driving and lock mechanisms.
[0048] As yet another example, the tie plate framework of the preferred embodiment can be configured for bi-directional or pass through access to the loading platform and wafer crib when the pedestal is down and the pressure vessel open, so as to accommodate a horizontal wafer pass-through conveyor system or robotic placement and removal of wafers from opposite sides. Also, particularly suitable for higher pressure systems, the tie plate and bolt system can be replaced with a large closed yoke structure, within which are arranged the inverted pressure chamber and the pedestal and motion systems, so that the yoke provides the structural tie that sustains the closing pressure between the pedestal and the pressure chamber.
[0049] As still yet another example, in order to maintain the closing force between the pedestal and the pressure vessel within an acceptable range during extended production cycles, with the aid of the pressure vessel computer control system, data such as pedestal back pressure, lock block motor torque, and lock block closing pressure can be continuously monitored with suitable sensors for trend information which can then be used for making on-the-fly adjustments to start, stop and gear shift positions for lock block motion and pedestal height. As an additional example, the lift mechanism for the pedestal may be hydraulic, threaded screw, or any other manner of jacking or extension mechanisms sufficiently robust to elevate the pedestal weight to the pre-locking closing height, and designed to tolerate the additional small vertical motion of the locking action.
[0050] The objects and advantages of the invention may be further realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as restrictive.
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An inverted pressure vessel system for conducting automated industrial processes requiring elevated pressure and temperatures has a vertically movable pedestal for opening and closing the underside loading port, with pedestal drive system and locking mechanism located below the pedestal top and isolated from the chamber opening. The chamber is connectible to a pressure control and process fluid supply system, and has heat exchangers connected to an external source for temperature control. Process fluids are distributed across a central process cavity through divergent inflow and convergent outflow process fluid channels.
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FIELD OF THE INVENTION
The present invention relates to a turbocharger for an internal combustion engine and more particularly to an improved turbocharger journal bearing and bearing spacer system.
BACKGROUND OF THE INVENTION
Turbochargers are unique mechanical devices in that they are expected to operate at extremely high RPM under conditions of high temperature and changing load, and yet are expected to provide long trouble-free service.
More specifically, a turbocharger is a type of forced induction system. Engine exhaust gases drive a turbine. The turbine is connected via a shaft to a compressor. Ambient air is compressed by the compressor and is fed into the intake manifold of the engine, allowing the engine to combust more fuel, and thus to produce more power for a given displacement. Considering the volumetric gas intake requirements of an engine operating at peak performance and the comparatively small size of a turbocharger, it can be appreciated that a turbocharger may be expected to rotate at speeds of up to 300,000 rpm.
The basic purpose of a bearing system is to provide a near frictionless environment to support and guide this rapidly rotating shaft over the life of the turbocharger, which should ideally correspond to that of the engine, which could be 500,000–1,000,000 km. The bearing system usually comprises two spaced-apart bearings, which function to dampen oscillations. Considering that the turbine is driven by engine exhaust gas, which may have a temperature as high as 1,300 F, it will be apparent that the bearing system must be designed so that a sufficient amount of lubricant is always channeled through the bearing system for removal of heat. Obviously, the turbocharger bearing system is a critical system that must be highly engineered.
On the other hand, it is highly desirable to design a turbocharger that is comprised of a minimum number of parts, which parts are easy to manufacture and easy to assemble, while still satisfying the demand for extended service life. Significant design effort has been directed toward improvements in turbocharger bearing systems.
In one popular turbocharger design the shaft is supported by a pair of floating radial bearings arranged in a cylindrical bore formed in the center housing (also referred to as the bearing housing) of the turbocharger. In this conventional bearing arrangement, the axial movement of each of the floating radial bearing is restricted by a pair of snap rings which are fitted into ring grooves formed on the inner wall of a cylindrical bore through the turbocharger center housing. See, for example, the turbocharger journal bearings described in U.S. Pat. Nos. 3,058,787 and 4,427,309. However, in the case wherein the floating radial bearings are axially restricted by a pair of snap rings, a problem occurs in that the end faces of the rapidly rotating floating radial bearings contact the stationary snap rings. This contact not only causes friction wear at the contact area, it may change the rotational speed of the bearing. In addition, a complicated machining process is necessary to form the four ring grooves on the inner wall of the cylindrical bore into which the snap rings must be seated, and, as a result, the manufacturing cost of the turbocharger is increased. Further, the seating of four snap rings is labor intensive. As the expected life of the engine increases, the turbocharger must be engineered for longer life.
An improvement came with the evolution of the “one piece” radial bearing assembly, in which the pair of floating radial bearings is connected by a cylindrical spacer. This eliminated the need for the respective inboard snap rings, and consequently reducing machining and assembly costs. Being one solid piece, this design was thought to provide good vibration damping characteristics. However, in such a radial bearing assembly, since the axial length of the radial bearing assembly is very long, and since the two bearings are rigidly connected and can not independently optimally adjust their position in the bore, there was a problem in that a complicated and precise machining process was necessary. In addition, since the bearing assembly is one continuous piece, any vibration due to shaft dynamics at one bearing end is instantly communicated to the other bearing end, and further, heat from the turbine side bearing is conducted through the thermally conductive metal spacer cylinder to the compressor side bearing. In addition, lubricating oil located in the sliding zone of the floating radial bearings cannot easily escape, and the friction loss of the floating radial bearings is increased.
In view of the above, U.S. Pat. No. 4,358,253 proposed to install a separate cylindrical “bearing spacer” axially between the pair of journal bearings. This bearing spacer was in the form of a tube in the space between a stationary housing and the rapidly rotating shaft. However, given the rapid flow of oil in this space, in order to stabilize and prevent “wobble” of the bearing spacer, the spacer was given an outer diameter corresponding substantially to that of the outer diameter of the bore. This greatly diminished or even completely stopped the rotation of the spacer, and thus prevented wobble. However, this spacer design tends to impede oil flow. Further, since the bearing spacer exhibits little or no rotational speed, wear is produced where the spacer contacts the rapidly rotating journal bearings. Further yet, given the high rotational speed of the shaft, the stationary spacer introduces drag and contributing to accelerated oil degradation in the space between the shaft and spacer.
It has also been proposed to utilize a bearing spacer having an inner diameter corresponding substantially to the outer diameter of the roatary shaft. While this snug fit would prevent wobble, such a close fit between bearing spacer and shaft causes the bearing spacer to rotate a high speed, causing shear and oil degradation, as well as drag on the shaft.
These prior designs utilizing a separate central bearing spacer have all proven satisfactory with regard to providing proper axial spacing of the radial bearings. However, the need to prevent wobble of the bearing spacer required the bearing spacer, if not integral with the bearings, to be either snugly fit to the shaft or snugly fit the bearing housing bore. These designs, though overcoming the problems associated with the four snap-ring design, have not provided adequate oil flow over and about the inner and outer diameter surfaces of the journal bearings and have not achieved satisfactory rotational speeds of the bearing spacer for reduction in drag, and as a result have suffered from relatively premature journal bearing failure.
As an improvement over the above described bearing spacers is provided in U.S. Pat. No. 4,902,144 entitled “Turbocharger Bearing Assembly”, teaching a bearing design employing a pair of journal bearings separated by a floating central spacer. The generally cylindrical, rotationally floating bearing spacer has opposite ends defining a pair of axially outwardly presented inboard thrust surfaces to maintain the two journal bearings in precision axial spaced relation. For radially locating or “piloting” the bearing spacer within the center housing bearing bore, the spacer exhibits pilot means radiating outwardly from the spacer outer diameter. This design allows unimpeded oil flow and thus achieves an improved oil flow over the journal bearings in comparison to the bearing system described in U.S. Pat. No. 4,358,253. However, the design of the bearing spacer is complex and thus is associated with manufacturing expense. Further, considering the changes in temperature, viscosity, and rotational speed of the turbocharger, it is difficult to design the spacer to have optimal rotational speeds over the entire rotational speed range of the turbocharger rotary shaft. Further yet, the three-piece design with the freely-floating bearing spacer lacks the inertia related stabilizing effect of the one-piece bearing spacer on any radial or rotational vibration of the journal bearings. Thus, one of the advantages of the “one piece” bearing system is missing in this “three piece” bearing system design.
Accordingly, there is a need for a simpler, easier to manufacture, lower cost bearing system for a turbocharger that achieves desired rotational dynamics of the three piece design, yet achieves the superior vibration damping characteristics of the one piece design, and yet does not suffer from the requirement for precise machining of the one-piece bearing.
SUMMARY OF THE INVENTION
The present invention overcomes the problems and disadvantages encountered in the prior art by providing an improved turbocharger bearing system wherein the bearing spacer is not only axially located by the bearings, but is additionally radial located by the bearings.
For this, the bearing inboard faces are provided with either a cylindrical axial protrusion or recess, and the bearing spacer is provided with a mating recess or protrusion, such that the bearing spacer is both axially and radially constrained.
Since the bearing spacer has a greater amount of surface area in contact with the bearings, it will rotate at approximately the same speed as the bearings, which is optimal. Since the bearing spacer does not have radial “pilot” protrusions, it will not cause shear of oil, will not introduce drag to impede rotation of the turbocharger. Since the bearing system is not a one-piece system, it will fit to the turbocharger without requiring precise machining. Since the bearing spacer is radially supported by the bearings, vibration can be transmitted from one bearing to the other to a limited extent, thus providing some inertial damping of vibration not possible with a free-floating bearing spacer. Since the three bearing pieces rotate at the same speed, friction wear is reduced. Since the bearing spacer is radially supported, the bearing spacer exhibits resistance to wobble. The invention also provides a bearing system that is simple and relatively inexpensive to manufacture, easy to assemble, and is highly durable.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not limitation in the accompanying drawings in which like reference numbers indicate similar parts, and in which:
FIG. 1 is a side cross-sectional view of a turbocharger incorporating a bearing system constructed in accordance with the present invention.
FIG. 2 a is an enlarged, cross-sectional view of a preferred embodiment of the bearing system of the present invention.
FIGS. 2 b–d show details of three possible designs of bearings securing the bearing spacer axially as well as radially.
DETAILED DESCRIPTION OF THE INVENTION
The illustrative turbocharger 10 depicted in FIG. 1 includes turbine wheel in a turbine housing, a compressor wheel in a compressor housing, a shaft connecting the two wheels, and a bearing system for rotationally and axially supporting the shaft.
The turbine more specifically comprises a turbine wheel 22 and a turbine housing 30 such that exhaust gas is guided to the turbine wheel 22 by the housing. The inertia and expansion energy in the exhaust gas turns the turbine. Once the gas has passed through the blades of the turbine wheel it leaves the turbine housing 30 via the exhaust outlet area 42 . If the engine is in idle mode the wheel will be spinning at a lower speed, and as more gas passes through the turbine housing the turbine wheel will rotate faster.
The function of the compressor is opposite to that of turbines. The compressor uses the energy, which has been extracted from the exhaust gas in the turbine by slowing and expanding (thereby cooling), in order to accelerate and compress (thereby heating) ambient air for the engine intake. The compressor is comprised of two sections—the compressor wheel 26 and the compressor housing 34 . The compressor wheel 26 is connected to the turbine by a shaft 20 . As the compressor wheel 26 spins, air is drawn in via an air inlet 44 and is compressed as the blades spin at a high velocity. The compressor housing 34 includes a volute portion designed to convert the high velocity, low pressure air stream into a high pressure, low velocity air stream through a diffusion process, thereby providing increased mass flow through the engine for increased performance and power output.
The turbocharger of the present invention includes an improved bearing arrangement for rotatably supporting the shaft 20 . The journal bearings 16 and 18 are of the free-floating rotational type. The journal bearing has inner and outer bearing surfaces. Usually the speed differential between the shaft and the journal bearing inner bearing surface is very high, and the speed differential between a journal bearing outer bearing surface and bearing housing is comparatively low. Thus, the oil film on the outer diameter of the journal bearing acts as a damper, and does not experience a high shear rate. The inner diameter of the journal bearing is smaller than the outer diameter. Thus, although higher shear forces act on the inner diameter of the journal bearing, the smaller total surface area of the journal inner bearing surface ensures that the journal bearing does not rotate too rapidly. The surface areas can be adjusted by beveling or otherwise reducing surface area.
The turbocharger bearing system is lubricated by oil from the engine. The oil is fed under pressure into the bearing housing 36 to lubricate the bearing surfaces within and about the journal bearings. Oil passes through individual bearing supply ports 31 and 32 for lubricating the journal bearings 16 and 18 . These supply ports 31 and 32 open at generally axially centered positions with respect to the two journal bearings, such that oil flow may occur in both directions axially to lubricate the bearing surfaces. Journal bearings 16 and 18 have axially centered lubricating oil flow bores 12 . Oil flowing over and through the journal bearings 16 and 18 is eventually collected within a bearing housing sump chamber 40 for return circulation through an outlet port 46 .
As shown in more detail in FIG. 2 a , the journal bearings 16 and 18 have a generally conventional sleeve bearing construction which can be formed by various manufacturing techniques utilizing a variety of known bearing materials, such as leaded or unleaded bronze, aluminum, etc. The journal bearings 16 and 18 have inner diameter surfaces sized to fit with relatively close clearance about the shaft 20 .
As in the the prior art, the improved turbocharger bearing assembly includes bearing spacer 14 for precise axial location and retention of the journal bearings 16 and 18 . In contrast to the prior art, the journal bearings 16 and 18 provide secure radial location and retention of the bearing spacer 14 for effectively substantial clearance relative to the shaft 20 and the bearing bore 38 , respectively, to permit substantially unimpeded oil flow from the journal bearings in the inboard direction and to provide acceptable rotational speed of the journal bearings 16 and 18 and bearing spacer 14 at different shaft rotational speeds. The journal bearings are not rigidly connected to the bearing spacer, thus they can conform to the alignment and geometry of the bearing bores, and there is no critical requirement for precise machining as in the case of the prior art one-piece bearing spacer.
More specifically, the journal bearings 16 and 18 are each constructed such that, in the inward facing axial thrust surface, a shape such as a step or recess or cylinder is formed 16 a ( 18 a ). The bearing spacer outer thrust surfaces are adapted to fit freely slidingly in these recesses. The invention is characterized by an area of axial overlap between bearing and bearing spacer, such that the bearing spacer is radially located.
The provision of the recess in the bearings 16 and 18 provides a relatively simple design adapted to locate and retain the bearing spacer 14 in precision spaced relation.
In addition, the journal bearings 16 and 18 include outer diameter surfaces sized to fit with relatively close clearance within an axially elongated bearing bore 38 formed within the bearing housing 36 . In the preferred form, the bearing bore 38 has a uniform diametric size to permit simple slide-in reception of the journal bearings, which are sized in turn for rotational floating within the bearing bore 38 during rotation of the shaft 20 .
The bearing spacer 14 provides a component adapted to locate and retain the bearings 16 and 18 in precision spaced relation. The spacer 14 can be constructed from a low cost plastic selected to withstand typical turbocharger operating temperature ranges. If constructed of metal, the thickness of the bearing spacer need not be substantial. The bearing spacer may even be formed from a sheet of metal rolled into a tube, such that insertion of this sub into cylindrical recesses in the bearings prevents opening of the tube.
As shown in FIG. 2 a , the outer diameter of the spacer 14 is formed on a diameter substantially less than the outer diameters of the journal bearings 16 and 18 . Similarly, the inner diameter of the bearing spacer 14 is formed on a diameter significantly greater than the inner diameter of the journal bearings 16 and 18 . Furthermore, the spacer 14 has large lubricating oil flow central output opening.
The improved turbocharger bearing assembly of the present invention thus provides relatively simple bearing components which can be installed by simple slide mounting onto the turbocharger shaft and within the bearing bore, as part of the overall turbocharger assembly process.
Although the bearing system has been shown in FIG. 2 a with the radially-locating step in the bearing being radially outward of the bearing spacer as shown in greater detail in FIG. 2 b , the invention is not limited to this embodiment, but includes embodiments wherein the step formed in the bearing is located radially inside of the bearing spacer as shown in FIG. 2 c , or the bearing may have two steps, one radially ouside and one radially inside the bearing as shown in FIG. 2 d.
While the invention has been described by reference to a specific embodiment chosen for purposes of illustration, it should be apparent that numerous modifications could be made thereto by those skilled in the art without departing from the spirit and scope of the invention.
The contact surface between bearing spacer and bearing need not be perfectly cylindrical. The ends of the spacer could be castellated, or the bearing inward facing sufaces could be a series of protrusions. However, for manufacturing purposes, the cylindrical design shown in the figures is easiest to produce.
Importantly, the improved bearing system comprises relatively simple components adapted for rapid yet accurate assembly to reduce the overall manufacturing complexity and cost of the turbocharger. Moreover, the bearing components are designed for enhanced bearing oil flow to achieve prolonged bearing life with minimal heating and wear. It is to be understood, however, that the bearing structure of the present invention is useful in conjunction with a variety of turbocharger assemblies, and is not to be limited to use with the particular turbocharger described herein.
Now that the invention has been described,
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A bearing system for a turbocharger, simple in design and easy to manufacture, having desired rotational dynamics of a three piece bearing design, yet having the superior vibration damping characteristics of a one piece bearing design. The inboard end of each journal bearing includes an axial recess for receiving an outboard end of a cylindrical bearing spacer, thereby axially locating the journal bearings as well as axially and radially locating the bearing spacer.
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BACKGROUND OF THE INVENTION
This invention relates to ring laser gyroscopes in general and more particularly to an improved system for eliminating lockin in a ring laser gyroscope.
Various types of ring laser gyroscope apparatus have been developed. Typical is the apparatus disclosed in U.S. Pat. No. 3,373,650. As explained therein, in a ring laser gyroscope, two monochromatic beams of light are generated in two opposite directions around a closed loop path about the axis of rotation. A rotation of the apparatus about that axis causes the effective path length for the two beams to change to produce a frequency difference between the two beams since the frequency of oscillation of a laser is dependent upon the length of a lasing path. It is possible, by combining the two waves, to generate interference patterns and from these patterns to obtain a measure of the rotational rate about the axis.
However, as explained in this patent, at low rotational rates, when the difference in frequency between the two beams is small, they tend to resonate together or lock-in and oscillate at only one frequency. As a result, low rotation rates become impossible to read. The device of U.S. Pat. No. 3,373,650, overcomes this problem by oscillating or dithering the apparatus so as to avoid lock-in of the two beams. A further apparatus of this nature is disclosed in U.S. Pat. No. 3,467,472. A detailed explanation of the problem and the various proposed solutions thereto, is contained in U.S. Pat. No. 3,879,130. The system disclosed therein takes a different approach to the problem using a saturable absorber internal to the ring laser cavity as a solution to this problem. The present invention relates basically to the type of solution proposed by U.S. Pat. Nos. 3,373,650 and 3,467,472, i.e., dithering. In all mechanical dithering systems to date, operation has been open loop. Although lock-in is avoided to a large degree, a certain amount of residual lock-in remains present and causes errors which are often unacceptably large. Similar problems occur when using optical dithering or some other type which has the same effect.
Thus, the need for a system which produces a dither in which the residual lock-in effect is absent or much smaller than in previous dither producing techniques, becomes evident.
SUMMARY OF THE INVENTION
The present invention overcomes this problem through the use of a dynamic feedback system between the output of the ring laser gyro and the dither-rate input. In general terms, it generates a dither signal which cancels the lock-in term.
The present invention is disclosed in terms of an analog implementation. However, it will become evident in the description that implementation could be digitally through the use of a micro computer or could be done with a combination of analog and digital hardware.
Furthermore, it is applicable to all types of dithering systems, e.g., mechanical, optical and any other system which achieves the same result as mechanical or optical dithering.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an over-all block diagram of the system of the present invention.
FIG. 2 is a conceptual block diagram of an implementation of the present invention.
FIG. 3 is a more detailed schematic drawing of a practical embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The general block diagram of the present invention is shown on FIG. 1. Shown is a block 11 representing the ring laser gyro. The ring laser gyro has two rotational inputs, one of which is the angular rate input on line 13 and the other of which is a dither-rate input on line 15. Total input rate consists of the sum of the external angular rate and the dither rate. The gyro, in use, would be mounted, for example, in an aircraft. As the aircraft rotates about the axis of the gyro, for example, in heading, an angular rate input ω will occur. As noted above, because of lock-in which is present in the ring laser gyro, small rotations are not detectable. Thus a dither rate input causing an oscillation of the ring laser gyro is utilized. The signal for the dither rate is generated in a dither generator 17. In the prior art, a dither generator which operated in an open-loop mode was used. However, in accordance with the present invention, the dither generator is now a feedback generator obtaining an input from the gyro readout output on line 19.
In order to determine the nature of the function which the feedback dither generator 17 must provide, it is necessary to examine the gyro behavior. This behavior is represented by the following equation:
dφ/dt = ω + ω.sub.d - ω.sub.L sinG(φ+β) (1)
where φ is the angle of the laser fringe pattern, i.e., the interference pattern between the two beams, relative to a reference point on the structure carrying the laser beams.
ω is the input angular velocity
ω d is the dither angular velocity
ω L is an angular rate corresponding to the lock-in frequency
G is the gyro scale factor
β is a fixed angle.
The gyro output c is the difference between the angle φ and the dither angle φ d . That is
c = φ - φ.sub.d (2)
where
φ.sub.d = ω.sub.d (3)
The object of the present invention is to generate a dither signal ω d that cancels the lock-in term ω L sinG(φ+β). Ideally, this would require that the dither signal be given by
ω.sub.d = ω.sub.L sinG(φ+β) = ω.sub.L sinG(c+φ.sub.d +β) (4)
The manner in which this is accomplished is illustrated by FIG. 2. The gyro output c on line 19 is provided to a summing junction 21 where it is summed with β, the best available estimate of the fixed angle β, and with feedback from an integrator 23. The result of this sum which will be c + φ d + β, is an input to a multiplier 25. Here it is multiplied by the gyro scale factor G, the best available estimate of G. This multiplication can be carried out using an operational amplifier properly scaled. The summing junction 21 can be the summing junction at the input of the amplifier. This signal is then provided as an input to a non-linear function generator 27 which provides an output which is the sine of its input. Any of the various generators known in the art may be used. Thus, an operational amplifier function generator, a servo driven sine potentiometer, or a read-only memory arrangement with the analog signal out of the multiplier 25 converted to a digital signal, and provided as an input to the read-only memory, the output thereof then converted back to an analog signal, may be used. The result, which will be the sin G(c + φ d + β) is then multiplied by the quantity ω L in an additional multiplier 29, e.g. a scaled operational amplifier. The resulting output is ω d of equation (4). This quantity is integrated in the integrator 23 to obtain φ d . This is necessary since the angle is not directly available, i.e., only the rate ω d is available. Quantities which are not measured, but which are subject to uncertainty or may change, are designated on FIG. 2 with an over-bar. In designing the system, the best available estimate of these quantities is used.
The system of FIG. 2 does not take into account the fact that, in order to generate the dither angular velocity, it will generally be necessary to use a mechanical torquer. Thus, it is necessary to take into account the behavior of the torquer which is covered by the following differential equation:
(dω.sub.d /dt) = -(1/T)ω.sub.d + u (5)
where u is the angular acceleration and T is the torquer time constant. The angular acceleration being proportional to the electrical input to the torquer. The feedback system must generate
u = (1/T)ω.sub.d + (dω.sub.d /dt) = (ω.sub.L /T)sinG(c + φ.sub.d + β) + (c+φ.sub.d)Gω.sub.L cosG(c+φ.sub.d +β) (6)
As can be seen from FIG. 2, all the required signals, except for c are present. This quantity can be generated using a differentiator. Thus, in order to implement a complete system having the characteristics of equation (6), the system of FIG. 3 may be used. On this Figure, portions which are identical to what was described in connection with FIG. 2 are given identical reference numerals. Thus, the gyro read-out c is provided on line 19 as an input to the summing junction 21 along with the quantity β and φ d from the integrator 23. Once again, this quantity is multiplied by G in a multiplier 25, e.g. a scaled amplifier which may be constructed as described above. It is necessary that both the sine and cosine of this quantity be taken and thus, there is provided a sine-cosine function generator 27a, e.g., a resolver. Again, this can be implemented in any of the ways noted above in connection with FIG. 2. The sine output is provided as an input to a multiplier 31 where it is multiplied by the factor 1/T. Again, this multiplication can be carried out by proper scaling in an operational amplifier. The output of the multiplier 31 is to a summing junction 33. The cosine output of the sine-cosine function generator 27a is one input to an analog multiplier 35. It obtains its second input from a multiplier 37 which will be essentially identical to the multiplier 25, i.e., it can be implemented through proper scaling of an operational amplifier. The input of the multiplier 37 is from a summing junction 39 which may be the summing junction at the input of the scaled amplifier used to implement multiplier 37. The summing junction receives as inputs the quantity φ d (which is equal to ω d ) and the quantity c which is obtained through an approximate differentiator 41 which may simply comprise a capacitive differentiator. If more accuracy is desired, an operational amplifier differentiator may be used.
The output of the multiplier 35 is the second input to the summing junction 33, the output of which is the input to the multiplier 29. Again, this summing junction may be the summing junction at the input thereof. The output of the multiplier 29 is the input to a torquer 43 which has the characteristic behavior represented by its equivalent circuit, i.e., it is represented by an integrator 45 having a summing junction 47 at its input where the output of the multiplier 29 is summed with feedback from the integrator output having a transfer function 1/T as indicated by block 49. The output of the torquer is the final output on line 15, i.e., the dither output.
Under ideal conditions, when the actual gyro parameters are equal to the best available estimates used in the design, the lock-in effect is entirely eliminated, i.e., there is no residual lock-in. Deviation of these parameters from their nominal values will cause some errors. However, because feedback is used, these errors will be much smaller than the errors present in the prior art open-loop dither technique.
It should be noted that, although the present invention has been disclosed in terms of an analog implementation, the feedback dither generator 17 of FIG. 1 could equally well be implemented digitally or in a hybrid analog digital system. Such becomes particularly attractive if a micro-processor is readily available. In such a case, it is only necessary that the readout quantity c on line 19 be converted to a digital value in an analog to digital converter and that value fed to the micro-processor. The micro-processor would then be programmed to solve the equations (4) or (6) with the output of the microprocessor then converted back into analog form through a digital to analog converter to provide the output signal on line 15.
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In a ring laser gyroscope the residual "lock-in" which normally remains with an open loop dither system is overcome through the use of a dynamic feedback system between the output of the ring laser gyro and the dither rate input.
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DESCRIPTION
1. Technical Field
The invention relates to the field for interlocking and coupling together separate structures and more particularly to a device for detachably and securely stacking separate items of furniture, stereo systems and computer peripherals and other equipment.
2. Background Art
Most people are aware of the occasional need in their houses for arranging multiple piece systems in vertical stacks. Such need extends to, for example, multiple housing parts for audio and video homed entertainment systems, and for computer peripherals. It has been recognized that means are desirable for arranging discrete parts in a vertical stack to save space, to present a more esthetics appearance and for convenience to the owner. In this way they can be linked together so that they do not slide or shift with respect to each other. In short the need is for securing the vertical arrangement so that is is not easily misaligned.
Among the known prior art are several patented systems which are concerned with much the same kind of problem(s) but which in structural and functional principles are clearly different and distinct from the instant system.
Cohen, U.S. Pat. No. 4,846,435, shows a rail system which is directed to supporting discrete parts of different housing lengths. FIG. 8 thereof is directed to details of the interrelated parts which are not pertinent to the instant system.
U.S. Pat. No. 4,691,891 teaches a system for preventing unauthorized removal or separation of a component from its support structure. It uses adhesive material on the underside of the component between support and component.
U.S. Pat. No. 4,519,656 discloses an attachement for securing a cabinet to the cover of a bathroom flush tank.
U.S. Pat. No. 4,293,072 shows a means for stacking containers which involves hooks engaging the underside of lips to hold the containers together.
U.S. Pat. No. 4,155,452 discloses corner devices which allow stacking of component housings in interlocking relationship without fear of lateral displacement of one housing with respect to another.
U.S. Pat. No. 4,025,015 teaches separable plug and socket adapters for mounting one component to another. Reference here is made to FIGS. 3 and 6 showing upper and lower members having adhesive means for their attachment to a mounting surface.
None of the above patents anticipates the instant invention. Other prior art references of possible interest are U.S. Pat. Nos. 3,053,558; 4,213,352; 3,000,680 and 1,254,636.
DISCLOSURE OF THE INVENTION
The device of this invention comprises two coacting parts which detachably interlock. A male plug member is secured by adhesive to an upper component and a female member is secured to a separate lower component so that the two, when aligned, interlock. The structural details are such that the two may be locked together if desired.
Accordingly, it is among the features of the invention to provide a device which not only prevents lateral movement, shifting or sliding of stacked pieces of equipment but also spaces the component housings one from the other to allow easier air circulation and cooling. Slippage is prevented from vibration, sudden impact, pets accidentally running into the equipment and from earth tremors. Furthermore, installation is simple and quick and the interlocking is such that theft of the equipment can be made difficult if not impossible by employing locking cables or long shank padlock links. The invention can be used not only for stackable, discrete housings for electronic components like stereos and computer peripherals but also for medical, scientific, industrial, aerospace and laboratory equipment. The device is simple, rugged and inexpensive to make.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of both parts of the device with a section cut away to show details of construction;
FIG. 2 is a side elevation view showing the device joined in interlocking arrangement between two hosing components;
FIG. 3 is a side elevation view showing the parts separated;
FIG. 4 is an exploded view with one part in cross section showing additional details of the structure; and
FIG. 5 is a view in perspective showing a simple cotter key inserted through the aligned holes to lock the two parts together.
BEST MODE FOR CARRYING OUT THE INVENTION
The invention, generally designated by the number 10, is comprised of two parts, namely a female portion generally designated by the number 12 and a male member generally designated by the number 14.
Female portion 12 is shaped to have a generally flat, round base wall section 16 and an upstanding cylindrical wall section 18 preferably integrally formed with base 16 as best seen in FIGS. 1 and 4. Wall section 18 has upper edge 20 and defines a cavity 22 having a cavity bottom surface 24. The bottom surface 27 of base 16 is provided with adhesive material 26 in the form, as an example, of a double back foam tape or other type of bonding tape. However, it is to be understood that a mechanical fastening device may be used for securing male and female parts to a component housing, such as by use of screws, pins or the like. Thus, the female member 12 can be attached to the upper or lower surface of a component housing 28A or B as seen in FIG. 2 in phantom.
The male member 14 also has a flat round base wall 30 with outwardly extending plug portion 32 which may be solid as shown or cylindrical like the female member. The male plug 32 is provided with hole or holes (if cylindrical) 34 which align with holes 29 in the female member. It will be seen that planar surface 35 of base 30 of the male member is provided with double foam tape 36 or equivalent adhesive material. It will be appreciated that a rubber or felt pad 40 may be attached to the bottom surface of a male member so that if a component is lifted free of the female member it can be set on a sensitive surface without marring the same.
When male plug 32 is inserted into cavity 22 of the female member a cotter pin 38 or other insertable means may be used to lock the two parts of the invention together. It will be appreciated that a cable, or a combination or key type padlock with a long shank pivotal link could be used in the aligned holes for the purposes of thwarting theft. Both members 12 and 14 are preferably formed of injection molded plastic but could also be made of metal if desired. While description of the invention has used the term `planar` for the surface which attaches to a component housing, it is to be realized that the attaching surface will be designed to conform with the surface configuration of the housing which in the vast majority of uses will be a planar surface.
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Device (10) for holding together adjoining component housings arranged in a vertical stack, said device (10) comprising a first female section (12) and a second male section (14) wherein the female member is provided with a cavity (22) to receive a male plug member (32). Each of the male and female members has a base (16,30) from which the coacting parts extend. The members (12, 14) are provided with aligned holes (29,34) through which a locking means (38) may be inserted for holding the members together. The base of each of the members is provided with an adhesive means (26,36) for adhering the member to a component housing surface.
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CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 08/010,448, filed Jan. 25, 1993, now U.S. Pat. No. 5,287,790, which is a continuation of application Ser. No. 07/694,385, filed May 1, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and apparatus for producing multi-layer tubular braids.
2. Description of the Prior Art
Single wall tubular braids are the predominant braided structures manufactured by conventional braiding machines. Existing machines can also produce belt or flat braids but few modifications beyond these shapes have been made.
In the flat-braiding machine, the serpentine, intersecting pairs of tracks in the track-defining plate are arranged along a circular path that is partially open, whereas in a braiding machine for producing tubular braids the circular track paths are completely closed. An example of a braiding machine that may be selectively utilized either as a tubular braider or as a flat braider is disclosed in U.S. Pat. No. 2,148,164.
Conventional braiding machines, however, cannot produce multi-layer tubular braided structures. Such structures would have applications beyond merely use as fiber-reinforcing plastic cores.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a method and an apparatus for braiding multi-layer tubular braids and to thereby broaden the field of use of fiber-reinforcing reinforcing plastics using tubular braided structures.
Pursuant to a first embodiment of an apparatus in accordance with the present invention, there is provided means, such as a plate, for defining a plurality of generally concentric pairs of serpentine, intersecting bobbin carrier guiding tracks. A bobbin carrier driving gear group is operatively associated with each pair of tracks and adjacent gear groups mesh at a plurality of bobbin crossover points. By way of example, two pairs of tracks may be provided, the corresponding driving gear groups meshing at four equally spaced crossover points. Alternatively, three pairs of tracks may be provided, the corresponding driving gear groups meshing at four equally spaced crossover points between adjacent pairs of tracks.
In accordance with an example of a method according to the invention for forming multi-layer tubular braided structures, a first group of bobbin carriers is circulated exclusively along one track of a first pair of intersecting tracks arranged along a first closed, substantially circular path. A second group of bobbin carriers is exclusively circulated along one track of a second pair of intersecting tracks arranged along a second closed, substantially circular path generally concentric with the first circular path. At least one other group of bobbin carriers is circulated exclusively along at least portions of the other tracks of the first and second pairs of intersecting tracks by means of crossover points connecting the first and second pairs of tracks.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects, advantages and features of the invention will become apparent from the Detailed Description, below, when read in conjunction with the accompanying drawings in which:
FIG. 1 is a plan view of a portion of a braiding apparatus showing the layout of bobbin carrier driving gears in accordance with a first embodiment of the invention;
FIG. 2 is a schematic diagram of the nominal paths followed by the bobbin carriers driven by the gears shown in FIG. 1;
FIG. 3 is a top plan view of the track arrangement of a braiding machine in accordance with a second embodiment of the invention for forming a different multi-layer tubular braid;
FIG. 4 is a plan view of the bobbin paths in a braiding machine having the track pattern of FIG. 3;
FIG. 5 is a top plan view of a bobbin carrier track pattern in accordance with a third embodiment of the invention for forming yet another multi-layer tubular braided structure; and
FIG. 6 is a plan view of the bobbin carrier paths in a braiding machine having the track pattern of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A braiding machine incorporating the present invention is basically similar to ordinary braiding machines for flat and tubular braided structures in that the braiding takes place by means of a plurality of groups of bobbin carriers intertwined in either a clockwise circular direction or a counterclockwise circular direction along the tracks formed in a track-defining plate. The braid is formed when each bundle of fibers, unwound from each bobbin onto its respective bobbin carrier, is introduced into a gathering guide positioned above the central section of the tracks. While rotating, the bobbin carrier is advanced along its path by the drive gears under the track-defining plate. Further, by changing the gear ratio, it is possible to change the speed of the bobbin carrier's movement and the speed of the winding of the braid and accordingly, to manufacture a braid having different angular fiber bundles.
With reference now to FIG. 1, a multi-layer tubular braided structure is formed by means of a braiding machine 8 in which drive gears for transporting bobbin carriers are arranged as shown. FIG. 2 shows schematically six different paths A through F followed by corresponding groups of bobbin carriers transported by the gears shown in FIG. 1.
The braiding machine 8 includes a braiding ring 10 and sixteen (16) gears 12 arranged in an outer circle 14 and eight (8) gears 16 arranged along an inner circle 18. The outer and inner gear circles 14 and 18 are centered on a braiding axis 20 and are driven by gears 22 connecting the gear circles at four equally spaced points. By means of gears 22, the bobbin carriers running on outer paths can move in to inner paths and vice versa. In a manner well known in the art, the gears 12, 16 and 22 are mounted on gear supporting plates 24 which define the serpentine, intersecting pairs of tracks.
As shown in FIG. 2, the six yarn bobbin carrier group paths A to F are path A, a full circle on the outer side; path B, a full circle on the inner side; and paths C through F occupying one-quarter circles or quadrants along the inner and outer circles, the inner and outer portions of the paths C through F being joined by connecting paths associated with connecting gears 22. Quadrant paths C and E and quadrant paths D and F are positioned symmetrically about the central braiding axis 20.
The letters A to F noted on the gears of FIG. 1 correspond to the entry position of the bobbin carriers running along the paths A to F shown in FIG. 2 and the circled letters represent that the bobbin carriers which run through the tracks, represented by the code, exist in the tracks. The bobbin carriers, designated by the circled letters, revolve in the direction of the gear having the same code. They never move to a position marked by any other code. There are a total of twenty eight (28) bobbin carriers in the braiding machine of FIGS. 1 and 2.
When braiding is formed by means of a braiding machine having six exclusive tracks as in FIGS. 1 and 2, a regularly constructed dual layer tubular braid is manufactured.
In the braiding machine shown in FIGS. 1 and 2, by placing bobbins wound with different fiber bundles into units of bobbin carrier groups respectively circulating through the two circular exclusive tracks A and B and the four exclusive quadrant tracks C to F of the abovementioned braiding machine, the braiding takes place. For example, by placing electrically conductive fiber bundle bobbins in each of the bobbin carrier groups circulating in the circular exclusive track A, circular exclusive track B and placing non-conductive fiber bundle bobbins in each of the bobbin carrier groups, circulating in the other exclusive tracks C to F, it is possible to produce a coaxial braided cable. Further, by placing electrically conductive fiber bundle bobbins in each of the bobbin carrier groups circulating in the circular exclusive quadrant track C, circular exclusive quadrant track E and place non-conductive fiber bundle bobbins in each of the bobbin carrier groups circulating in the other exclusive tracks A, B, D and F, it is possible to fabricate a braided structure which can function as an electric cable. Furthermore, by adding bobbins carrying glass or carbon fiber bundles to the bobbin carriers circulating respectively through each of the exclusive tracks A to F, it is possible to produce a high strength braid while at the same time reducing the quantity of expensive carbon fibers used.
The type of fiber supplied longitudinally (that is, along the length of the braided structure) may be changed during the formation of the braided structure. For example, at the commencement of braiding, electrically conductive fiber bundle bobbins may be placed in each of the bobbin carrier groups circulating in the circular exclusive track B and nonconductive fiber bundle bobbins may be placed in each of the bobbin carrier groups circulating in the other exclusive tracks A and C to F. Then, at some later stage of the braiding operation, electrically conductive fiber bundle bobbins may be placed in each of the bobbin carrier groups circulating in the circular exclusive track A and nonconductive fiber bundle bobbins may be placed in each of the bobbin carrier groups circulating in the other exclusive tracks B and C to F. In this fashion, it is possible to obtain a conductive braid having electrically conductive fiber bundles exposed on selected portions of the final braided structure. Further, at each of the switchover points the conductive bundles are joined to each other.
FIGS. 3 and 4 show braiding machine bobbin carrier tracks and paths for forming a different two layer tubular braid. This braiding machine is similar to the first embodiment in that it is a composite circular braiding machine having twenty four (24) bobbin carrier drive gears arranged along an outer circle and eight (8) meshing bobbin carrier gears along an inner circle concentric with the outer circle. The gear circles are connected by means of gears at four, equally spaced points. The embodiment of FIGS. 3 and 4 has exclusive bobbin carrier paths similar to the first embodiment, the number of bobbin carriers being thirty six (36).
By changing the type of bundle supplied in the latitudinal direction, and utilizing three pairs of tracks as shown in FIGS. 5 and 6, it is possible to produce a triple layer braid which employs the same basic machine.
The braiding machine of this embodiment includes in concentric circles, a track region 30, having associated therewith thirty two driving gears 32; a track region 34, which has associated therewith twenty four driving gears 36; and a track region 38 which has associated therewith sixteen driving gears 40. Each of these track regions comes into contact at crossover points 42-49 and are connected as shown in FIG. 6. The track regions include three circular exclusive tracks 50, 52 and 54 shown by the broken lines, and exclusive track 56, shown by the solid line, portions of which are in all three track regions 30, 34 and 38 and include the crossover points and in which bobbins circulate so that on the third time around, they return to their original position.
In the braid formed by this braiding machine, for example, by placing electric conductive fiber bundle bobbins in each of the bobbin carrier groups circulating in the circular exclusive track 50 and circular exclusive track 54 and placing non-conductive fiber bundle bobbins in each of the bobbin carrier groups circulating in the other exclusive tracks 52 and 56, it is possible to produce coaxial braided cable. This braid has durability at each of the extremities which is greater than the braided coaxial cable of the previous embodiment. During the formation of the braid or thereafter, it is possible to insert a filler between the walls of the braid, in which case the durability is enhanced even further. It is also effective, as part of an insertion step, to heat treat the braid with the insertion of synthetic plastic resin chips or other materials between the walls of the braid.
Further, by placing electrically conductive fiber bundle bobbins in each of the bobbin carrier groups circulating in the circular exclusive track 50 and circular exclusive track 54 and placing non-conductive fiber bundle bobbins in each of the bobbin carrier groups circulating in the other exclusive tracks 52 and 56, it is possible to produce a braid which can function as an electric cable. In either case, it is possible to obtain an electric cable having elastibility. Further, as in the previous example, it is possible to form a braid by changing the type of fiber bundle supplied in the longitudinal direction.
The foregoing explanation concentrates on electrically conductive braids but it is possible to produce braids having other functions such as insulation. Further, in general, it is also possible to develop a braid cross section having an extremely wide variety of uses.
Each of the layers of the various multiple tubular braids produced as described are closely coupled with each other and it is possible to produce a structure of high strength when glass, carbon, aramid or other fibers are used and the braid is employed as a core material for use in fiber-reinforced plastics.
In summary, it is possible with the present invention to easily produce a multi-layer tubular braid. Furthermore, when the multi-layer tubular braid which is produced is employed as a core material in fiber-reinforcing plastics, it is possible to obtain a fiber of extreme strength making it possible to broaden further the fields of use of fiber-reinforcing plastics using braids as core materials.
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Multi-layer tubular braided structures are produced by apparatus including a plurality of generally concentric pairs of serpentine, intersecting bobbin carrier-guiding tracks. A bobbin carrier driving gear group is associated with each pair of tracks, adjacent gear groups meshing at a plurality of bobbin carrier crossover points. According to the method, multi-layer tubular braided structures are produced by circulating a first group of bobbin carriers exclusively along one track of a first pair of tracks, circulating a second group of bobbin carriers exclusively along one track of a second pair of tracks, and circulating at least one other group of bobbin carriers exclusively along at least portions of the other tracks of said pairs of tracks via the crossover points.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an engine block having at least one cooling duct extending in an intermediate wall between the cylinders, said wall having a minimum casting material thickness of less than 5 mm, also a casting mold for the manufacture of such an engine block, and a method for manufacturing such an engine block.
2. Description of the Related Art
In order to keep the length of an engine block, e.g. a cast aluminum block, as short as possible, efforts are made to arrange the cylinder cavities of a row of cylinders closely adjacent to one another. As a result, the intermediate walls between the cylinders are correspondingly thin. Because of the more closely adjacent combustion chambers and the reduced heat conduction, these thin intermediate walls are exposed to increased thermal stress, especially at the end of the cylinder face closest to the cylinder head. Consequently, it is necessary to provide a cooling duct in the intermediate wall.
It is known in the art that a cooling duct can be produced by machining, namely by cutting into the engine block from the cylinder head seating surface of the block and then sealing the opening shut. This leaves behind a cooling duct that connects sections of a cooling jacket enclosing the row of cylinders, said sections of the cooling jacket extending on opposite sides of the row of cylinders. Alternatively, the engine block is drilled into from the side in order to produce such a cooling duct, and afterwards the drilled passage between the cooling jacket and the outer surface of the engine block must be sealed shut again.
SUMMARY OF THE INVENTION
It is the purpose of the present invention to create an engine block of improved quality while reducing the effort involved in its manufacture.
This task is performed by an engine block according to the invention, characterized in that the cooling duct is bordered solely by a skin of casting material, i.e. the engine block according to the invention is produced in a casting mold in which, for the purpose of producing the cooling duct, a duct mold core, secured only at its ends, is arranged between the mold cores for the cylinder cavities.
In an engine block according to the invention, the strength and durability are increased in comparison with a known engine block of similar type by virtue of the fact that the cooling duct is formed without any machining, i.e. without intervening in the solidification structure of the cast material.
In a preferred embodiment of the invention, the cross sectional area of the cooling duct is reduced from its ends towards a transverse axis of the cooling duct that perpendicularly intersects the axes of the cylinders. This reduction in cross sectional area takes account of the fact that the wall between the cylinders is reduced in thickness as this transverse axis is approached. As the thickness of the intermediate wall increases on both sides, so the cross sectional area of the cooling duct also increases, thereby advantageously reducing the flow resistance of the duct and increasing the throughflow of coolant.
The minimum width of the cooling duct in the direction of the transverse duct axis perpendicularly intersecting the axes of the cylinders may range between 0.5 and 1.5 mm.
While it is conceivable for the cross sectional area to have any desired form, the cross sectional area of the duct is preferably elongate, with a longitudinal axis running parallel to the cylinder axes. While the width of the cooling duct is limited by the thickness of the wall between the cylinders, in the direction of the cylinder axes the cooling duct can widen to a relatively large extent, thus increasing the throughflow cross section.
In a preferred embodiment of the invention, the cooling duct extends in a straight line between oppositely arranged sections of a cooling jacket enclosing the row of cylinders.
The casting mold core is made of a material that is soluble in a liquid, or combustible, and/or brittle, namely in particular a salt, carbon and/or glass.
Once the casting material has been poured and has solidified, a salt core can be removed from the casting by dissolving it out. It is obvious that a soluble salt must be chosen that has a melting temperature above the temperature of the casting material used. A carbon core can be burnt out, for which purpose it may be necessary to supply oxygen to promote the combustion process. It is further conceivable that a pyrotechnical core material may be used, said material comprising carbon and an oxidizing agent added to the carbon, such that the composition of the material ensures full removal of the core by combustion while, however, avoiding explosive combustion.
A brittle glass core may be removed from a narrow cooling duct, even if the entrances to the cooling duct are not accessible to tools, by using, for example, ultrasonic means to shatter the core into small pieces. The glass core may be appropriately prepared for this process by being pre-stressed. Alternatively, the glass core may be removed by a pressurized water jet.
In a further preferred embodiment of the invention, the casting mold core is attached at its ends to a part of the casting mold possessing the cores for forming the cylinders. This measure ensures that the cooling duct is arranged in the prescribed position within the intermediate wall, with little deviation in tolerance, relative to the cores forming the cylinder cavities and thus relative to the cylinder cavities themselves. If the cooling duct mold were attached to another part of the casting mold, larger manufacturing tolerances would have to be accepted with respect to the positioning of the cooling duct due to fluctuations in the exactness of the fit of the casting mold parts relative to each other.
The invention will now be explained and described in more detail on the basis of embodiments and the attached drawings referring to these embodiments.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 depicts a top view of part of a casting mold according to the invention.
FIG. 2 is a cross sectional view through the said casting mold and contains the casting mold part shown in FIG. 1
FIG. 3 is a cut-away side elevation of the engine block according to the invention.
FIG. 4 is a cross-sectional view of the engine block depicted in FIG. 3 .
FIG. 5 depicts a further embodiment of an engine block according to the invention having a curved cooling duct shown in cross-sectional view, and
FIG. 6 is a top view of the engine block depicted in FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2 the reference number 1 denotes a casting mold part having cores 2 and 3 for forming cylinder cavities.
In addition, the casting mold part 1 possesses lugs 4 and 5 provided with a groove 6 or 7 respectively. The ends of a salt core 8 are inserted into the grooves 6 and 7 . Each of the grooves 6 , 7 is long enough to give the salt core 8 room to expand in each groove.
As can be seen from FIG. 2, the lugs form an opening in the top part 11 of the engine block facing the cylinder head. While securing the salt core 8 in the grooves 6 , 7 the lugs 4 , 5 abut against a further casting mold part 12 , by means of which a cooling jacket surrounding the cylinders is formed.
At 13 an intermediate wall of casting material is formed between the cylinder cavities; the minimum width of this wall is indicated by the arrows in the drawing.
As is apparent from FIG. 1, the initially constant width of the salt core 8 decreases from each end towards a transverse axis 14 perpendicularly intersecting the cylinder axes, and at this axis attains a width of 1 mm, while the outer sections of the salt core in this embodiment are 2.5 mm wide. The minimum thickness of the intermediate wall formed from the casting material at 13 , including the minimum duct width, is 2.5 mm. Grey cast iron bushings still to be cast into the engine block, thus making the overall web width 5.5 mm, are not shown here. The salt core 8 is rectangular in cross section, with the long rectangular side of the cross section extending perpendicular to the cylinder axes and having a dimension of 4 mm in the embodiment depicted.
The salt core 8 is manufactured from NaCl that has a melting point higher than the temperature of the liquid aluminum casting material used to manufacture the engine block. Depending on the casting material, other salts and salt mixtures may be used.
In the embodiment depicted, the salt core 8 is manufactured by pressing and subsequent sintering.
Following a casting and solidification process, hot water is used to dissolve the salt core out of the casting and a cooling duct is formed linking the sections of the cooling jacket on both sides of the row of cylinders, said cooling duct being bordered solely by a continuous skin of casting material, thereby imparting a high degree of strength to the thin wall between the cylinders. The cooling duct ensures adequate heat removal and thus high thermal resistance of the engine produced from the engine block.
During the casting process, the salt core expands, and the length of the grooves 6 , 7 offers sufficient space for this expansion to occur.
Deviating from the embodiment shown, the salt core could be broader at its ends than is depicted here, thus enhancing the cooling effect.
Mounting the salt core on the lugs 4 , 5 , which are elements of casting mold part 1 holding the cores 2 , 3 , ensures that the cooling duct is arranged in the intermediate wall at 13 in the desired position relative to the cylinder axes, with minimal deviations in tolerance. If, instead, the core 8 were to be mounted on casting mold part 12 forming the cooling jacket, the position of the cooling duct would be subject to large fluctuations.
When the core 8 is dissolved out of the formed casting, the dissolution process can be accelerated by using hot and possibly pressurized water.
Reference is now made to FIGS. 3 and 4.
FIG. 3 shows a first cylinder cavity 15 of an engine block having a lining 16 , a first intermediate wall 17 between the cylinders, and a lining 18 of a next cylinder cavity 19 .
FIG. 4 contains half views of the cylinder cavities 15 , 19 , with the intermediate wall 17 between them. The circled sections A and B additionally depict the status of the casting mold.
Also visible in the FIGS. are an outer wall 20 of the engine block, a cylinder head surface 21 , a water jacket 22 , and two stud bolts 23 for attaching a cylinder head.
In the encircled areas A and B is depicted the mold core 24 forming the water jacket 22 . In this mold core is incorporated a graphite plate 26 having two thickened end sections 25 . Between these thickened end sections 25 the graphite plate is approximately 1.2 mm thick and approximately 12 mm high. It extends, with these dimensions, centrally through the thickness of the intermediate wall 17 at a height immediately below the stud bolts 23 .
Outside the encircled areas A and B in FIGS. 3 and 4 the graphite plate 26 is shown still in place in the cast engine block after the latter has been removed from the mold.
The graphite plate 26 is then removed by burning it out. The graphite plate is ignited while blowing oxygen over it, and it burns up completely if oxygen is continuously blown into the duct opened up by the burning process. To accelerate the process, the oxygen may be introduced from both ends. In a variant of this embodiment, an oxidizing agent may be added to the graphite material so that the burning can take place without the need for any such supporting measures.
The water circulates in the engine block with a slight difference in pressure between one side of the row of cylinders and the other side. As a result, it flows through the duct formed by the graphite plate 26 , thereby enabling the removal of heat.
The procedure may be used equally advantageously to produce other thin passageways conducting water, oil or gas in a cylinder block or cylinder head, and it is particularly suitable also for producing narrow water ducts between the valve bores in a cylinder head.
Reference is now made to FIGS. 5 and 6. In the said Figs., the reference number 27 denotes a cast engine block. The engine block 27 , depicted in cross section by means of broad hatching, is produced from an aluminum alloy. Reference number 28 denotes a casting mold part used to form a cooling jacket enclosing the cylinders of the engine block 27 . Cylinder liners 29 are integrated into the engine block 27 by pouring the casting material around them. The cylinder liners 29 sit in the casting mold with their entire inner surface in contact with a hollow cylindrical chill mould element 30 . The casting mold, which is not further depicted here, is a sand mold.
In FIGS. 5 and 6, the reference number 31 denotes a glass core extending between neighbouring cylinder cavities 32 of the engine block 27 , from one part 33 of the sand casting mold to another part 34 of the sand casting mold. The parts 33 , 34 of the sand casting mold are linked with the part 28 of the sand casting mold, said part forming the cooling jacket, and their purpose is to form openings in the cooling jacket at the seating surface of the cylinder head on the engine block 1 .
The arcuately configured glass core is embedded at either end in casting mold parts 33 and 34 respectively.
In the embodiment depicted here, the glass material has a thermal expansion coefficient of slightly less than 10 −6 K −1 . The glass transition temperature is 700° C. The glass core 31 has a diameter of 1 mm.
As shown in FIGS. 5 and 6, a core is arranged between each of the cylinder cavities 32 of the engine block 27 .
During the casting process, the glass core 31 is surrounded by casting material, the glass being able to withstand the temperature stress associated with being thus embedded. Soon after it is surrounded by the casting material, the glass core reaches the same temperature as this material and thus at the same time attains its maximum thermal expansion during the casting process. The glass core then cools down in thermal equilibrium together with the casting material. Because of its higher coefficient of thermal expansion, the latter material shrinks to a greater extent than the glass core 31 . This shrinkage regularly causes the glass core 31 to shatter. To encourage this, the glass core may be suitably pretreated by quenching, abrasive blasting, etching and/or scoring, in particular in such a way that a large number of easily removable fragments is formed.
In the embodiment depicted, the glass core 31 is arcuately laid, such that a flexible pushing tool can be inserted through the openings formed at the seating surface of the cylinder head to remove the glass core from the mold in the event that it does not break, or only partially breaks, when the shrinkage occurs.
The arcuate glass core in the depicted embodiment could also be straight. In that case, ultrasonic treatment or high-pressure jet treatment of the casting could be considered as a means of removing the glass core from the casting.
In the manner described above, it is possible to produce ducts having very smooth inner walls, similar to the quality of bores, without having to intervene in the structure of the casting. Advantageously, no deposits from the coolant can attach themselves to the walls of these ducts. It would not be possible, without damaging the engine block, to produce such cooling ducts by drilling between the cylinder cavities in the engine block.
It is advantageous to pretreat the glass core in the manner described above so that it is given a structure, in particular a stressed structure, that will enable the glass to fracture more easily when shrinkage occurs or when it is subsequently broken out of the block.
In addition to the examples shown, which relate to an engine block having a cooling duct between the cylinders, salt cores, graphite cores or glass cores may also be used in other parts of the engine block, for example to produce ducts through which coolant or oil may be supplied to certain functional elements in the engine.
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In an engine block having cylinder cavities arranged close together, a cooling duct is produced in an intermediate wall between the cylinders by pouring the casting material around a mold core made preferably from a material that is soluble in a liquid, combustible and/or brittle, so that the mold core can easily be removed from the duct once the casting has solidified. In the casting mold, the duct mold core is secured solely at its ends so that a cooling duct is formed that is bordered exclusively by a skin of casting material.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to bight and needle positioning controls for sewing machines.
2. Description of the Prior Art
It is well known to provide a sewing machine with a bight control enabling an operator to select the amplitude of side to side motion of a needle bar for pattern sewing, and to further provide other control means enabling the operator to dispose the needle bar in a right or left of center position.
A prime object of the present invention is the provision of an improved control arrangement for a sewing machine enabling an operator utilizing a single input control member to select not only what the bight of a needle bar shall be for pattern sewing, but also to dispose the needle bar in either of alternate side positions for straight stitch sewing, or in an extreme side position for effecting disengagement of the needle bar from a drive therefor.
Other objects and advantages of the invention will become apparent during a reading of the specification taken in connection with the accompanying drawings.
SUMMARY OF THE INVENTION
A pivoted member movable according to a selected pattern to be sewn on a machine is operably connected to linkage means for imparting side to side motion to a needle bar. The operable connection between the pivoted member and linkage means includes a slot in one, and a pin on the other adjustable within the slot for changing the amplitude of side to side movement of the needle bar in response to movement of the pivoted member. The slot includes enlarged end portions where the pin may be disposed to disengage the linkage means and pivoted member. Fixed structure engages the pin while in the enlarged end portions of the slot and defines particular off-center positions for the needle bar. The pin is positionable within the slot by an input member provided for use by an operator.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a bight and needle positioning control including mechanism according to the invention;
FIG. 2 is an enlarged exploaded perspective view showing said mechanism; and
FIGS. 3, 4, 5 and 6 are top plan views showing the mechanism of the invention in various control positions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, reference characters 10 and 12 designate the top and bottom plates, respectively, of a control module 13 of the kind disclosed in the copending application of W. Weisz for "Push-Button Control Module for Sewing Machine", Ser. No. 449,721, filed Dec. 14, 1982. As shown, a member 14 is pivotally mounted at 16 and 18 on a shaft 20, which is affixed at the ends of the plate. Such member includes a slot 22, in an arm 24, which overlies top plate 10 and extends perpendicularly with respect to the pivotal axis 26 of the member. Member 14 is pivotally movable against the bias of a spring 28 in a predetermined manner by any one of a plurality of cam followers 30 when caused by suitable pattern selecting means 32 as in the manner described in said patent application of W. Weisz, to effectively engage both an associated cam 34, in a cam stack 36 and the member 14.
Linkage means including a link 38, a bell crank 40, and a link 42 with an adjustable extension 44 are provided to operably connect member 14 with a needle bar post 46. A gate 48 and needle bar 50 are laterally movable, in a manner well known, by the post 46. A pin 52, at one end of link 38, serves to operably connect the link with member 14. The pin 52 extends into slot 22 in member 14 after first passing through an aligned slot 54 in a bracket 56 which extends over arm 24 and is affixed to top plate 10 with screws 57, 58 and 60. Link 38 is connected at the opposite end from pin 52 to an arm 62 of bell crank 40 by a pin 66. The bell crank is pivotally connected at 70 to one end of link 42, and is movable about a pin 71 in plate 10. The opposite end of link 42 is connected by a screw 72 to adjustable extension 44, and the adjustable extension is pivotally connected at 74 to needle post 46.
The pivotal axis 26, of member 14, passes through slot 22 at the junction of an enlarged end portion 76 of the slot and an intermediate portion 78 connecting the enlarged end portion 76 with an opposite end enlarged portion 80. Slot 54, in bracket 56, includes an intermediate portion 82, which is directly above and is wider than intermediate portion 78 of slot 22. One end of slot 54 is formed with a pin receiving and confining narrowed end portion 84 which directly overlies and is less in width than enlarged end portion 76 of slot 22. The opposite end of slot 54 is formed with pin receiving and confining first and second narrowed end portions 86 and 88, which directly overlie and are less in width than enlarged end portion 80 of slot 22. Slot 54 is formed with a ramp 90 for leading pin 52 into end portion 84, and with ramps 92 and 93 for leading the pin into end portions 86 and 88 respectively.
A linkage arrangement, including a lever 94 and links 96 and 98, is provided for positioning pin 52 on link 38 in slots 22 and 54. Lever 94 is pivotally mounted at one end on a pin 100 extending from a boss 102 which is affixed in plate 10. An opposite end 104 of lever 94 is free and fashioned for manipulation by an operator. A pin 106 extending from the lever 94 at an intermediate location registers in a slot 108 in link 96 to operably connect the lever with link 96. One end of link 96 is pivotally mounted on a pin 110 projecting from a boss 112 affixed in plate 10 and the opposite end is pivotally connected by a pin 114 to one end of link 98. The opposite end of link 98 is connected to pin 52 for pivotal movement thereon.
Pin 52 is positionable in slots 22 and 54 with lever 94 acting through links 96 and 98. For any position of pin 52 in the intermediate portion 78 of slot 22 (FIG. 3), the pin is rocked by member 14 about axis 26 in response to pivotal movement of the member as determined by a selected follower 30 and actuating cam 34. Pin 52 acting through link 38, bell crank 40, link 42 and extension 44 imparts side to side motion to needle bar 50, and a needle 116 carried by the needle bar is thereby enabled to sew a pattern as the needle bar is vertically reciprocated by driving mechanism 118. The amplitude of the side to side motion (bight) of needle 116 may be increased by disposing pin 52 with lever 94 in slot portion 78 to increase the distance of the pin from axis 26, and may be decreased by disposing the pin to decrease the distance of the pin from said axis. Regardless of the position of pin 52 in slot portion 78, the pin while moved by member 14 remains out of contact with the sides of slot 54 in bracket 56 because of the greater width of the intermediate portion 82 of slot 54 as compared to the width of intermediate portion 78 of slot 22, and the limited movement of which member 14 is capable as predetermined by the cams 34.
The intermediate portion 78 of slot 22 is a circular track with a radius corresponding to the distance between pins 52 and 66 at the opposite ends of link 38, and while the needle bar is in a central position, pin 52 can be positioned by lever 94 along with pivotal movement of link 38 about pin 66 without disturbing the needle bar. By locating pin 52 with lever 94 in slot 22 beyond slot portion 78, pin 52 is disengaged from member 14 and the needle bar is caused to assume a left or right of center position.
When pin 52 is moved with lever 94 to the left of intermediate portion 78 and 82 in slots 22 and 54 respectively, the pin passes into enlarged end portion 76 of slot 22 wherein the pin is disengaged from member 14. At the same time, pin 52 is moved downwardly by way of ramp 90 into narrowed end portion 84 of slot 54 (FIG. 4), and in so doing acts through link 38, bell crank 40, link 42 and extension 44, to thereby move the needle bar 50 at extension 44 to the left, as viewed in FIG. 1. End portion 84 of slot 54 defines a particular left of center, straight stitching, position for the needle bar.
When pin 52 is moved with lever 94 to the right of intermediate portions 78 and 82 in slots 52 and 54, the pin passes into enlarged end portion 80 of slot 22 and is disengaged from member 14. The pin is then also moved over ramp 92 up into first narrowed end portion 86 of slot 54 (FIG. 5), or over ramps 92 and 93 up into second narrowed end portion 88 of the slot depending upon the extent of movement of lever 94 (FIG. 6). The pin then acts through link 38, bell crank 40, link 42 and extension 44, and thereby causes needle bar 50 at extension 44 to be moved to the right. First narrowed end portion 86 of slot 54 defines a particular right of center, straight stitch portion for the needle bar, and second narrowed end portion 88 of the slot defines a further right of center needle bar position wherein the needle bar is disconnected from the driving mechanism 118 as in the manner described in U.S. Pat. No. 3,782,311 of Kenneth D. Adams et al for "Simplified Basting Stitch Mechanism", issued Jan. 1, 1974.
It is to be understood that the present disclosure relates to a preferred embodiment of the invention which is for purposes of illustration only, and is not to be construed as a limitation of the invention. Numerous alterations and modifications of the structure herein disclosed will suggest themselves to those skilled in the art, and all such modifications and alterations which do not depart from the spirit and scope of the invention are intended to be included within the scope of the appended claims.
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A control for a sewing machine is arranged to enable an operator, utilizing a single input control member, to select the amplitude of side to side motion of a needle bar for pattern sewing, or to dispose the needle bar in defined off-center positions for either straight stitch sewing or for effecting disengagement of the needle bar from driving mechanism.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a method for assaying nucleic acids which can efficiently detect nucleic acids, etc. by fluorescence.
2. Related Art
In medical and biological fields, a means for labeling, for example, a DNA (or RNA) probe with a radioactive isotope, hybridizing the labeled probe with a target nucleic acid and then detecting the target nucleic acid by autoradiography has been currently performed widely.
However, the isotope method involves many drawbacks which are serious obstacles to application and development of this technology.
The drawbacks of the isotope method are as follows.
(a) In nucleic acid hybridization, the isotope method lacks any spatial resolution sufficient to reveal relative positional relationship between contiguous signal.
(b) Experimental procedures using isotopes can only be carried out in isotope laboratories equipped with special facilities. This is a cause for hindering application of the hybridization method especially to clinical inspection.
(c) Use of isotope is dangerous for laboratory workers even in laboratories. In addition, a danger for ordinary people also always exists because of wastes, etc.
(d) A long time (several weeks to several months) may be required for detection, so application to rapid clinical diagnostics is difficult.
(e) Radioactivity decays with a definite half-life period so that experiments should be scheduled to fit a purchase date of the isotope. If the schedule chart is slightly altered, there would be a danger of wasting isotope or experimental results in a large scale.
(f) In order to enhance detect ion sensitivity, it is required to incorporate radioactivity to the nucleic acid probe as high as possible. However, the nucleic acid labeled enough to increase its radioactivity easily suffers from radioactive disintegration.
(g) In general, isotope is extremely expensive and it is not unusual to use isotope worth several hundred yen in one run. This prevents general spread of the hybridization method.
In view of such background, some DNA or RNA labeling methods in place of radioactive isotope have been developed so far. For example, BLU GENE KIT commercially available from Bethesda Research Laboratories Inc. (BRL Inc.) is known. Furthermore, "Nucleic acid probe and use thereof" is disclosed in Japanese Patent Application Laid-Open No. 60-226888.
However, these techniques merely eliminate a part of the drawbacks described above. In particular, detection sensitivity is not comparable to that of the isotope method.
In view of such problems, an object of the present invention is to provide a method for assaying nucleic acids which solves the drawbacks of safety precautions, etc. in the isotope method and provides excellent detection sensitivity.
SUMMARY OF THE INVENTION
The present invention provides a method for assaying nucleic acids or the like which comprises binding phosphatase to a sample such as nucleic acids, etc., reacting the phosphatase with a naphthol derivative phosphate, then irradiating the reaction products with an excited light and detecting fluorescence emitting therefrom.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is the test results detected in Example 1.
FIG. 2 is the test results detected in Example 1.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Examples of the phosphatase include alkali phosphatase acid phosphatase, etc.
The detection of a sample in the present invention includes detection of nucleic acid (DNA or RNA), detection of protein, immunological detection of a chemical compound using antibody, etc.
An example of the phosphatase fluorescence substance wherein a naphtol derivative phosphate used in a method for assaying is represented the formula P-Nap-R .sub.(n).
In the formula described above, Nap represents a naphthalene, P represents a phosphate combined with said naphthalene, R .sub.(n) represents a substitution combined with said naphthalene.
In the formula described above, P-Nap-R .sub.(n) is represented by the following formula 1 or 2: ##STR1##
In the formula 1 or 2 described above, R 1 represents amide, vinyl, alkyl which C are 1˜3, ester, or is represented by the following formula 3: ##STR2##
(In the formula 3 described above, X represents alkoxide, phenoxide), and R 2 represents aryl, condensing aromatic, thio-aryl, alkyl, alkoxide, phenoxide, and R 3 , R 4 are the same or different, and represents hydrogen, halogen, alkyl, alkoxide, phenoxide, aminoacetyl, cyano, ester.
In the formula 1 or 2 described above, R 2 is aryl and represented by the following formula 4: ##STR3##
In the formula 4 described above, M 1 , M 2 , M 3 are the same different, and represent hydrogen, halogen, alkyl where C are 1˜3, alkoxide, phenoxide, aminophenyl, benzyl, aminoacetyl, cyano, or represents by the following formula 5: ##STR4##
In the formula 5 described above, M 4 represents hydrogen, alkyl where C are 1˜3, alkoxide, cyano, aminoacetyl.
In the formula 1 or 2 described above, if R 2 is condensation aromatic, R 2 is represented by the following formula 6, 7, or 8: ##STR5##
In the formula 1 or 2 described above, if R 2 is thioaryl, R 2 is represented by the following formula 9: ##STR6##
In the formula 9 described, M 5 represents hydrogen, alkyl where C is 1 or 2, alkoxide, cyano, aminoacetyl.
In the method for assay in accordance with the present invention, the naphthol derivative phosphate is reacted with the phosphatase described above followed by irradiating with an excited light, whereby the dephosphating product of the naphthol derivative phosphate emits fluorescence. Then, the emitted fluorescence can be detected.
The aforesaid naphthol derivative phosphate is reacted with the phosphatase combined with a sample (e.g. nucleic acids) on a membrane filter made of nylon so as to produce a dephosphating product of the naphthol derivative phosphate, which adheres to the nylon membrane filter and displays fluorescence. Then, fluorescence and the pattern thereof (spots, and bands produced by electrophoresis) are detected by irradiating with the excited light.
In the present invention, intense fluorescence can be obtained by the use of the naphthol derivative phosphate described above so that detection sensitivity can be improved; for example, 10 -13 g of DNA is detectable.
In the present invention, no isotope is used and therefore, the drawbacks of the prior art can be removed.
Thus, according to the present invention, a method for assaying nucleic sensitivity can be presented.
Further, according to the method of the present invention, the dephosphating product of the naphthol derivative phosphate can be produced in high yield.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
For the purpose of verifying the effect of the naphthol derivative phosphate as a probe for nucleic acids, DNA Labeling and Detection kit of Boehringer Mannheim, and 2-allyl[2'-(3,4-dimethylphenyl)]3-naphtol phosphate were used to detect DNA on a nylon membrane filter.
DNA was labeled with digoxigein (Dig), diluted and spotted on the nylon membrane filter. Each of the spots included DNA of herring spermatozoa in the amount of 50 ng (50×10 -9 g) as DNA of no peculiarity.
The aforesaid experiment was conducted on 0.08 to 25 pg of Dig-labeled DNA as shown in FIG. 1. 0 pg in the Figure shows a blank test. The test results are shown in FIG. 1. Reference numeral 1 designates a carrier filter for a specimen of nucleic acids, and 11 designates fluorescence sensitized portions. "+" represents a fact that the DNA can be detected. "±" represents that the DNA cannot distinctly be detected. "-" represents that DNA cannot be detected. As apparent from the above, DNA could satisfactorily be detected even in the small amount of 0.4 pg.
Then, using the smaller amount of the aforesaid DNA, another experiment was conducted on 0.0156 to 0.5 pg of Dig-labeled DNA, another experiment was conducted on 0.0156 to 0.5 pg of Dig-labeled DNA in the same manner as described above. The test results are shown in FIG. 2 similarly in FIG. 1. As shown in FIG. 2, satisfactory detection could be attained in the 0.0125 pg (125 fg). In the amount of 0.125 pg, detection was not satisfactory.
In this former experiment, a conventional color development detection using azo-color, Fast Blue BB (of POLYSCIENCE, INC.) was conducted. As the result of this detection, the detective spot included 0.5 pg (0.5×10 -12 g) of the DNA.
A naphthol derivative phosphate of the present invention was produced by the following processes.
1 mol equivalent amount of 3,4-dimethylbenzylchloride and triphenylphosphine were mixtured, then the mixture was stirred at the room temperature for 10 minutes with no solvent. Next, the mixture was added with 7 ml of the xylene anhydride, then is stirred at the oil temperature 130° for 1 hour. When the crystal was formed, the reaction was terminated. The crystal was filtered by aspiration, and was washed with ether. Then the crystal was re-crystallized with acetonitrile anhydride to give the fall rate 40% of 3,4-dimethylbenzylphosphonium(A) shown by the following formula 10. ##STR7##
At the other hand, 9 ml of pyridine anhydride was added to 5 g of 1-hydroxy-2-naphtoaldehyde, and the mixture were stirred at 0° for 10 minutes, then the mixture was stirred with 2 mol of refined acetic anhydride at 0° C. for 1 hours, next at the room temperature for 2 hours. After reaction, the reaction mixture was stirred with solvent that at a ratio of water/ether:chloroform is 4:1, then was extracted. Then, the organic phase was washed with 1N of HCl until the water phase became faint acid.
Then, the precipitates was washed with water, and after confirming neutral, the precipitates was washed with saturated common salt solution. After drying with magnesium sulfate, the solvent was removed therefrom with the evaporator to give the crystal of 1-acetyl-2-naphthoaldehyde was formed. Then, the crystal was recrystalizated with ethanol anhydride to give the fall rate 50% of 1-acetyl-2-naphthoaldehyde(B) shown by the following formula 11. ##STR8##
Then, 4 ml of tetrahydrofuran anhydride was added with 1.64 g of aforesaid 3,4-dimethetylbenzylphosphonium(A), then after stirring at 0° C. for 10 minutes, the mixture was stirred with 1.1 mol equivalent amount of sodium ethylate at 0° C. for 1 hours. The reaction mixture appeared red.
Then, 1.1 mol equivalent amount of said 1-acetyl-2-naphthoaldehyde (B) was slowly added to 4 ml of tetrahydrofuran anhydride. When red color of reaction solution disappeared, the reaction was stopped with saturated ammonium chloride, then 10% of hydrochloric acid was added to the reaction fluid so that the reaction fluid reached pH=4. Then, the residue was extracted with ether, and was washed with saturated common salt solution, and after drying with magnesium sulfate, the ether was removed therefrom with the evaporator to give the crystal.
The crystal was purified by silica gel column chromatography to give the fall rate 25% of 1-acetyl-2-alyl-[2'-(3,4-dimethylphenyl)]naphthalene(C) shown by the following formula 12. ##STR9##
Then, 4 ml of ethanol was added to 150 mg of said 1-acetyl-2-alyl-[2'-(3,4-dimethylphenyl)]naphthalene(C), and excess calcium carbonate was added to the mixture, then the mixture was stirred at the room temperature for 1 hour. After confirming the disappearance of raw material with TLC, the reaction mixture was filtrated. Then the solvent was removed, and 5 cc of HCl of 1N was added to the mixture, then the mixture was extracted with chloroform, and was washed with saturated common salt solution, and was dried, and was filtrated. Then chloroform was removed from the mixture to give the fall rate 90% of 2-alyl-[2'-(3,4-dimethylphenyl)]naphthol(D) shown by the following formula 13. ##STR10##
Then, 1 g of 2-alyl-[2'-(3,4-dimethylphenyl)]naphthol(D) was added to 8 ml of pyridine, then the mixture was stirred at 0° C. for 30 minutes, and was stirred with cooled oxy-phosphorus chloride (2.5 eq) at 0° C. for 4 hours. After this, the reaction was stopped with ice.
The reaction mixture was purified on a reverse phase silica gel column and then a normal phase silica gel column to give 2-aryl-[2'-(3,4-dimethylphenyl)]3-naphthol phosphatase shown by the following formula 14. ##STR11##
Detection test was conducted on this 2-aryl-[2'-(3,4-dimethylphenyl)]3-naphthol phosphatase.
EXAMPLE 2
According to the description of Enzyme Histochemistry, 5 g (0.027 mol) of 2-hydroxy-3-naphthoic acid, 3.8 g (0.023 mol) of 2-amino-4-methylbenzothiazole and 40 ml of xylene anhydride were stirred in a 100 ml NASU flusk provided with Graham condenser at 80° C. for 10 minutes.
Then, 0.01 mol of phosphorous trichloride was added thereto. The resulting mixture was refluxed for 2 hours. Thereafter, the reaction solution was decanted as in hot state to skim the supernatant fluid. After cooling the fluid at 4° C., it was subjected to filtration. The precipitates thus obtained was eluted with xylene and then water. Further, the precipitates was neutralized with 2% aqueous solution of sodium carbonate, and xylene was removed therefrom by boiling.
Then, the precipitates was rendered pH=9 with 2% aqueous solution of sodium carbonate, filtrated and cooled. The precipitates thus obtained was eluted with water. The precipitates was added to 3% HCl solution, heated, filtrated and then cooled. Then the precipitates was washed with hot water and dried.
Next, the precipitates were recrystallized to produce 3-hydroxy-2-naphthoamide (4 methylbenzothiasole) shown by the following formula 15. ##STR12##
1 g of this naphtol derivative was dissolved in 8 ml of pylidine. After stirring this solution at 0° C. for 30 minutes, phosphous oxychloride (2.5 eq) cooled similarly was added thereto and stirred at 0° C. for 4 hours. Then, ice was added to the solution to terminate the reaction.
The reaction product thus obtained was purified by reverse phase silica gel column chromatography and then by normal phase silica gel column chromatography to produce 3-hydroxy-2-naphtthoamide(4-methylbenzothiasole)phosphate shown by the following formula 16. ##STR13##
EXAMPLE 3
1 g (2.95×10 -3 mol) of 2-hydroxy-3-naphthoic acid (2'-phenylanilide) was dissolved in 10 ml of chloroform anhydride. Next, 0.5 mol equivalent amount of phosphorus 5 chloride(PCl 5 ) was added to the solution and it was stirred at 40° C. for 2 hours. Then, chloroform was removed therefrom with the evaporator. The crystal of residue was dissolved in 10 ml of methanol anhydride, then 10 mol equivalent amount sodium methoxide was added to the solution fluid under ice cooled state. After the solution was stirred at 0° C. all night, the solution was purified by column chromatography to give 100 mg of 2-hydroxy-(2'-phenylanilide)-methyl-3-naphthoate.
Then, 3 ml of pyridine was dissolved with anhydride 2-hydroxy-(2'-phenylanilide)-methyl-3-naphthoate, after this the solution was stirred 0° C. for 30 minutes, and the 2.5 mol equivalent amount of oxy-phosphorus chloride was added to the solution fluid and the solution fluid was stirred 0° C. for 4 hours. After this, the ice was added to solution to terminate the reaction. Then, the solution fluid was purified by reverse silica gel column chromatography to give 30 mg of 2-hydroxy-(2'-phenylanilide)-methyl-3-naphthoate phosphate shown by the following formula 17. ##STR14##
EXAMPLE 4
5 g of 2-amino-3-naphthol (0.0314 mol), 6.2 g of (0.0314 mol) and 40ml of xylene anhydride was stirred in a 100 ml NASU flask at 80° C. for 10 minutes.
Then, in the same manner as Example 2, N-(2'- phenylbenzoic acid)-2-hydroxy-3-naphtylamine phosphate shown by the following formula 18 was given. ##STR15##
EXAMPLE 5
5 g of 2-amino-7-naphthol (0.0314 mol), 6.2 g of (0.0314 mol) and 40 ml of xylene anhydride were stirred in a 100 ml NASU flask at 80° for 10 minutes.
Then, in the same manner as Example 2, N-(4'-phenylbenzoic acid)-2-hydroxy-8-naphthylamine phosphate shown by the following formula 19 was given. ##STR16##
EXAMPLE 6
5 g of 2-hydroxy-6-naphthol (0.011 mol), 1.8 g of 2-phenyl aniline (0.011 mol) and 30 ml of xylene anhydride were stirred in a 100 ml NASU flask at 80° C. for 10 minutes.
Then, in the same manner as Example 2, 2-hydroxy-6-naphthoeacid (2'-phenylanilide) phosphate shown by the following formula 20 was given. ##STR17##
Detection test similar to Example 1 was conducted on each of the naphthol derivative phosphatate by the same method as in Example 1, i.e. spotting on the carrier filter for a specimen of nucleic acids.
The test results are shown in Table 1. As apparent from Table 1, the extremely small amount of DNA can be detected in high sensitivity.
TABLE 1______________________________________ Dig-labeled DNA (pg)EXAMPLE 0 0.125 0.5 1 10 25 50______________________________________1 - ± + + + + +2 - - - ± + + +3 - - - - - - +4 - - - - - - +5 - - - ± + + +6 - - - ± + + +______________________________________
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Methods for detecting nucleic acids in a sample, using naphthol derivative phosphates, are provided. Nucleic acids present in a sample are contacted with phosphatase, producing a modified phosphatase. A naphthol derivative phosphate is contacted with the modified phosphatase to produce a reaction product. Any reaction product formed is detected by irradiating it with an excited light and detecting a fluorescence emitted from the reaction product. Naphthol derivative phosphates useful in these methods are also provided. Methods for production of naphthol derivative phosphates are also provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image display apparatus that includes a liquid crystal spatial light modulating element and is configured to conduct time division display of a frame by dividing the frame into plural sub frames. The present invention also relates to a method of driving a spatial light modulating element with an alternative current.
2. Description of the Related Art
In recent years and continuing, with the dramatic increase in computer processing capabilities, technology for displaying a higher resolution image in a computer is developing and in turn, high resolution capabilities are being demanded in an image display apparatus. However, in apparatuses such as a projector, the resolution of a spatial light modulating element for displaying an image may not be able to keep up with the increasing resolution of the image to be displayed. Accordingly, various techniques are proposed for achieving a higher resolution image in such apparatuses. For example, in Japanese Laid-Open Patent Publication No.2003-90992, a configuration of a projector including an optical deflecting element is disclosed.
FIG. 1 shows a configuration of a projector according to the disclosure of Japanese Laid-Open Patent Publication No.2003-90992. The projector illustrated in this drawing includes an LED light source that is formed by a two-dimensional array of LED lamps and is arranged to emit light towards a screen, a diffuser positioned in the light emitting direction with respect to the light source, a condenser lens, a spatial light modulating element in the form of a transmissive LCD panel, and a projection lens. Further, the projector includes an optical deflecting element that is arranged at the light path between the transmissive LCD panel and the projection lens.
In this projector, illuminating light that is emitted from the LED light source is equalized at the diffuser, and is controlled and synchronized with an illuminating light source by the condenser using an LCD panel drive part to realize critical illumination of the illuminating light onto the transmissive LCD panel. Then, the illuminating light is spatially modulated by the transmissive LCD panel and is incident onto the optical deflecting element as image light. The image light is then shifted by a given distance in the positioning direction of pixels.
Also, in this projector a panel drive part is arranged to divide an image of one frame into plural sub frames so that the sub frames may be sequentially displayed through time divisional display at the transmissive LCD panel. In turn, the optical deflecting element deflects the light path in synch with the display of each sub frame so that the display positions of the sub frames may be shifted with respect to each other. In this way, it may appear as though the number of pixels displayed is multiplied.
The optical deflecting element may correspond to a device for deflecting the light path of incident light and may be realized by forming a lateral directional electrical field on a chiral smectic C liquid crystal layer. According to this example, an average inclination of the optical axis of the chiral smectic C liquid crystal layer, which generates its own polarity, is used to change the electrical field direction to enable high speed light path deflection.
When liquid crystal is used to realize the spatial light modulating element, an alternating current needs to be applied as the drive current for the spatial light modulating element as is known among persons skilled in the art. When a direct current is used as the drive current, the liquid crystal may be susceptible to damage such as burns. Accordingly, in a display apparatus such as a projector including an optical deflecting element that divides an image of one frame into plural sub frames and sequentially displays the sub frames through time division display, a frame polarity reversing drive method is conventionally used for switching the polarity of a drive voltage for the liquid crystal spatial light modulating element. Examples of such a method are illustrated in FIGS. 2˜4 and are described in detail below.
FIG. 2 illustrates an example of dividing a frame into four sub frames and displaying the sub frames with the spatial light modulating element through time division display while changing the light path with the optical deflecting element so that one pixel of the spatial light modulating element displays four pixels on the display screen. The arrows shown in this drawing represent the pixel shifting direction of a light path shifting unit.
FIG. 3 shows a case in which the pixels of the spatial light modulating element displays the same image of FIG. 2 on the screen.
FIG. 4 illustrates an exemplary operation of signals for driving the spatial light modulating element. In this drawing, Vsync represents a vertical synchronizing signal that is generated in sync with a display period T 2 for one sub frame. Vd represents a drive voltage that is applied to a given pixel electrode of the spatial light modulating element. Vcom represents a voltage that is applied to a common electrode. Generally, each pixel is driven by a difference voltage (Vd−Vcom) corresponding to a difference between the drive voltage Vd that is applied to a corresponding pixel electrode and the voltage Vcom that is applied to an opposing electrode corresponding to a common electrode for the pixels that is arranged on the other side of the liquid crystal layer.
It is noted that periods [1] through [4] indicated in this drawing represent the respective sub frame periods making up one frame. As is indicated in the drawing, the polarity of the drive voltage Vd within one period T 1 is reversed with respect to the voltage Vcom in a next frame period T 1 , and in this way, the pixels of the spatial light modulating element may be driven by an alternating current.
However, when a drive method of reversing the polarity for every frame is used, the alternating current drive frequency may be decreased causing a perceptible flicker on the display screen.
Accordingly, a method of increasing the alternating current drive frequency to prevent such a flicker effect is known. Japanese Laid-Open Patent Publication No.6-27902 discloses one example of such a method in which the polarity of the drive voltage Vd is reversed for every vertical synchronization period, that is, for every sub frame period. However, in the case of applying such a method to a projector having a light path shifting unit (e.g., optical deflecting element) as is described above, the applied drive current may end up being a direct current, and thereby, the method may not be directly applied. For example, FIG. 5 illustrates the drive voltage Vd of the spatial light modulating element in the case of applying this method to the projector described above. It may be easily understood from this drawing that the drive voltage Vd in this example ends up being a direct current rather than an alternative current.
Japanese Laid-Open Patent Publication No.6-38149 discloses another exemplary method for preventing the flicker effect in which the polarity of the voltage Vd is reversed with respect to every one or more horizontal synchronizing periods and every vertical synchronizing period. However, this method also creates the same problem as is described above.
Japanese Laid-Open Patent Publication No.7-175443 discloses a method of converting the drive voltage into an alternating current by reversing the drive voltage polarity with respect to every vertical synchronizing period within one sub frame period, the method being realized in a case where a sub frame period and a vertical synchronizing period do not correspond and at least two vertical synchronizing periods are provided within one sub frame to realize high speed writing of image data. FIG. 6 corresponds to a diagram illustrating such an arrangement.
However, in a display apparatus that is arranged to temporarily display a predetermined gray level (e.g., black display) at the spatial light modulating element upon switching the sub frame display, unless the drive voltage for temporarily displaying the predetermined gray level with the pixels of the spatial light modulating element upon switching the sub frame display corresponds to zero, asymmetry is created between positive and negative voltages so that the applied voltage corresponds to a direct current. FIG. 7 illustrates the problem described above in relation to the arrangement of FIG. 6 in which a voltage V 1 is applied for a time period T 3 upon switching the sub frame display.
Generally, at a spatial light modulating element, scanned pixel data are written one line at a time owing to restrictions on the amount of using such a spatial light modulating element that is based on a line-sequential system in the image display apparatus that is capable of multiplying the number of displayed pixels by a light path shifting unit, light shifting is conducted simultaneously on all the pixels of the spatial light modulating element, and thereby, a so-called image crosstalk may occur in which the same image may be displayed before and after the light path shifting resulting in the degradation of image quality.
SUMMARY OF THE INVENTION
The present invention has been conceived in response to the one or more problems of the related art and its object is to provide a technique for preventing damage such as burns from being generated in liquid crystal of a spatial light modulating element due to use of a direct current as the drive current in an image display apparatus that is arranged to divide a frame into plural sub frames and sequentially display the sub frames using the liquid crystal spatial light modulating element.
Also, it is another object of the present invention to provide a technique for preventing a direct current from being superposed on a drive voltage by maintaining the drive voltage polarity reversing order to be constant while changing the order in which the sub frames are to be displayed with respect to each frame.
Also, it is an object of the present invention to provide a technique for effectively preventing screen flicker from occurring in an image display apparatus.
Also, it is an object of the present invention to provide a technique for effectively controlling image display particularly in the case of multiplying the number of displayed pixels using a light path shifting unit.
Also, it is an object of the present invention to provide a technique for preventing damage such as burns from being generated in liquid crystal of a spatial light modulating element due to use of a direct current as a drive voltage in an image display apparatus that is arranged to divide a sub frame period into plural vertical synchronizing periods, reverse the drive voltage polarity for a pixel of the spatial light modulating element for every vertical synchronizing period, and temporarily display a predetermined gray level upon switching the sub frame display.
The present invention according to a first aspect provides an image display apparatus that divides a frame into 2i sub frames (i corresponding to a natural number), the apparatus including:
a liquid crystal spatial light modulating element configured to sequentially display the sub frames; and
a first alternative current drive unit configured to reverse a polarity of a drive voltage for a pixel of the spatial light modulating element for every j sub frame(s) (j corresponding to a natural number that is less than 2i) and for every n frame(s) (n corresponding to a natural number).
The present invention according to a second aspect provides an image display apparatus that divides a frame into 2i sub frames (i corresponding to a natural number), the apparatus including:
a liquid crystal spatial light modulating element configured to sequentially display the sub frames; and
a display control unit configured to reverse a polarity of a drive voltage for a pixel of the spatial light modulating element for every j sub frame(s) (j corresponding to a natural number that is less than 2i) and change a display order of the sub frames for every n frame(s) (n corresponding to a natural number).
According to a preferred embodiment, the image display apparatus of the present invention further includes a second alternative current drive unit configured to reverse the drive voltage polarity for every m horizontal synchronizing period(s) (m corresponding to a natural number).
According to another preferred embodiment, the image display apparatus of the present invention further includes a resetting unit configured to temporarily display the pixel of the spatial light modulating element at a predetermined gray level when the sub frame display is to be switched.
The present invention according to another aspect provides an image display apparatus that divides a frame into 2i sub frames (i corresponding to a natural number), the apparatus including:
a liquid crystal spatial light modulating element configured to sequentially display the sub frames;
a resetting unit configured to temporarily display a pixel of the spatial light modulating element at a predetermined gray level when the sub frame display is to be switched; and
an alternative current drive unit configured to divide a display period of each of the sub frames into 2k periods (k corresponding to a natural number) and reverse a polarity of a drive voltage for the pixel for every divided period and for every n frame(s) or sub frame(s) (n corresponding to a natural number).
The present invention according to another aspect provides an image display apparatus that divides a frame into 2i sub frames (i corresponding to a natural number), the apparatus including:
a liquid crystal spatial light modulating element configured to sequentially display the sub frames;
a resetting unit configured to display a pixel of the spatial light modulating element at a predetermined gray level when the sub frame display is to be switched; and
a display control unit configured to divide a display period of each of the sub frames into 2k periods (k corresponding to a natural number), reverse the drive voltage polarity for every divided period, and change a display order of the sub frames for every n frame(s) (n corresponding to a natural number).
The present invention according to another aspect provides an alternative current drive method for driving a liquid crystal spatial light modulating element of an image display apparatus that divides a frame into 2i sub frames (i corresponding to a natural number) and sequentially displays the sub frames using the spatial light modulating element, the method including the steps of:
reversing a polarity of a drive voltage for a pixel of the spatial light modulating element, for every j sub frame(s) (j corresponding to a natural number that is less than 2i); and
reversing the drive voltage polarity for every n frame(s) (n corresponding to a natural number).
The present invention according to another aspect provides an alternative current drive method for driving a liquid crystal spatial light modulating element of an image display apparatus that divides a frame into 2i sub frames (i corresponding to a natural number) and sequentially displays the sub frames using the spatial light modulating element, the method including the steps of:
reversing a polarity of a drive voltage for a pixel of the spatial light modulating element, for every j sub frame(s) (j corresponding to a natural number that is less than 2i); and
changing a display order of the sub frames for every n frame(s) (n corresponding to a natural number).
The present invention according to another aspect provides an alternative current drive method for driving a liquid crystal spatial light modulating element of an image display apparatus that divides a frame into 2i sub frames (i corresponding to a natural number), sequentially displays the sub frames using the spatial light modulating element, and temporarily displays a pixel of the spatial light modulating element at a predetermined gray level when the sub frame display is to be switched, the method including the steps of:
dividing a display period of each of the sub frames into 2k periods (k corresponding to a natural number);
reversing a polarity of a drive voltage for the pixel of the spatial light modulating element for every divided period; and
reversing the drive voltage polarity for every n frame(s) or sub frame(s) (n corresponding to a natural number).
The present invention according to another aspect provides an alternative current drive method for driving a liquid crystal spatial light modulating element of an image display apparatus that divides a frame into 2i sub frames (i corresponding to a natural number), sequentially displays the sub frames using the spatial light modulating element, and temporarily displays a pixel of the spatial light modulating element at a predetermined gray level when the sub frame display is to be switched, the method including the steps of:
dividing a display period of each of the sub frames into 2k periods (k corresponding to a natural number);
reversing a polarity of a drive voltage for the pixel of the spatial light modulating element for every divided period; and
changing a display order of the sub frames for every n frame(s) (n corresponding to a natural number).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing a configuration of a projector according to the prior art;
FIG. 2 is a diagram illustrating an example of dividing a frame into four sub frames and displaying the sub frames by a spatial light modulating element;
FIG. 3 is a diagram illustrating a frame image that is displayed on a screen in a case where pixels of the spatial light modulating element display the same image of FIG. 2 ;
FIG. 4 is a diagram illustrating an exemplary operation of signals for driving the spatial light modulating element;
FIG. 5 is a diagram illustrating another exemplary operation of signals for driving the spatial light modulating element in a case where the polarity of a drive signal is reversed for every sub frame;
FIG. 6 is a diagram illustrating another exemplary operation of signals for driving the spatial light modulating element in a case where the polarity of a drive signal is reversed for every vertical synchronizing period within a sub frame period;
FIG. 7 is a diagram illustrating another exemplary operation of signals for driving the spatial light modulating element in a case where the polarity of a drive signal is reversed for every vertical synchronizing period within a sub frame period and a voltage V 1 is applied to the drive signal for a period of T 3 when the sub frame display is to be switched;
FIG. 8 is a block diagram showing a configuration of an LCD panel drive unit according to an embodiment of the present invention;
FIG. 9 is a block diagram showing a configuration of a polarity switching unit according to an embodiment of the present invention;
FIG. 10 is a diagram illustrating an exemplary operation of signals according to a first embodiment of the present invention;
FIG. 11 is a diagram illustrating another exemplary operation of signals according to a second embodiment of the present invention;
FIG. 12 is a diagram illustrating another exemplary operation of signals according to a third embodiment of the present invention; and
FIG. 13 is a diagram illustrating another exemplary operation of signals according to a fourth embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, preferred embodiments of the present invention are described with reference to the accompanying drawings.
First Embodiment
FIG. 8 shows a configuration of a panel drive unit that is implemented in an image display apparatus according to an embodiment of the present invention. It is noted that the present embodiment may be applied to the image display apparatus shown in FIG. 1 , for example. In the embodiment described below, it is assumed that one frame is divided into four sub frames and the sub frames are sequentially displayed through time division display by a transmissive LCD panel corresponding to a spatial light modulating element.
As is shown in this drawing, image data of one frame Di may be input to an input interface (I/F), the input image data conforming to a standard such as DVI (Digital Video Interface).
In turn, the input I/F decodes the input signal Di to output image data of three primary colors Ri, Gi, and Bi. Also, the input I/F reproduces and outputs a synchronizing clock WCK, and outputs horizontal and vertical synchronizing signals HD and VD corresponding to the input image.
A write control unit is arranged to determine the number of scanning lines by counting the horizontal synchronizing signal pulse number within a vertical synchronizing period and determine the number of valid pixels within a horizontal synchronizing period based on the synchronizing clock WCK to determine the size of the original image input to the apparatus. Then, the write control unit generates and outputs a write control signal WA for controlling writing of the image data Ri, Gi, and Bi to a frame memory. The write control signal WA includes a write address, which is made up of a horizontal direction address part corresponding to the main scanning direction address, and a vertical direction address part corresponding to the sub scanning direction address.
The frame memory sequentially writes the image data Ri, Gi, and Bi according to the control signal WA and in synch with the synchronizing clock WCK. It is noted that as the frame memory, a memory having a dual port function is preferably used for enabling reading of the image data by a read address RA that is asynchronous with the writing of the image data.
A read control unit is arranged to generate a read address RA for reading image data stored in the frame memory based on a control signal S 1 output from a synchronization control unit. In this case, data corresponding to a sub frame that is to be displayed are sequentially read out.
The frame memory reads image data Ro, Go, and Bo according to the read address RA and outputs the image data to a D/A conversion unit.
The D/A conversion unit converts the image data Ro, Go, and Bo input from the frame memory into voltage signals AR, AG, and AB, and outputs the voltage signals to a polarity switching unit.
The polarity switching unit is arranged to convert the analog image data AR, AG, and AB input from the D/A conversion unit into voltage signals through level conversion with respect to a common voltage Vcom and switch the polarity (positive/negative) of the voltage signals with respect to the common voltage Vcom based on a control signal S 2 from the synchronizing control unit to output signals ARo, AGo, and ABo.
A control signal generating unit is arranged to generate a signal LC for controlling the display of the transmissive LCD panel based on a control signal S 3 from the synchronizing control unit. It is noted that the signal LC includes a vertical synchronizing signal Vsync and the common voltage Vcom.
The synchronizing control unit is arranged to generate the control signals S 1 ˜S 3 for the read control unit, the polarity switching unit, and the control signal generating unit, respectively, as described above. The synchronizing control signal is also generates signals PS 1 and PS 2 for controlling driving of the optical deflecting element, and outputs these signals to the optical deflecting element drive unit.
It is noted that according to the embodiment described below, when the signal PS 1 corresponds to ‘H’ and the signal PS 2 corresponds to ‘L’ for a given pixel of the LCD panel, the optical deflecting element is driven to display the corresponding image at the position for sub frame 1 shown in FIGS. 2 and 3 . Similarly, when the signal PS 1 corresponds to ‘H’ and the signal PS 2 corresponds to ‘H’, the optical deflecting element is driven to display the corresponding image at the position for sub frame 2 . When the signal PS 1 corresponds to ‘L’ and the signal PS 2 corresponds to ‘H’, the optical deflecting element is driven to display the corresponding image at the position for sub frame 3 , and when the signal PS 1 corresponds to ‘L’ and the signal PS 2 corresponds to ‘L’, the optical deflecting element is driven to display the corresponding image at the position for sub frame 4 . However, the present invention is not limited to such an embodiment.
FIG. 9 shows a configuration of the polarity switching unit according to an embodiment of the present invention. It is noted that in this illustrated example, image data AR are input and processed at the polarity switching unit, however, the image data AG and AB may also be processed in the same manner.
According to the present example, an amplifier 1 receives the image data AR from the D/A conversion unit along with the common voltage Vcom added thereto. Accordingly, an image data signal with a positive polarity with respect to the common voltage Vcom is output. On the other hand, amplifier 2 corresponds to a differential amplifier at which the image data AR are supplied as a negative input and the common voltage Vcom is supplied as a positive input. Accordingly, an image data signal with a negative polarity with respect to the common voltage Vcom is output from the amplifier 2 .
An analog switch is controlled by the control signal S 2 , and is arranged to selectively output one of either an output from the amplifier 1 or an output from the amplifier 2 and transmit the selected output to the LCD panel.
It is noted that in the embodiment described below, when the control signal S 2 corresponds to ‘H’, image data with a positive polarity is output, and when the control signal S 2 corresponds to ‘L’, image data with a negative polarity is output. However, the present invention is not limited to this embodiment, and for example, the corresponding relation between the control signal levels H/L and the positive/negative polarity outputs may be reversed. Also, it is noted that in this embodiment, the polarity of the drive voltage within a vertical synchronizing period is arranged to be constant; however, the control signal S 2 may be switched at each horizontal synchronizing period, for example.
FIG. 10 is a diagram illustrating an exemplary operation of signals according an embodiment of the present invention. According to this example, the sub frames are displayed according to a predetermined order such as [1 ], [2], [3], [4] . . . , and the polarity of the drive voltage Vd for a pixel is reversed with respect to the common voltage Vcom for every sub frame as well as for every frame. In this way, the optical deflecting element may be driven by an alternative current so that flicker may be avoided and a good image display quality may be achieved.
Second Embodiment
FIG. 11 shows another exemplary operation of signals according to an embodiment of the present invention. In the present example, the polarity of the drive voltage Vd is switched for every sub frame according to a predetermined cycle, and the respective sub frames within the frames are read alternatingly in the order of [1], [2], [3], [4] and [2], [1], [4], [3]. In this way, the optical deflecting element may be driven by an alternative current so that flicker may be avoided and a good image display quality may be achieved.
Third Embodiment
FIG. 12 illustrates another exemplary operation of signals according to an embodiment of the present invention. In this example, the polarity of the drive voltage Vd is switched for every sub frame according to a predetermined cycle as is the case for the second embodiment; however, in contrast to the second embodiment, the reading order of the sub frames within the frames is alternatingly switched between [1], [2], [4], [3] and [2], [1], [3], [4]. Also, according to this example, upon switching the display of sub frames, the drive voltage is set to V 1 or V 0 so that pixels may temporarily be displayed at a predetermined gray level such as black. In this way, the optical deflecting element may be driven by an alternative current so that flicker may be avoided and a good image display quality may be achieved. In addition, the generation of the so-called image crosstalk in which the same image is displayed before and after pixel shifting may be prevented, and an even higher quality display image may be obtained.
Fourth Embodiment
FIG. 13 illustrates another exemplary operation of signals according to an embodiment of the present invention. In the present example, one sub frame period is arranged to be made up of two vertical synchronizing periods and the polarity of the drive voltage Vd for a pixel is arranged to be reversed for every vertical synchronizing period as well as for every frame period.
It is noted that in the present example, the polarity reversing order within a sub frame period is switched for every frame; however, in another embodiment, the polarity reversing order within a sub frame period may be kept constant and the display order of the sub frames may be switched for every frame.
Further, the present invention is not limited to the specific embodiments described above, and variations and modifications may be made without departing from the scope of the present invention.
The present application is based on and claims the benefit of the earlier filing date of Japanese Patent Application No.2004-025175 filed on Feb. 2, 2004, the entire contents of which are hereby incorporated by reference.
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A reliable image display apparatus is provided that is capable of preventing a direct current from being applied to liquid crystal of a spatial light modulating element so that damage such as burns in the liquid crystal and screen flicker may be prevented and a high resolution image with high image quality may be displayed. The image display apparatus is configured to divide a frame into 2i sub frames (i corresponding to a natural number) and sequentially display the sub frames using the liquid crystal spatial light modulating element. The image display apparatus includes a polarity switching unit configured to reverse the polarity of a drive voltage for a pixel of the spatial light modulating element for every j sub frame(s) (j corresponding to a natural number that is less than 2i) and for every n frame(s)(n corresponding to a natural number).
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] The invention relates generally to the field of pumps, such as compressors and vacuum pumps, and more particularly, to a compressor having a fan guard with a channel to direct cooling air to a piston cylinder.
[0004] Reciprocating piston or diaphragm pumps typically have a metal housing, for example, a cast aluminum alloy, in which bearings are mounted which journal the shaft which drives the pump. A metal housing is needed, particularly for larger pumps, to withstand the forces of driving the piston or diaphragm and containing the pressure exerted in the compression chamber of the pump.
[0005] A rotary electric motor is usually used to drive these pumps and the motor requires cooling. In one such pump, the motor is provided between two housings, each of which is separate from the other and houses one compression chamber. The shaft of the motor is a through shaft so that each end of the shaft mounts one of the pistons or diaphragms that work to vary the volume of the compression chamber in the housing at the corresponding end of the shaft. Further out from where the piston or diaphragm is mounted, a rotary fan blade is mounted to each end of the shaft to draw a flow of cooling air into the housing at that end and blow it onto the rotor and stator coils of the motor.
[0006] For cooling efficiency, it is desirable to make the part of the housing in which the rotary fan blade is mounted circular and just slightly larger than the diameter of the fan blade. The clearance between the tips of the fan blades and the interior housing surface should be as small as possible because, if not, the air drawn into the housing by the fan blades will simply blow back out past the tips of the blade, and not be directed over the coils of the motor. For applications in which the pump is contained inside of a separate enclosure, it may be permissible to leave open the end of the housing at which the fan blade is mounted. However, if the pump is going to be exposed or sold as a stand-alone product, the end of the housing must be closed with a cover that permits air to be drawn into the housing, but prevents the insertion of larger objects or fingers. This cover, typically called a fan guard, should not deleteriously affect the operation of the fan nor add to the lateral size or detract from the appearance of the fan.
[0007] The effectiveness of the cooling system in reducing the stator temperature of the motor affects the range of applications in which the pump may be employed. The voltage at which the motor is driven and the output pressure of the pump affect the amount of heat that is generated in the motor. More effective cooling expands the range of applications suitable for a given pump and motor.
[0008] The motor is not the only temperature-sensitive component in a pump. Wobble pistons are sometimes used in oil-less air compressors and vacuum pumps. A wobble piston includes a peripheral seal on the piston head that engages the cylinder bore. The piston head and its connecting rod are fixed to each other, and the connecting rod is mounted on an eccentric on a shaft. As the eccentric is turned by the shaft, the wobble piston is moved in and out and “wobbles” from side to side. Wobble pistons typically employ a Teflon® or other similar material disc or cup which serves both as a guide for the wobble piston and as a pneumatic seal between the piston and the wall of the cylinder in which it moves. The working surface of the cylinder has a hardened polished surface, providing a smooth surface for cooperating with the Teflon® seal of the piston. The service life of the Teflon® material depends in part on the temperature of the cylinder with which the seal interfaces. A higher temperature typically corresponds to a shorter service life due to increased friction between the cup and the cylinder wall.
[0009] The bearings used to support the motor shaft also have a service life determined at least in part by temperature. Generally, a higher bearing temperature equates to a shorter bearing service life.
[0010] Hence, cooling efficiency not only affects the range of applications for a particular pump, but also the service life of temperature-sensitive components in the pump. The present invention addresses these problems.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention is directed generally to a fan guard that directs cooling air flow to a piston cylinder.
[0012] One aspect of the invention is seen in a pump including a housing, a shaft supported by the housing, a piston assembly, a fan blade, and a fan guard. The piston assembly includes a piston cylinder and is operably coupled to the shaft. The fan blade is operable to generate cooling flow. The fan guard is mounted to the housing and includes a channel configured to direct at least a first portion of the cooling flow to the piston cylinder.
[0013] Another aspect of the present invention is seen in a fan guard. The fan guard includes a front surface defining a cooling flow opening and sidewalls defining a channel having a first end proximate the cooling flow opening. A baffle is positioned proximate a second end of the channel.
[0014] Other objects, advantages and features of the present invention will become apparent from the following specification when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements and in which:
[0016] FIG. 1 is an isometric view of a pump in accordance with one embodiment of the present invention;
[0017] FIG. 2 is a partial cross section view of the pump of FIG. 1 ;
[0018] FIG. 3 is an end view of the pump of FIG. 1 with the fan guard removed; and
[0019] FIG. 4 is an isometric back view of a fan guard employed in the pump of FIG. 1 .
[0020] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0021] While the present invention may be embodied in any of several different forms, the present invention is described here with the understanding that the present disclosure is to be considered as setting forth an exemplification of the present invention that is not intended to limit the invention to the specific embodiment(s) illustrated. Nothing in this application is considered critical or essential to the present invention unless explicitly indicated as being “critical” or “essential.”
[0022] FIG. 1 illustrates a pump 10 of the invention having a motor 12 with a housing 14 at one end and a housing 16 at the other. The housings 14 , 16 are cast of aluminum alloy and are essentially identical. A head assembly 18 , which includes head members 20 , 22 and connecting tubes 24 , 26 , is bolted to the housings 14 , 16 above respective compression chamber portions 28 , 30 of the housings 14 , 16 to help hold the housings 14 , 16 together and maintain their angular position with respect to each other. The pump 10 also includes fan guards 32 , one at each end, which are essentially identical to one another. The pump 10 of the present invention may be employed in a variety of applications, including but not limited to cable drying, sewage aeration, tire inflation, etc.
[0023] Referring to FIGS. 2 and 3 , a partial cross section view of the pump 10 and an end view of the pump 10 with the fan guard 32 removed are shown, respectively. The motor 12 has a shaft 34 which extends through it and into both housings 14 , 16 , nearly to the end of each respective housing 14 , 16 . As both housings 14 , 16 are essentially identical, only the housing 14 is shown in FIG. 2 . Each end of the shaft 34 mounts a rotary fan blade 36 which is rotated by the shaft 34 within a fan cavity 37 defined by the housing 14 in a direction so as to draw air into each respective housing 14 , 16 and direct it over the coils of the motor 12 (i.e., an axial component of the cooling flow). In one embodiment, the rotary fan blade 36 is secured to the shaft 34 using a spring clip 38 .
[0024] The housings 14 , 16 are provided with ventilation slots 39 to allow the exhausting of cooling air. The housings 14 , 16 mount bearings 40 which journal the shaft 34 . The housings 14 , 16 also have openings (not shown) in them which provide for the axial through-flow of air so that air moved by the fan blade 36 reaches the coils of the motor 12 .
[0025] The pump 10 includes a piston assembly 42 including a piston cylinder 44 and a piston head 46 operating within the piston cylinder 44 to compress the operating fluid (e.g., air) to provide the pumping action. The piston head 46 is coupled by a connecting rod 48 to an eccentric 50 fixed to the shaft 34 . In operation, the shaft 34 and attached eccentric 50 rotates causing the connecting rod 48 and piston head 46 to move within the piston cylinder 44 . A flapper valve (not shown) mounted to the valve plate 52 allows the air to enter the piston cylinder 44 on the downstroke of the piston cycle and seals to prevent air passage on the upstroke. The piston head 46 also includes a piston cup 54 constructed of Teflon® or other similar material that provides a sliding seal between the piston head 46 and the piston cylinder 44 . The piston cup 54 has a service life that may vary based on the temperature of the piston cylinder 44 , with a higher cylinder temperature resulting in a shorter service life.
[0026] Besides allowing axial cooling air flow to dissipate heat that is transferred from the motor 12 to the housings 14 , 16 to the bearings 40 , the fan guard 32 also directs cooling flow over the piston cylinder 44 to dissipate heat generated during the compression process. The housings 14 , 16 includes openings 56 (shown in FIG. 1 ) to allow the exhaust of cooling air directed over the piston cylinder 44 .
[0027] Turning now to FIG. 4 an isometric back view of the fan guard 32 is provided. The front surface of the fan guard 32 is visible in FIG. 1 . The fan guard 32 defines a cooling flow opening 57 in its front surface to provide for the passage of cooling flow past the fan guard 32 . The fan guard includes rib members 58 spanning the cooling flow opening 57 and support members 60 running perpendicular to the rib members 58 . The spacing and arrangement of the rib and support members 58 , 60 may vary depending on the particular implementation. In general, the rib and support members 58 , 60 are arranged to allow the passage of cooling flow, but to prevent foreign objects from entering the area proximate the moving rotary fan blade 36 . In the illustrated embodiment, the fan guard 32 is made of a resilient plastic resin, such as a polyester polymer. The fan guard 32 includes a tab 62 that interfaces with a corresponding notch 64 (shown in FIG. 2 ) in the housing 14 to secure the bottom portion of the fan guard 32 to the housing 16 . Mounting holes 66 are defined in the fan guard 32 to allow the passage of screws for securing the fan guard 32 to the housing 14 via corresponding holes 68 (shown in FIG. 3 ) in the housing 14 . Any means may be used to secure the fan guard 32 to the housing 14 .
[0028] The fan guard 32 includes sidewalls 70 that define a channel 72 . The channel 72 terminates in a baffle 74 that changes the direction of radial cooling flow generated by the rotary fan blade 36 to impinge on the piston cylinder 44 , as indicated by the arrow 76 shown in FIG. 2 . The sidewalls 70 also define a flared portion 78 that collects the radial air flow and directs the flow into the channel 72 .
[0029] Returning to FIG. 2 , the rotary fan blade 36 includes an extended hub 80 that abuts the eccentric 50 to positively locate the rotary fan blade 36 along the shaft 34 within the fan cavity 37 . The rotary fan blade 36 is positioned to optimize the cooling provided to the piston cylinder 44 by the cooling flow redirected by the fan guard 32 . The optimal shaft position may be determined empirically and may vary depending on the particular geometry of the pump 10 . In the illustrated embodiment, the rotary fan blade 36 extends axially beyond the fan cavity 37 defined by the housing 14 into the space bounded by the fan guard 32 . This position has been found to increase the effectiveness of the fan guard 32 in redirecting the radial air flow to cool the piston cylinder 44 .
[0030] Redirecting cooling flow over the piston cylinder 44 , as described herein, reduces the operating temperature of the piston assembly 42 . The combination of the rotary fan blade 36 and fan guard 32 also reduces the temperature of the bearings 40 and the motor 12 . Such temperature reductions increase the operating lives of the piston cup 54 and the bearings 40 for a given set of operating conditions. The improved heat dissipation characteristics may also be employed to extend the operating range of the pump 10 to allow operation at higher pressures, different voltages, and/or lower frequency voltage inputs.
[0031] The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the claims below.
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A pump includes a housing, a shaft supported by the housing, a piston assembly, a fan blade, and a fan guard. The piston assembly includes a piston cylinder and is operably coupled to the shaft. The fan blade is operable to generate cooling flow. The fan guard is mounted to the housing and includes a channel configured to direct at least a first portion of the cooling flow to the piston cylinder.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Nonprovisional application Ser. No. 11/199,856, entitled “Noise Suppressing Multi-Microphone Headset” and filed on Aug. 8, 2005, which claims the benefit of U.S. Provisional Application No. 60/599,468, entitled “Jawbone Headset” and filed Aug. 6, 2004; this application further claims the benefit of U.S. Provisional Application No. 60/599,618, entitled “Wind and High Noise Compensation in a Headset” and filed Aug. 6, 2004, all of which are herein incorporated by reference for all purposes.
[0002] This application is related to the following U.S. patent applications assigned to AliphCom, of San Francisco, Calif. These include:
1. A unique noise suppression algorithm (reference Method and Apparatus for Removing Noise from Electronic Signals, filed Nov. 21, 2002, and Voice Activity Detector ( VAD )— Based Multiple Microphone Acoustic Noise Suppression, filed Sep. 18, 2003) 2. A unique microphone arrangement and configuration (reference Microphone and Voice Activity Detection ( VAD ) Configurations for use with Communications Systems, filed Mar. 27, 2003) 3. A unique voice activity detection (VAD) sensor, algorithm, and technique (reference Acoustic Vibration Sensor, filed Jan. 30, 2004, and Voice Activity Detection ( VAD ) Devices and Systems, filed Nov. 20, 2003) 4. An incoming audio enhancement system named Dynamic Audio Enhancement (DAE) that filters and amplifies the incoming audio in order to make it simpler for the user to better hear the person on the other end of the conversation (i.e. the “far end”). 5. A unique headset configuration that uses several new techniques to ensure proper positioning of the loudspeaker, microphones, and VAD sensor as well as a comfortable and stable position.
All of the U.S. patents referenced herein are incorporated by reference herein in their entirety.
FIELD
[0008] The disclosed embodiments relate to systems and methods for detecting and processing a desired signal in the presence of acoustic noise.
BACKGROUND
[0009] Many noise suppression algorithms and techniques have been developed over the years. Most of the noise suppression systems in use today for speech communication systems are based on a single-microphone spectral subtraction technique first develop in the 1970's and described, for example, by S. F. Boll in “Suppression of Acoustic Noise in Speech using Spectral Subtraction,” IEEE Trans. on ASSP, pp. 113-120, 1979. These techniques have been refined over the years, but the basic principles of operation have remained the same. See, for example, U.S. Pat. No. 5,687,243 of McLaughlin, et al., and U.S. Pat. No. 4,811,404 of Vilmur, et al. Generally, these techniques make use of a microphone-based Voice Activity Detector (VAD) to determine the background noise characteristics, where “voice” is generally understood to include human voiced speech, unvoiced speech, or a combination of voiced and unvoiced speech.
[0010] The VAD has also been used in digital cellular systems. As an example of such a use, see U.S. Pat. No. 6,453,291 of Ashley, where a VAD configuration appropriate to the front-end of a digital cellular system is described. Further, some Code Division Multiple Access (CDMA) systems utilize a VAD to minimize the effective radio spectrum used, thereby allowing for more system capacity. Also, Global System for Mobile Communication (GSM) systems can include a VAD to reduce co-channel interference and to reduce battery consumption on the client or subscriber device.
[0011] These typical microphone-based VAD systems are significantly limited in capability as a result of the addition of environmental acoustic noise to the desired speech signal received by the single microphone, wherein the analysis is performed using typical signal processing techniques. In particular, limitations in performance of these microphone-based VAD systems are noted when processing signals having a low signal-to-noise ratio (SNR), and in settings where the background noise varies quickly. Thus, similar limitations are found in noise suppression systems using these microphone-based VADs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 Overview of the Pathfinder noise suppression system.
[0013] FIG. 2 Overview of the VAD device relationship with the VAD algorithm and the noise suppression algorithm. embodiment.
[0014] FIG. 3 Flow chart of SSM sensor VAD embodiment.
[0015] FIG. 4 Example of noise suppression performance using the SSM VAD.
[0016] FIG. 5 A specific microphone configuration embodiment as used with the Jawbone headset.
[0017] FIG. 6 Simulated magnitude response of a cardioid microphone at a single frequency.
[0018] FIG. 7 Simulated magnitude responses for Mic 1 and Mic 2 of Jawbone-type microphone configuration at a single frequency.
[0019] FIG. 1-A : Side slice view of an SSM (acoustic vibration sensor).
[0020] FIG. 2A-A : Exploded view of an SSM.
[0021] FIG. 2B-A : Perspective view of an SSM.
[0022] FIG. 3-A : Schematic diagram of an SSM coupler.
[0023] FIG. 4-A : Exploded view of an SSM under an alternative embodiment.
[0024] FIG. 5-A : Representative areas of SSM sensitivity on the human head.
[0025] FIG. 6-A : Generic headset with SSM placed at many different locations.
[0026] FIG. 7-A : Diagram of a manufacturing method that may be used to construct an SSM.
[0027] FIG. 8 : Diagram of the magnitude response of the FIR highpass filter used in the DAE algorithm to increase intelligibility in high-noise acoustic environments.
[0028] FIG. 1-B : Perspective view of an assembled Jawbone earpiece.
[0029] FIG. 2-B : Perspective view of other side of Jawbone earpiece.
[0030] FIG. 3-B : Perspective view of assembled Jawbone earpiece.
[0031] FIG. 4-B : Perspective Exploded and Assembled view of Jawbone earpiece.
[0032] FIG. 5-B : Perspective exploded view of torsional spring-loading mechanism of Jawbone earpiece.
[0033] FIG. 6-B : Perspective view of control module.
[0034] FIG. 7-B : Perspective view of microphone and sensor booty of Jawbone earpiece.
[0035] FIG. 8-B : Top view orthographic drawing of headset on ear illustrating the angle between the earloop and body of Jawbone earpiece.
[0036] FIG. 9-B : Top view orthographic drawing of headset on ear illustrating forces on earpiece and head of user.
[0037] FIG. 10-B : Side view orthographic drawing of headset on ear illustrating force applied by earpiece to pinna.
DETAILED DESCRIPTION
The Pathfinder Noise Suppression System
[0038] FIG. 1 is a block diagram of the Pathfinder noise suppression system 100 including the Pathfinder noise suppression algorithm 101 and a VAD system 102 , under an embodiment. It also includes two microphones MIC 1110 and MIC 2112 that receive signals or information from at least one speech source 120 and at least one noise source 122 . The path s(n) from the speech source 120 to MIC 1 and the path n(n) from the noise source 122 to MIC 2 are considered to be unity. Further, H 1 (z) represents the path from the noise source 122 to MIC 1 , and H 2 (z) represents the path from the signal source 120 to MIC 2 .
[0039] A VAD signal 104 , derived in some manner, is used to control the method of noise removal, and is related to the noise suppression technique discussed below as shown in FIG. 2 . A preview of the VAD technique discussed below using an acoustic transducer (called the Skin Surface Microphone, or SSM) is shown in FIG. 3 . Referring back to FIG. 1 , the acoustic information coming into MIC 1 is denoted by m 1 (n). The information coming into MIC 2 is similarly labeled m 2 (n). In the z (digital frequency) domain, we can represent them as M 1 (z) and M 2 (z). Thus
[0000] M 1 ( z )= S ( z )+ N ( z ) H 1 ( z )
[0000] M 2 ( z )= N ( z )+ S ( z ) H 2 ( z ) (1)
[0040] This is the general case for all realistic two-microphone systems. There is always some leakage of noise into MIC 1 , and some leakage of signal into MIC 2 . Equation 1 has four unknowns and only two relationships and, therefore, cannot be solved explicitly. However, perhaps there is some way to solve for some of the unknowns in Equation 1 by other means. Examine the case where the signal is not being generated, that is, where the VAD indicates voicing is not occurring. In this case, s(n)=S(z)=0, and Equation 1 reduces to
[0000] M 1n ( z )= N ( z ) H 1 ( z )
[0000] M 2n ( z )= N ( z )
[0000] where the n subscript on the M variables indicate that only noise is being received. This leads to
[0000]
M
1
n
(
z
)
=
M
2
n
(
z
)
H
1
(
z
)
H
1
(
z
)
=
M
1
n
(
z
)
M
2
n
(
z
)
(
2
)
[0041] Now, H 1 (z) can be calculated using any of the available system identification algorithms and the microphone outputs when only noise is being received. The calculation should be done adaptively in order to allow the system to track any changes in the noise.
[0042] After solving for one of the unknowns in Equation 1, H 2 (z) can be solved for by using the VAD to determine when voicing is occurring with little noise. When the VAD indicates voicing, but the recent (on the order of 1 second or so) history of the microphones indicate low levels of noise, assume that n(s)=N(z)≠0. Then Equation 1 reduces to
[0000] M 1s ( z )= S ( z )
[0000] M 2s ( z )= S ( z ) H 2 ( z )
[0000] which in turn leads to
[0000]
M
2
s
(
z
)
=
M
1
s
(
z
)
H
2
(
z
)
H
2
(
z
)
=
M
2
s
(
z
)
M
1
s
(
z
)
[0000] This calculation for H 2 (z) appears to be just the inverse of the H 1 (z) calculation, but remember that different inputs are being used. Note that H 2 (z) should be relatively constant, as there is always just a single source (the user) and the relative position between the user and the microphones should be relatively constant. Use of a small adaptive gain for the H 2 (z) calculation works well and makes the calculation more robust in the presence of noise.
[0043] Following the calculation of H 1 (z) and H 2 (z) above, they are used to remove the noise from the signal. Rewriting Equation 1 as
[0000] S ( z )= M 1 ( z )− N ( z ) H 1 ( z )
[0000] N ( z )= M 2 ( z )− S ( z ) H 2 ( z )
[0000] S ( z )= M 1 ( z )−[ M 2 ( z )− S ( z ) H 2 ( z )] H 1 ( z )
[0000] S ( z )[1 −H 2 ( z ) H 1 ( z )]= M 1 ( z )− M 2 ( z ) H 1 ( z )
[0000] allows solving for S(z)
[0000]
S
(
z
)
=
M
1
(
z
)
-
M
2
(
z
)
H
1
(
z
)
1
-
H
2
(
z
)
H
1
(
z
)
(
3
)
[0000] Generally, H 2 (z) is quite small, and H 1 (z) is less than unity, so for most situations at most frequencies
[0000] H 2 ( z ) H 1 ( z )<<1,
[0000] and the signal can be estimated using
[0000] S(z)≈M 1 (z)−M 2 (z)H 1 (z) (4)
[0000] Therefore the assumption is made that H 2 (z) is not needed, and H 1 (z) is the only transfer function to be calculated. While H 2 (z) can be calculated if desired, good microphone placement and orientation can obviate the need for the H 2 (z) calculation.
[0044] Significant noise suppression can best be achieved through the use of multiple subbands in the processing of acoustic signals. This is because most adaptive filters used to calculate transfer functions are of the FIR type, which use only zeros and not poles to calculate a system that contains both zeros and poles as
[0000]
H
1
(
z
)
→
MODELS
B
(
z
)
A
(
z
)
[0000] Such a model can be sufficiently accurate given enough taps, but this can greatly increases computational cost and convergence time. What generally occurs in an energy-based adaptive filter system such as the least-mean squares (LMS) system is that the system matches the magnitude and phase well at a small range of frequencies that contains more energy than other frequencies. This allows the LMS to fulfill its requirement to minimize the energy of the error to the best of its ability, but this fit may cause the noise in areas outside of the matching frequencies to rise, reducing the effectiveness of the noise suppression.
[0045] The use of subbands alleviates this problem. The signals from both the primary and secondary microphones are filtered into multiple subbands, and the resulting data from each subband (which can be frequency shifted and decimated if desired, but it is not necessary) is sent to its own adaptive filter. This forces the adaptive filter to try to fit the data in its own subband, rather than just where the energy is highest in the signal. The noise-suppressed results from each subband can be added together to form the final denoised signal at the end. Keeping everything time-aligned and compensating for filter shifts is essential, and the result is a much better model to the system than the single-subband model at the cost of increased memory and processing requirements.
[0046] An example of the noise suppression performance using this system with an SSM VAD device is shown in FIG. 4 . In the top plot is the original noisy acoustic signal 402 and the SSM-derived VAD signal 404 , the middle plot displays the SSM signal as taken on the cheek 412 , and the bottom plot the cleaned signal after noise suppression 422 using the Pathfinder algorithm outline above.
[0047] More information may be found in the applications referenced above in the Introduction, part 1.
[0048] Microphone Configuration
[0049] In an embodiment of the Pathfinder noise suppression system, unidirectional or omnidirectional microphones may be employed. A variety of microphone configurations that enable Pathfinder are shown in the references in the Introduction, part 2. We will examine only a single embodiment as implemented in the Jawbone headset, but many implementations are possible as described in the references cited in the Introduction, so we are not so limited by this embodiment.
[0050] The use of directional microphones has been very successful and is used to ensure that the transfer functions H 1 (z) and H 2 (z) remain significantly different. If they are too similar, the desired speech of the user can be significantly distorted. Even when they are dissimilar, some speech signal is received by the noise microphone. If it is assumed that H 2 (z)=0, then, as in Equation 4 above, even assuming a perfect VAD there will be some distortion. This can be seen by referring to Equation 3 and solving for the result when H 2 (z) is not included:
[0000] S ( z )[1 −H 2 ( z ) H 1 ( z )]= M 1 ( z )− M 2 ( z ) H 1 ( z ) (5)
[0000] This shows that the signal will be distorted by the factor [1−H 2 (z)H 1 (z)]. Therefore, the type and amount of distortion will change depending on the noise environment. With very little noise, H 1 (z) is nearly zero and there is very little distortion. With noise present, the amount of distortion may change with the type, location, and intensity of the noise source(s). Good microphone configuration design minimizes these distortions.
[0051] An embodiment of an appropriate microphone configuration is one in which two directional microphones are used as shown in configuration 500 in FIG. 5 . The relative angle f between vectors normal to the faces of the microphones is in a range between 60 and 135 degrees. The distances d 1 and d 2 are each in the range of zero (0) to 15 centimeters, with best performance coming with distances between 0 and 2 cm. This configuration orients one the speech microphone, termed MIC 1 above, toward the user's mouth, and the noise microphone, termed MIC 2 above, away from the user's mouth. Assuming that the two microphones are identical in terms of spatial and frequency response, changing the value of the angle f will change the overlap of the responses of the microphones. This is demonstrated in FIG. 6 and FIG. 7 for cardioid microphones. In FIG. 6 , a simulated spatial response at a single frequency is shown for a cardioid microphone. The body of the microphone is denoted by 602 , the response by 610 , the null of the response by 612 , and the maximum of the response by 614 . In FIG. 7 , the responses of two cardioid microphones are shown with f=90 degrees. The responses overlap, and where the response of Mic 1 is greater than that of Mic 2 the gain G
[0000]
G
=
M
1
(
z
)
M
2
(
z
)
[0000] is greater than 1 ( 730 ), and where the response of Mic 1 is less than Mic 2 G is less than 1 ( 720 ). Clearly as the angle f between the microphones is varied, the amount of overlap and thus the areas where G is greater or less than one varies as well. This variation affects the noise suppression performance both in terms of the amount of noise suppression and the amount of speech distortion, and a good compromise between the two must be found by adjusting f until satisfactory performance is realized.
[0052] In addition, the overlap of microphone responses can be induced or further changed by the addition of front and rear vents to the microphone mount. These vents change the response of the microphone by altering the delay between the front and rear faces of the diaphragm. Thus, vents can be used to alter the response overlap and thereby change the denoising performance of the system.
Design Tips:
[0053] A good microphone configuration can be difficult to construct. The foundation of the process is to use two microphones that have similar noise fields and different speech fields. Simply put, to the microphones the noise should appear to be about the same and the speech should be different. This similarity for noise and difference for speech allows the algorithm to remove noise efficiently and remove speech poorly, which is desired. Proximity effects can be used to further increase the noise/speech difference (NSD) when the microphones are located close to the mouth, but orientation is the primary difference vehicle when the microphones are more than about five to ten centimeters from the mouth. The NSD is defined as the amount of difference in the speech energy detected by the microphones minus the difference in the noise energy in dB. NSDs of 4-6 dB result in both good noise suppression and low speech distortion. NSDs of 0-4 dB result in excellent noise suppression but high speech distortion, and NSDs of 6+ dB result in good to poor noise suppression and very low speech distortion. Naturally, since the response of a directional microphone is directly related to frequency, the NSD will also be frequency dependent, and different frequencies of the same noise or speech may be denoised or devoiced by different amounts depending on the NSD for that frequency.
[0054] Another very important stipulation is that there should be little or no noise in Mic 1 that is not detected in some way by Mic 2 . In fact, generally, the closer the levels (energies) of the noise in Mic 1 and Mic 2 , the better the noise suppression. However, if the speech levels are about the same in both microphones, then speech distortion due to de-voicing will also be high, and the overall increase in SNR may be low. Therefore it is crucial that the noise levels be as similar as possible while the speech levels are as different as possible. It is normally not possible to simultaneously minimize noise differences while maximizing speech differences, so a compromise must be made. Experimentation with a configuration can often yield one that works reasonably well for noise suppression and acceptable speech distortion.
[0055] In summary, the design process rules can be stated as follows:
1. The noise energy should be about the same in both microphones 2. The speech energy has to be different in the microphones 3. Take advantage of proximity effect to maximize NSD 4. Keep the distance between the microphones as small as practical 5. Use venting effects on the directionality of the microphones to get the NSD to around 4-6 dB
[0061] In the configuration above, the amount of response overlap, and therefore the angle between the axes of the microphones f will depend on the responses of the microphones as well as mounting and venting of the microphones. However, a useable configuration is readily found through experimentation.
[0062] The microphone configuration implementation described above is a specific implementation of one of many possible implementations, but the scope of this application is not so limited. There are many ways to specifically implement the ideas and techniques presented above, and the specified implementation is simply one of many that are possible. For example, the references cited in the Introduction contain many different variations on the configuration of the microphones.
[0063] VAD Device
[0064] The VAD device for the Jawbone headset is based upon the references given in the Introduction part 3. It is an acoustic vibration sensor, also referred to as a speech sensing device, also referred to as a Skin Surface Microphone (SSM), and is described below. The acoustic vibration sensor is similar to a microphone in that it captures speech information from the head area of a human talker or talker in noisy environments. However, it is different than a conventional microphone in that it is designed to be more sensitive to speech frequencies detected on the skin of the user than environmental acoustic noise. This technique is normally only successful for a limited range of frequencies (normally ˜100 Hz to 1000 Hz, depending on the noise level), but this is normally sufficient for excellent VAD performance.
[0065] Previous solutions to this problem have either been vulnerable to noise, physically too large for certain applications, or cost prohibitive. In contrast, the acoustic vibration sensor described herein accurately detects and captures speech vibrations in the presence of substantial airborne acoustic noise, yet within a smaller and cheaper physical package. The noise-immune speech information provided by the acoustic vibration sensor can subsequently be used in downstream speech processing applications (speech enhancement and noise suppression, speech encoding, speech recognition, talker verification, etc.) to improve the performance of those applications.
[0066] The following description provides specific details for a thorough understanding of, and enabling description for, embodiments of a transducer. However, one skilled in the art will understand that the invention may be practiced without these details. In other instances, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments of the invention.
[0067] FIG. 1-A is a cross section view of an acoustic vibration sensor 100 , also referred to herein as the sensor 100 , under an embodiment. FIG. 2A-A is an exploded view of an acoustic vibration sensor 100 , under the embodiment of FIG. 1-A . FIG. 2B-B is perspective view of an acoustic vibration sensor 100 , under the embodiment of FIG. 1-A . The sensor 100 includes an enclosure 102 having a first port 104 on a first side and at least one second port 106 on a second side of the enclosure 102 . A diaphragm 108 , also referred to as a sensing diaphragm 108 , is positioned between the first and second ports. A coupler 110 , also referred to as the shroud 110 or cap 110 , forms an acoustic seal around the enclosure 102 so that the first port 104 and the side of the diaphragm facing the first port 104 are isolated from the airborne acoustic environment of the human talker. The coupler 110 of an embodiment is contiguous, but is not so limited. The second port 106 couples a second side of the diaphragm to the external environment.
[0068] The sensor also includes electret material 120 and the associated components and electronics coupled to receive acoustic signals from the talker via the coupler 110 and the diaphragm 108 and convert the acoustic signals to electrical signals. Electrical contacts 130 provide the electrical signals as an output. Alternative embodiments can use any type/combination of materials and/or electronics to convert the acoustic signals to electrical signals and output the electrical signals.
[0069] The coupler 110 of an embodiment is formed using materials having acoustic impedances similar to the impedance of human skin (the characteristic acoustic impedance of skin is approximately 1.5×10 6 Pa×s/m). The coupler 110 therefore, is formed using a material that includes at least one of silicone gel, dielectric gel, thermoplastic elastomers (TPE), and rubber compounds, but is not so limited. As an example, the coupler 110 of an embodiment is formed using Kraiburg TPE products. As another example, the coupler 110 of an embodiment is formed using Sylgard® Silicone products.
[0070] The coupler 110 of an embodiment includes a contact device 112 that includes, for example, a nipple or protrusion that protrudes from either or both sides of the coupler 110 . In operation, a contact device 112 that protrudes from both sides of the coupler 110 includes one side of the contact device 112 that is in contact with the skin surface of the talker and another side of the contact device 112 that is in contact with the diaphragm, but the embodiment is not so limited. The coupler 110 and the contact device 112 can be formed from the same or different materials.
[0071] The coupler 110 transfers acoustic energy efficiently from skin/flesh of a talker to the diaphragm, and seals the diaphragm from ambient airborne acoustic signals. Consequently, the coupler 110 with the contact device 112 efficiently transfers acoustic signals directly from the talker's body (speech vibrations) to the diaphragm while isolating the diaphragm from acoustic signals in the airborne environment of the talker (characteristic acoustic impedance of air is approximately 415 Pa×s/m). The diaphragm is isolated from acoustic signals in the airborne environment of the talker by the coupler 110 because the coupler 110 prevents the signals from reaching the diaphragm, thereby reflecting and/or dissipating much of the energy of the acoustic signals in the airborne environment. Consequently, the sensor 100 responds primarily to acoustic energy transferred from the skin of the talker, not air. When placed against the head of the talker, the sensor 100 picks up speech-induced acoustic signals on the surface of the skin while airborne acoustic noise signals are largely rejected, thereby increasing the signal-to-noise ratio and providing a very reliable source of speech information.
[0072] Performance of the sensor 100 is enhanced through the use of the seal provided between the diaphragm and the airborne environment of the talker. The seal is provided by the coupler 110 . A modified gradient microphone is used in an embodiment because it has pressure ports on both ends. Thus, when the first port 104 is sealed by the coupler 110 , the second port 106 provides a vent for air movement through the sensor 100 . The second port is not required for operation, but does increase the sensitivity of the device to tissue-borne acoustic signals. The second port also allows more environmental acoustic noise to be detected by the device, but the device's diaphragm's sensitivity to environmental acoustic noise is significantly decreased by the loading of the coupler 110 , so the increase in sensitivity to the user's speech is greater than the increase in sensitivity to environmental noise.
[0073] FIG. 3-A is a schematic diagram of a coupler 110 of an acoustic vibration sensor, under the embodiment of FIG. 1-A . The dimensions shown are in millimeters and are only intended to serve as an example for one embodiment. Alternative embodiments of the coupler can have different configurations and/or dimensions. The dimensions of the coupler 110 show that the acoustic vibration sensor 100 is small (5-7 mm in diameter and 3-5 mm thick on average) in that the sensor 100 of an embodiment is approximately the same size as typical microphone capsules found in mobile communication devices. This small form factor allows for use of the sensor 110 in highly mobile miniaturized applications, where some example applications include at least one of cellular telephones, satellite telephones, portable telephones, wireline telephones, Internet telephones, wireless transceivers, wireless communication radios, personal digital assistants (PDAs), personal computers (PCs), headset devices, head-worn devices, and earpieces.
[0074] The acoustic vibration sensor provides very accurate Voice Activity Detection (VAD) in high noise environments, where high noise environments include airborne acoustic environments in which the noise amplitude is as large if not larger than the speech amplitude as would be measured by conventional microphones. Accurate VAD information provides significant performance and efficiency benefits in a number of important speech processing applications including but not limited to: noise suppression algorithms such as the Pathfinder algorithm available from AliphCom, San Francisco, Calif. and described in the Related Applications; speech compression algorithms such as the Enhanced Variable Rate Coder (EVRC) deployed in many commercial systems; and speech recognition systems.
[0075] In addition to providing signals having an improved signal-to-noise ratio, the acoustic vibration sensor uses only minimal power to operate (on the order of 200 micro Amps, for example). In contrast to alternative solutions that require power, filtering, and/or significant amplification, the acoustic vibration sensor uses a standard microphone interface to connect with signal processing devices. The use of the standard microphone interface avoids the additional expense and size of interface circuitry in a host device and supports for of the sensor in highly mobile applications where power usage is an issue.
[0076] FIG. 4-A is an exploded view of an acoustic vibration sensor 400 , under an alternative embodiment. The sensor 400 includes an enclosure 402 having a first port 404 on a first side and at least one second port (not shown) on a second side of the enclosure 402 . A diaphragm 408 is positioned between the first and second ports. A layer of silicone gel 409 or other similar substance is formed in contact with at least a portion of the diaphragm 408 . A coupler 410 or shroud 410 is formed around the enclosure 402 and the silicon gel 409 where a portion of the coupler 410 is in contact with the silicon gel 409 . The coupler 410 and silicon gel 409 in combination form an acoustic seal around the enclosure 402 so that the first port 404 and the side of the diaphragm facing the first port 404 are isolated from the acoustic environment of the human talker. The second port couples a second side of the diaphragm to the acoustic environment.
[0077] As described above, the sensor includes additional electronic materials as appropriate that couple to receive acoustic signals from the talker via the coupler 410 , the silicon gel 409 , and the diaphragm 408 and convert the acoustic signals to electrical signals representative of human speech. Alternative embodiments can use any type/combination of materials and/or electronics to convert the acoustic signals to electrical signals representative of human speech.
[0078] The coupler 410 and/or gel 409 of an embodiment are formed using materials having impedances matched to the impedance of human skin. As such, the coupler 410 is formed using a material that includes at least one of silicone gel, dielectric gel, thermoplastic elastomers (TPE), and rubber compounds, but is not so limited. The coupler 410 transfers acoustic energy efficiently from skin/flesh of a talker to the diaphragm, and seals the diaphragm from ambient airborne acoustic signals. Consequently, the coupler 410 efficiently transfers acoustic signals directly from the talker's body (speech vibrations) to the diaphragm while isolating the diaphragm from acoustic signals in the airborne environment of the talker. The diaphragm is isolated from acoustic signals in the airborne environment of the talker by the silicon gel 409 /coupler 410 because the silicon gel 409 /coupler 410 prevents the signals from reaching the diaphragm, thereby reflecting and/or dissipating much of the energy of the acoustic signals in the airborne environment. Consequently, the sensor 400 responds primarily to acoustic energy transferred from the skin of the talker, not air. When placed again the head of the talker, the sensor 400 picks up speech-induced acoustic signals on the surface of the skin while airborne acoustic noise signals are largely rejected, thereby increasing the signal-to-noise ratio and providing a very reliable source of speech information.
[0079] There are many locations outside the ear from which the acoustic vibration sensor can detect skin vibrations associated with the production of speech. The sensor can be mounted in a device, handset, or earpiece in any manner, the only restriction being that reliable skin contact is used to detect the skin-borne vibrations associated with the production of speech. FIG. 5-A shows representative areas of sensitivity 500 - 520 on the human head appropriate for placement of the acoustic vibration sensor 100 / 400 , under an embodiment. The areas of sensitivity 500 - 520 include numerous locations 502 - 508 in an area behind the ear 500 , at least one location 512 in an area in front of the ear 510 , and in numerous locations 522 - 528 in the ear canal area 520 . The areas of sensitivity 500 - 520 are the same for both sides of the human head. These representative areas of sensitivity 500 - 520 are provided as examples only and do not limit the embodiments described herein to use in these areas.
[0080] FIG. 6-A is a generic headset device 600 that includes an acoustic vibration sensor 100 / 400 placed at any of a number of locations 602 - 610 , under an embodiment. Generally, placement of the acoustic vibration sensor 100 / 400 can be on any part of the device 600 that corresponds to the areas of sensitivity 500 - 520 ( FIG. 5-A ) on the human head. While a headset device is shown as an example, any number of communication devices known in the art can carry and/or couple to an acoustic vibration sensor 100 / 400 .
[0081] FIG. 7-A is a diagram of a manufacturing method 700 for an acoustic vibration sensor, under an embodiment. Operation begins with, for example, a uni-directional microphone 720 , at block 702 . Silicon gel 722 is formed over/on the diaphragm (not shown) and the associated port, at block 704 . A material 724 , for example polyurethane film, is formed or placed over the microphone 720 /silicone gel 722 combination, at block 706 , to form a coupler or shroud. A snug fit collar or other device is placed on the microphone to secure the material of the coupler during curing, at block 708 .
[0082] Note that the silicon gel (block 702 ) is an optional component that depends on the embodiment of the sensor being manufactured, as described above. Consequently, the manufacture of an acoustic vibration sensor 100 that includes a contact device 112 (referring to FIG. 1-A ) will not include the formation of silicon gel 722 over/on the diaphragm. Further, the coupler formed over the microphone for this sensor 100 will include the contact device 112 or formation of the contact device 112 .
[0083] VAD Device Performance
[0084] The SSM device described above has been implemented and used in a variety of systems at AliphCom. Most importantly, the SSM is a vital part of the Jawbone headset and its proper functionality is critical to the overall performance of the Jawbone headset. Without the SSM or a similar device supplying VAD information, the noise suppression performance of the Jawbone headset would be very poor.
[0085] Referring again to FIG. 1 and FIG. 2 , a VAD system 102 of an embodiment includes a SSM VAD device 230 providing data to an associated algorithm 101 . As detailed above, the SSM is a conventional microphone modified to prevent airborne acoustic information from coupling with the microphone's detecting elements.
[0086] During speech, when the SSM is placed on the cheek or neck, vibrations associated with speech production are easily detected. However, the airborne acoustic data is not significantly detected by the SSM. The tissue-borne acoustic signal, upon detection by the SSM, is used to generate the VAD signal in processing and denoising the signal of interest, as described above with reference to the energy/threshold method outlined in FIG. 3 . This technique is used quite successfully in the Jawbone headset to determine VAD and leads to noise suppression performances similar to that shown in FIG. 4 . In this Figure, plots are shown including a noisy audio signal (live recording) 402 along with a corresponding SSM-based VAD signal 404 , the corresponding SSM output signal 412 , and the denoised audio signal 422 following processing by the Pathfinder system using the VAD signal 404 , under an embodiment. The audio signal 402 was recorded using an AliphCom microphone set in a “babble” (many different human talkers) noise environment inside a chamber measuring six (6) feet on a side and having a ceiling height of eight (8) feet. The Pathfinder system is implemented in real-time, with a delay of approximately 10 msec. The difference in the raw audio signal 402 and the denoised audio signal 422 clearly show noise suppression approximately in the range of 20-25 dB with little distortion of the desired speech signal. Thus, denoising using the SSM-based VAD information is effective.
[0087] The implementation described above is a specific implementation of a VAD transducer, but the scope of this application is not so limited. There are many ways to specifically implement the ideas and techniques presented above, and the specified implementation is simply one of many that are possible.
[0088] Dynamic Audio Enhancement
[0089] Dynamic Audio Enhancement is a technique developed by AliphCom to help the user better hear the person he or she is conversing with. It uses the VAD above to determine when the person is not speaking, and during that time, a long-term estimate of the environmental noise power is calculated. It also calculates an estimate of the average power of the far-end signal that the user is trying to hear. The goal is to increase intelligibility over a wide range of noise levels with respect to incoming far-end levels; that is, a wide range of signal to noise ratio: far-end speech/near-end noise. The system varies the gain of the loudspeaker and filters the incoming far-end to attain these goals.
Introduction
[0090] The DAE system comprises three stages:
1. Static high-pass filter (HP). 2. Measure of far-end and noise power levels (FL and NL) 3. Gain management (GM)
[0094] These sub-systems operate on frames of 16 samples at a time (2 ms at 8 kHz) but are not so limited. First, the far-end signal is statically filtered trough an FIR high-pass filter. Then, for each frame the FL and NL sub-systems calculate the average power level in dB, Lf or Ln respectively, to the GM sub-system. Finally, the gain management sub-system varies slowly the gain such that a specific target SNR can be attained. This gain multiplies the far-end level and provides the signal to be sent to the speaker.
High-Pass Filter
[0095] It has been demonstrated that raising high frequencies of speech can improve intelligibility. We use a 33-tap high-pass FIR to do so, but are not so limited. FIG. 8 shows the frequency response of the filter used and it only attenuates the signal (the gain is always less than or equal to unity). This is in order to prevent the signal from clipping internally. The highpass filter is included in the far-end processing as soon as the system decides that the environment is loud enough to increase the gain and trigger the DAE process.
Level Measurements
[0096] Power levels are measured in the frequency range of 250 Hz-4000 Hz. They are calculated for each frame and filtered over a large number of frames (equivalent to 1 second of signal) using a cascade of two moving average (MA) filters. The moving average filter was chosen for its ability to completely “forget the past” after a period of time corresponding to the length of its impulse response, preventing large impulses from affecting for too long the system's response. Furthermore, the choice of a cascade of two filters was made where the second filter is fed with the decimated output of the first stage, guarantying low memory usage. One long MA would have required as many as 500 taps where a cascade of two requires only 25+20=45.
[0097] More specifically, once the power p is measured in the current frame and converted into a log scale (dB), it is processed by the following system:
1. Mean of p is calculated over past 25 frames once every 25 frames. 2. A delay corresponding to the duration of a long unvoiced speech is added here (for noise measure only, see below). 3. Second MA filter stage using 20 taps.
This process only takes place when the signal that is under consideration is considered to be valid:
1. For the FL sub-system: The far-end signal is speech (not comfort or other noise). 2. For the NL sub-system: The signal is environmental noise only (no near-end speech or speaker's echo present in the noise microphone).
If these constraints are not satisfied, the last valid power level is used.
[0103] A delay mechanism is implemented that removes possible unvoiced regions from the measurements (250 ms before any valid voicing frame and 200 ms after). This adds latency to the overall delay of the system and explains the delay mentioned above.
[0104] In addition, since a single false positive from the VAD can freeze adaptation for as long as 450 ms, a pulse rejection technique is used as follow: a frame is declared as voiced if there was at least 20 voiced frames among the most current past 25 frames.
[0105] Concerning the far-end signal, it is obvious that the level should not be measured during silences or comfort noise. This requires us to be able to detect speech in far-end, “far-end activity”, on a wide range of cell phones and volumes settings. This normally is not an issue and it is likely that a single fixed energy threshold can be used to separate comfort noise from weak speech. Otherwise, one can also use a system that ignores energies below the lowest 10% of the observed energy range for example.
[0106] Concerning the noise microphone, the problem is more challenging: It seems quite regrettable to limit noise level measures only to non-speech and non-echo frames (only around 30% of frames). However, the energy of the near-end speech in the noise microphone can be substantial, even if an LMS-based algorithm similar to Pathfinder or Pathfinder itself is used to remove the speech. Since we can't make assumption on the near-end speech intensity, it seems like we have no choice but stop measuring the noise level when near-end speech occurs.
[0107] Second, the energy of an echo from the far-end speech can be large as well but the measure is performed on the echo-cancelled signal, which can still contain an important residual echo. When measures are performed in presence of echo, it can lead the system to raise the speaker's gain G, which increases the echo, etc. This positive feedback loop is certainly not desirable. Since the gain is limited by a maximal value, it can actually start oscillating under certain conditions. There are ways around this; such as limiting the rate at which the gain can increase, but we have found the system to be much more reliable if the noise power level is only calculated when there is no near- or far-end speech taking place.
Gain Management
[0108] A cutoff is used on the incoming levels Lf and Ln in order to prevent problems at start-up:
[0000] Lf =max( Lf, − 60 dB)
[0000] Ln =max( Ln, − 60 dB)
[0000] The projected signal-to-noise ratio R is calculated. This is the SNR that would be reached if the gain remains unchanged:
[0000] R=Lf−Ln+ 20*log10( G )
[0000] The difference with the target SNR T is:
[0000]
dR=R−T
[0000] Finally, a decision is made to change the gain if the actual SNR is too far from the target:
[0000] If dR< 3 dB, then G= 1.05 *G
[0000] If dR>− 3 dB, then G= 0.95 *G
[0000] Otherwise the gain remains unchanged. Also, the gain is saturated if it reaches a maximum gain limit (0 dB) or a minimum gain limit (−18 dB). This lowest limit is chosen such that it leads to a speaker's volume that is 3 dB above the level achieved when the DSP system is by-passed. Consequently, the system guaranties the volume of the speaker to increases by at least 3 dB at start-up. In fact, when the system is powered-up, G starts at the minimum value and converges to whatever gain corresponds to the desired target SNR.
[0109] Jawbone Headset
[0110] The Jawbone headset is a specific combination of the techniques and principles discussed above. It is presented as an explicit implementation of the techniques and algorithms discussed above, but the construction of a headset with the specified techniques and algorithms is not so limited to the configuration shown below. Many different configurations are possible whereby the techniques and algorithms discussed above may be implemented.
[0111] The physical Jawbone headset consists of two main components: an earpiece and a control module. The earpiece can be worn on either ear of the user. The control module, which is connected to the earpiece via a wire, can be clipped to the user's clothing during use. A unique attribute of the headset design is the design aesthetic of each component and, equally, of the two components together. These attributes are described in detail below:
Design of “shield” ( 110 ) on earpiece ( 100 ) and control module ( 310 ) (see FIGS. 1-B through 6 -B)
The earpiece and the control module both bear a curved rectangular (brushed metal or other) metal shield. This metal shield has the effect of “shielding”, or protecting the complex electronics contained behind it. It is an iconic, classic, and memorable design. This “shield” on the earpiece and the control module is also accented with an off-center hole/circle on its curved surface. For the earpiece, this off-center circle represents the axis on which the shield can rotate around the earbud barrel (so the user can switch ears). On the control module, this off-center circle displays activity information when the product is in use. The earpiece body, or “whale”, behind the shield is designed to allow sensor interaction and is covered with soft-touch paint to reduce irritation to the user's skin during use.
Common Design Language and Connectibility (see FIG. 3-B )
The design language used for the shield ( 110 ) on the earpiece ( 300 ) and the control module ( 310 ) is conspicuously similar: both components have the curved rectangular surface and the off-center circle. The industrial design of the earpiece and the control module allow them to physically snap to each other for better storage and portability when the headset is not in use.
Mechanical Design
[0119] The Jawbone headset is a comfortable, bi-aural, earpiece containing a number of transducers, which is attached via a wire to a control module bearing integrated circuits for processing the transducer signals. It uses the technology described above to suppress environmental noise so that the user can be understood more clearly. It also uses a technique dubbed DAE so that the user can hear the conversation more clearly.
[0120] By virtue of its design and the signal processing technology integrated within it, this headset is comfortable and stable when worn on either ear and is able to deliver great incoming and outgoing audio quality to its user in a wide range of noise environments.
[0000] The Earpiece ( FIGS. 1B through 10B )
[0121] The earpiece is made up of an earloop 120 , and earbud barrel 130 , and a body 240 which are connected together as one device prior to operation by user. Once assembled during manufacture, there is no requirement for the user to remove any components from the headset. The headset is intended for use on either ear, and on one ear at a time. The objective in such a design is to ensure that the headset is mechanically stable on either ear, comfortable on either ear, and the acoustic transducers are properly positioned during use.
[0122] The first mechanical design achievement is the ability for the headset to be used on either ear, without the need to remove any components. In addition, the electronic wiring that is used to connect the headset to a mobile phone or other device must be fed through the earloop 120 to ensure proper stability and comfort for the user. If this wiring is not fed through the earloop, but is rather allowed to drop directly down from the body of the earpiece, the stability of the headset can be significantly compromised. The body 240 is attached to the earbud barrel 130 , around which the body is free to rotate. The “polarity” of the headset (i.e. whether it is configured for the left or right ear) is changed by rotating the body 240 through a 180° angle around the earbud barrel. Since the earloop is symmetrical along the plane of its core, the headset feels and functions in exactly the same way on both ears.
[0123] The second mechanical design achievement is the spring-loaded-body mechanism, which ensures that the body 240 is always turned inwards towards the cheek during use. This feature achieves three important requirements:
1. Slight pressure of the body 240 on the cheek enhances the overall stability and comfort of the headset during use 2. Having the body 240 against the cheek ensures that the primary microphone 710 is always pointed towards the user's mouth during use 3. Having the body 240 applied with slight pressure against the cheek ensures that the speech vibration sensor 720 —a component critical to enhanced voice quality—is always in contact with the skin.
[0127] The spring-loading of the body is achieved by means of a symmetrical metal spring element 520 and a bi-polar cam 510 which together generate a torsional force between the earpiece body 810 and the earloop 500 respectively, around a rotational axis which is the earloop core. Note that the earloop is mechanically fastened to the cam, and the body is mechanically fastened to the spring. The spring is free to rotate within the cam. The metal spring is symmetrical in one axis, and the cam is symmetrical along the rotational axis, ensuring the headset behaves in exactly the same manner on each ear. When the earpiece is placed on the ear, the angle [θ] between the earloop 820 and the body 810 is widened, forcing the cam to rotate within and against the spring. The spring provides a reactive torsional force which operates to reduce the angle [θ] between the body 810 and the earloop 820 . The body is thus always kept in contact with the user's cheek and the primary microphone 710 is always aligned toward the user's mouth.
[0128] The third mechanical design achievement is the 3-point headset mounting system, which ensures that the headset is stable and comfortable on a wide variety of ear anatomies. The first feature of this system is the semi-rigid, but elastic, earloop 820 , which lightly grips the root of the pinna (see FIGS. 9-B and 10 -B) through a pinching force F 4 provided by its elasticity, and a compressive forced F 2 provided by the spring-loading. The second feature of the system is the earbud barrel 840 which is fitted behind the tragus (or tragal notch 850 ) and holds the earpiece inwards through a reactive force R 3 ( FIG. 9-B ) and provides efficient acoustic coupling of the speaker driver to the ear entry point, without occlusion. The third feature of this system is the spring-loaded body described above, which maintains pressure against the cheek during use through a compressive force F 1 . The result of these three features is unique earpiece stability and user comfort during use, given that the forces applied by the body and the earloop (F 1 and F 2 , respectively) are anchored by the reactive force of the tragal notch (R 3 ).
APPLICATIONS
[0129] The Jawbone headset captures the speech and VAD information in the earpiece. This information is then routed to the control module where the VAD and noise levels are calculated and the audio from Mic 1 is noise suppressed. The output of this process is a cleaned speech signal. This cleaned speech signal may be directed to any number of communications devices such as mobile phones, landline phones, portable phones, Internet telephones, wireless transceivers, personal digital assistants (PDAs), VOIP telephones, and personal computers. The control module can be connected to the communication device using wired or wireless connections. The control module can be separated from the earpiece (as in the Jawbone implementation) or can be built into the earpiece, headset, or any device designed to be worn on the body.
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A new type of headset that employs adaptive noise suppression, multiple microphones, a voice activity detection (VAD) device, and unique mechanisms to position it correctly on either ear for use with phones, computers, and wired or wireless connections of any kind is described. In various embodiments, the headset employs combinations of new technologies and mechanisms to provide the user a unique communications experience.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to optical encoders. Particularly, the present invention relates to optical encoders with enhanced resolution for measuring angles and displacements.
2. Description of the Related Art
An optical encoder includes a main scale having a first optical grating, and an index scale having a second optical grating. Disposed opposite the main scale is a light source for irradiating the main scale with light, and a photoreceptor element that receives light via the optical grating of the main scale and the optical grating of the index scale. A photoreceptor element array that also functions as an index scale has been used in this type of optical encoder.
FIG. 9 is a schematic diagram showing the construction of a conventional photoelectric encoder. As shown in FIG. 9 , a detecting-side grating substrate 232 includes photoreceptor elements 258 disposed at a regular pitch. As shown in FIG. 10 , each of the photoreceptor elements 258 includes a first signal lead-out layer 252 composed of a light-blocking, conductive material such as a metal film, a PN semiconductor layer 254 that converts light into an electric signal, and a second signal lead-out layer 256 composed of a light-transmitting, conductive material such as In 2 O 3 , SnO 2 , Si, or a mixture thereof, laminated in that order on a light-transmitting base 250 composed of, for example, glass. The photoreceptor elements 258 are disposed opposite a main scale 224 , and the photoreceptor elements 258 form slits.
Light reaches the PN semiconductor layer 254 via the second signal lead-out layers 256 of the photoreceptor elements 258 , and is photoelectrically converted at the boundary between an N-type amorphous silicon film 260 and a P-type amorphous silicon film 262 . The resulting signals are extracted to the outside from output terminals 264 and 266 .
In this type of optical encoder, a light-emitting-side grating substrate 230 is formed integrally with light-emitting elements 212 , and the detecting-side grating substrate 232 is formed integrally with the photoreceptor elements 258 , serving to reduce the number of parts and to reduce size and weight.
FIG. 11 shows the relationship between an example of a pattern of photoreceptor photodiodes in the encoder and a pattern of detected bright and dark light. Photodiodes S 1 to S 4 are repeatedly subject to signal phase shifts of 0°, 90°, 180°, and 270° with respect to a bright and dark pattern of light represented by a sine wave. Signals generated by the photodiodes S 1 to S 4 are input to a current-voltage converter circuit (not shown). Then the signals from the current-voltage conversion are shifted by 90° with respect to each other. By differential amplification, analog sine-wave voltage signals of two phases are obtained. For example, phase A (S 1 –S 3 ) and phase (S 2 –S 4 ) having phases of 0° and 90°, are obtained.
Actually in the encoder, the analog sine-wave voltage signals are input into a comparator, and the resulting digital signals are fed into a counter circuit or the like.
In a conventional encoder, in order to further enhance resolution, the pitch of the scale and the bright and dark regions of the photoreceptor elements must be further reduced.
However, when the scale pitch is reduced, a considerable decrease in precision occurs. This is because the amplitudes of signals obtained by the photoreceptor elements become smaller, causing noise or affecting the hysteresis of the comparator used for digitization, resulting in a considerable decrease in precision.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome one or more of the problems described above, and to provide an optical encoder in which the resolution is enhanced without reducing the scale pitch or the photoreceptor element pitch.
Accordingly, in one aspect, the present invention provides an optical encoder including a scale having an optical grating; a plurality of photoreceptor elements that are movable with respect to the scale and that are disposed in relation to a pitch of the optical grating; light source means having at least two light sources for irradiating the photoreceptor elements through the scale with light rays from at least two different directions; and control means for switching light-emitting status of the at least two light sources; wherein the control means obtains relative-position information of the scale and the photoreceptor elements by processing information obtained from the light-emitting status of the light sources when the light-emitting status of the light sources is switched.
According to another aspect of the present invention, an optical encoder with enhanced resolution is provided. The optical encoder includes a scale having an optical grating and a plurality of movable photoreceptor elements. Note that each movable photoreceptor element is positioned based on a pitch of the optical grating. The optical encoder further includes first and second light sources for providing light to the photoreceptor elements such that light is provided in a first direction by the first light source and in a second direction by the second light source.
Also included in the optical encoder is a switch for controlling the light-emitting status of the first light source and the second light source. This switch is capable of using the light emitting status of the first and the second light sources to acquire relative-position information of the scale and the photoreceptor elements.
Further objects, features and advantages of the present invention will become apparent from the following description of the preferred embodiments (with reference to the attached drawings).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the construction of an optical encoder according to a first embodiment of the present invention.
FIG. 2 is a perspective view of light-emitting elements.
FIG. 3 is a diagram showing the relationships between scale positions and signals in cases where the respective light-emitting elements are turned on.
FIG. 4 is a diagram showing the construction of an optical encoder according to a second embodiment of the present invention.
FIG. 5 is a perspective view of light-emitting elements.
FIG. 6 is a diagram showing the relationships between scale positions and signals in cases where the respective light-emitting elements are turned on.
FIG. 7 is a diagram showing the construction of an optical encoder according to a third embodiment of the present invention.
FIG. 8 is a diagram showing a case where the balance of powers of lights emitted by signal light sources is changed.
FIG. 9 is a diagram showing the construction of a conventional optical encoder.
FIG. 10 is a sectional view of a detecting-side grating substrate.
FIG. 11 is a diagram showing the relationship between an example of a pattern of a photodiode array and a bright and dark pattern of detected light.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, preferred embodiments of the present invention will be described in detail with reference to FIGS. 1 to 8 .
FIG. 1 is a diagram showing the construction of an optical encoder according to a first embodiment. In FIG. 1 , the optical encoder includes two light-emitting elements 11 and 12 disposed in parallel to each other. The optical encoder also includes both an encoder scale having an optical grating and having a movable member at a middle part, and a photoreceptor 14 having photodiodes S 1 to S 4 on a surface thereof, disposed opposing the light-emitting elements 11 and 12 across the encoder scale 13 .
As shown in FIG. 2 , the light-emitting elements 11 and 12 have light-emitting windows 11 a and 12 a , receive voltages through wires 11 b and 12 b , respectively, and also receives a common voltage through a common electrode 15 . One advantage of the present invention is that at least two light-emitting windows 11 a and 12 a are provided so that light-emitting states are controlled independently of each other. In contrast, in the related art, windows are provided for light-emitting elements and lights are emitted simultaneously at multiple points.
The light-emitting elements 11 and 12 are positioned such that lights received on the photoreceptor 14 are mutually shifted in position by 45°. Thus, the intensity of light received on the photoreceptor 14 when the light-emitting element 11 is turned on is as indicated by 11 ′ in FIG. 1 , and the intensity of light received on the photoreceptor 14 when the light-emitting element 12 is turned on is as indicated by 12 ′.
FIG. 3 is a diagram showing the relationships between positions of the encoder scale 13 and signal outputs in cases where the light emitting elements 11 and 12 are turned on, respectively. In FIG. 3 , part (a) also shows the relationship between an analog waveform and digitally counted values obtained by multiplying one cycle of the analog waveform by four.
When the encoder scale 13 attached to the movable member is moved, a pattern of bright and dark regions moves over the photoreceptor 14 . On the photoreceptor 14 , a set of photodiodes S 1 to S 4 is arranged so as to divide each cycle of the bright and dark pattern by four, and by processing the divided parts of the bright and dark pattern, two-phase signals including phase-A signals (S 1 –S 3 ) and phase-B signals (S 1 –S 3 ) are output.
For the light distribution of the state 11 ′ with the light-emitting element 11 turned on, signal values shown in part (a) of FIG. 3 are output from processing circuits for phase A and phase B. On the other hand, for the light distribution of the state 12 ′ with the light-emitting element 12 turned on, signal values shown in part (b) of FIG. 3 are output from the processing circuits for phase A and phase B.
When the bright and dark pattern moves over the photoreceptor 14 , the light-emitting element 11 , which is temporally shifted by 90° in phase, is turned on, and signals of phase A and phase B by the encoder scale 13 are obtained. Thus, the amount of movement can be detected by counting the number of wave cycles of phase A and phase B. When the encoder scale 13 is at a halt at a certain point P 1 , signal levels take two points a in part (a) of FIG. 3 .
When the light-emitting element 11 is turned off and the light-emitting element 12 is turned on, the positional relationship between the light-emitting elements 11 and 12 and the encoder scale 13 changes as shown in part (b) of FIG. 3 . Thus, the relationship between positions and signals also changes; more specifically, the signals at points a in part (a) of FIG. 3 change to points b in part (b) of FIG. 3 . This is equivalent to moving the encoder scale 13 by 45° in the arrow direction.
With regard to signals output from the signal processing circuits, when the light-emitting element 11 is on, points a are High for both phase A and phase B. On the other hand, when the light-emitting element 12 is on, points b are Low for phase A and High for phase B. The switching for phase B indicates that when the encoder 13 actually stops moving after further moving by 45°, the signal for phase A switches. That is, phase A and phase B reside in a 45° to 90° region within the 90° region at High level, so that the resolution becomes twice as high.
If the signal for phase A remains high, phase A and phase B exist within a 0° to 45° range in the above 90° region at high level.
Table 1 below shows the relationship between counter values, and digital signal level changes after switching of light-emitting elements, and position.
TABLE 1
Counter value
Change in digital signal
Position in one cycle
0
No change
0°–45°
0
Change
45°–90°
1
No change
90°–135°
1
Change
135°–180°
2
No change
180°–225°
2
Change
225°–270°
3
No change
270°–315°
3
Change
315°–360°
By switching between the light-emitting elements 11 and 12 as described above, the present invention can double the resolution of conventional art systems by reflecting a result obtained to another bit of counter value.
FIG. 4 is a diagram showing the construction of an optical encoder according to a second embodiment. In the first embodiment, the two light-emitting elements 11 and 12 are provided and switched to achieve a resolution that is twice as high compared with the related art. In the second embodiment, light-emitting elements 21 and 22 are further arranged on both sides of the light-emitting elements 11 and 12 to achieve a resolution that is four times as high compared with the related art.
In FIG. 4 , lines 11 ′, 12 ′, 21 ′, and 22 ′ represent the intensities of lights received on the photoreceptor 14 when the light-emitting elements 11 , 12 , 21 , and 22 are turned on, respectively. The light-emitting elements 11 , 21 , 12 , and 22 are positioned such that lights received thereby on the photoreceptor 14 are shifted in position by 22.5°.
FIG. 5 is a perspective view of the light-emitting elements in the second embodiment. The light-emitting elements 11 , 12 , 21 , and 22 have light-emitting windows 11 a , 12 a , 21 a , and 22 a , and are connected to wires 11 b , 12 b , 21 b , and 22 b for supplying voltages, respectively.
FIG. 6 shows the relationship between the positions of the encoder scale 13 and phase-A signals in cases where the light-emitting elements 11 , 12 , 21 , and 22 are turned on. When the light-emitting element 11 is on, and when the encoder scale 13 stops at a certain point P 2 , signal a is obtained as a phase-A voltage. At this time, the voltage is at High level. Then, the light-emitting element 21 is turned on, whereby a signal c is obtained. Furthermore, as the light-emitting elements are switched to turn on the light-emitting elements 12 and 22 sequentially, the voltage changes to Low level when the light-emitting element 22 is switched on. The state where the light-emitting element 22 is on corresponds to the state where the encoder scale 13 is moved by 67.5°. That is, a point at which signal level changes correspond to a movement of the encoder scale by 67.5°. Thus, it is understood that P 2 is in a range of 22.5° to 45° of the region of the counter value 1.
Table 2 summarizes similar relationships.
TABLE 2
Change in digital signal after switching
Counter
of light-emitting elements
Position in one
value
11→21
21→12
12→22
22→11
cycle
0
No change
No change
No change
No change
0°–22.5°
0
No change
No change
Change
No change
22.5°–45°
0
No change
Change
No change
No change
45°–67.5°
0
Change
No change
No change
No change
67.5°–90°
1
No change
No change
No change
No change
90°–112.5°
1
No change
No change
Change
No change
112.5°–135°
1
No change
Change
No change
No change
135°–157.5°
1
Change
No change
No change
No change
157.5°–180°
2
No change
No change
No change
No change
180°–202.5°
2
No change
No change
Change
No change
202.5°–225°
2
No change
Change
No change
No change
225°–247.5°
2
Change
No change
No change
No change
247.5°–270°
3
No change
No change
No change
No change
270°–292.5°
3
No change
No change
Change
No change
292.5°–315°
3
No change
Change
No change
No change
315°–337.5°
3
Change
No change
No change
No change
37.5°–360°
Thus, according to this embodiment, one cycle of waveform can be divided by 16.
FIGS. 7 and 8 show the construction of an optical encoder according to a third embodiment. In the first embodiment, the two light-emitting elements 11 and 12 are provided and switched to achieve a resolution that is twice as high compared with the related art. In the third embodiment, light-emitting powers of the two light-emitting elements 11 and 12 are changed and the lights are combined to produce a signal.
Referring to FIG. 7 , when the light-emitting element 11 and the light-emitting element 12 are turned on individually, patterns of bright and dark occur at positions shifted by 90° corresponding to one wave cycle on the photoreceptor 14 . The bright and dark pattern indicated by 11 ′ is achieved on the photoreceptor 14 when only the light-emitting element 11 is turned on while the light-emitting elements 11 and 12 and the encoder scale 13 are in a certain positional relationship. When the light-emitting element 12 is then switched on, the bright and dark pattern is shifted by 90° on the photoreceptor 14 , as indicated by 12 ′.
When the light-emitting elements 11 and 12 are simultaneously caused to emit light at a power of 1/√2 compared with the related art, signals output from the processing circuits are combined as indicated by 13 ′. This is equivalent to the signal in a case where the photoreceptor 14 is shifted by 45° with respect to the light-emitting element 11 .
FIG. 8 shows a case where the balance of light-emitting powers of the light-emitting elements 11 and 12 is changed. As shown in FIG. 8 , a signal in a case where the photoreceptor 14 is shifted by 30° with respect to the light-emitting element 11 can be obtained by setting a ratio such that the light-emitting power of the light-emitting element 11 is cos(30°)=√ 3/2 and the light-emitting power of the light-emitting element 12 is sin(30°)=½. As for other points, similarly, signals corresponding to shifts in light-emitting position can be obtained by changing the light-emitting powers of the light-emitting elements 11 and 12 .
Thus, after the encoder scale 13 is stopped, by changing the balance between the light-emitting elements 11 and 12 as if the device is moving, and finding a point where the digital signal level changes, the stop position can be detected at a desired resolution.
Optical power can be changed by stabilizing optical power while detecting it. Or, the optical power can be controlled based on current values assuming a substantially linear relationship between optical power and current. Although not discussed, optical power may also be changed by using other methods.
Although this embodiment relates to a transmissive optical encoder, the same advantages can be achieved by a reflective optical encoder, with the light-emitting elements and the photoreceptor element disposed on the same side.
According to one aspect of the present invention, by switching between or changing the power of light sources, a resolution much higher than that of a conventional optical encoder can be achieved.
While the present invention has been described with reference to what are presently considered to be the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
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In an optical encoder, a plurality of light sources is controlled on and off so as to use light rays to irradiate an optical grating of a scale from a plurality of different directions. The light rays are received by a plurality of photoreceptor elements. Operations are performed using signals output from the photoreceptor elements. Accordingly, the relative position between the photoreceptor elements and the scale is detected precisely.
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BACKGROUND OF THE INVENTION
1) Field of the Invention
The present invention relates to apparatuses and methods for preforming thermoplastic materials and, more specifically, to apparatuses and methods for bending thermoplastic sheets to form preforms for ducts.
2) Description of Related Art
Ducts provide transport passageways for a wide variety of applications. For example, tubular ducts are widely used for air flow in aircraft environmental control systems. Similarly, ducts provide passageways for transporting gases for heating and ventilation in other vehicles and in buildings. Water distribution systems, hydraulic systems, and other fluid networks also often use ducts for fluid transport. In addition, solid materials, for example, in particulate form can be delivered through ducts. Ducts for the foregoing and other applications can be formed of metals, plastics, ceramics, composites, and other materials.
One conventional aircraft environmental control system utilizes a network of ducts to provide air for heating, cooling, ventilation, filtering, humidity control, and/or pressure control of the cabin. In this conventional system, the ducts are formed of a composite material that includes a thermoset matrix that impregnates, and is reinforced by, a reinforcing material such as Kevlar®, registered trademark of E. I. du Pont de Nemours and Company. The thermoset matrix is typically formed of an epoxy or polyester resin, which hardens when it is subjected to heat and pressure. Ducts formed of this composite material are generally strong and lightweight, as required in many aircraft applications. However, the manufacturing process can be complicated, lengthy, and expensive, especially for ducts that include contours or features such as beads and bells. For example, in one conventional manufacturing process, ducts are formed by forming a disposable plaster mandrel, laying plies of fabric preimpregnated with the thermoset material on the mandrel, and consolidating and curing the plies to form the duct. The tools used to mold the plaster mandrel are specially sized and shaped for creating a duct of specific dimensions, so numerous such tools must be produced and maintained for manufacturing different ducts. The plaster mandrel is formed and destroyed during the manufacture of one duct, requiring time for curing and resulting in plaster that typically must be removed or destroyed as waste. Additionally, the preimpregnated plies change shape during curing and consolidation and, therefore, typically must be trimmed after curing to achieve the desired dimensions. The jigs required for trimming and for locating the proper positions for features such as holes and spuds are also typically used for only a duct of particular dimensions, so numerous jigs are required if different ducts are to be formed. Like the rotatable tools used for forming the mandrels, the jigs require time and expense for manufacture, storage, and maintenance. Additionally, ducts formed of conventional thermoset epoxies typically do not perform well in certain flammability, smoke, and toxicity tests, and the use of such materials can be unacceptable if performance requirements are strict. Further, features such as beads typically must be post-formed, or added after the formation of the duct, requiring additional manufacture time and labor.
Alternatively, ducts can also be formed of thermoplastic materials. A thermoplastic duct can be formed by forming a thermoplastic sheet of material, cutting the sheet to a size and configuration that corresponds to the desired shape of the duct, bending the sheet to the desired configuration of the duct, and joining longitudinal edges of the sheet to form a longitudinal joint or seam. For example, apparatuses and methods for forming thermoplastic ducts and consolidation joining of thermoplastic ducts are provided in U.S. application Ser. Nos. [. . . ] and [. . . ], titled “Thermoplastic Laminate Duct” and “Consolidation Joining of Thermoplastic Laminate Ducts,” both of which are filed concurrently herewith and the contents of which are incorporated herein by reference. Such thermoplastic ducts can be formed by retaining the thermoplastic sheet in the bent configuration until the ends are joined, and then releasing the duct so that the resulting joint continues to restrain the duct in the bent configuration. However, stresses induced in the thermoplastic material during bending can cause the duct to deform or distort from the desired configuration after joining, e.g., when released from the joining apparatus.
Thus, there exists a need for improved apparatuses and methods of preforming ducts, i.e., providing a preform configured to correspond generally to the desired configuration of the duct in a substantially unstressed condition. The method should not require the laying of individual plies on a disposable plaster mandrel. Preferably, the method should be compatible with thermoplastic ducts, including reinforced thermoplastic ducts formed from flat sheets, which provide high strength-to-weight ratios and meet strict flammability, smoke, and toxicity standards.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method for preforming sheets to form preforms for forming ducts. The preforms can be formed from thermoplastic materials, such as flat sheets of reinforced thermoplastic laminate. Thus, individual plies need not be laid on a disposable plaster mandrel. The thermoplastic material can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. Additionally, the method is compatible with ducts that are formed by consolidation joining thermoplastic laminates. In an unstressed condition, the preforms correspond generally to the desired configuration of the ducts. Thus, longitudinal edges of the preforms can be joined to form the duct, and the duct does not deform when released from the joining apparatus.
According to one embodiment, the present invention provides an apparatus for preforming a thermoplastic member to form a preform that generally corresponds to the desired configuration of the duct, which defines a passage. The apparatus includes first and second rotatable rollers, which are substantially parallel and define a nip, and a heater configured to heat the thermoplastic member to a processing temperature, for example, less than a glass transition temperature of the thermoplastic member and within about 70° F. of the glass transition temperature. In one advantageous embodiment, the processing temperature is between about 5° F. and 70° F. less than the glass transition temperature. At least one of the rollers is heated and at least one of the rollers is configured to rotate and thereby translate the thermoplastic member through the nip so that the thermoplastic member is heated, compressed, and bent generally to the desired configuration of the duct. A rotational actuator can be configured to rotate one of the rollers, and the first roller can be heated by the heater located therein. An actuator can also be configured to adjust at least one of the rollers in a transverse direction to adjust the nip. Additionally, a fastener can be provided to connect a longitudinal leading edge of the thermoplastic member to the first roller. A non-stick layer can be disposed on the rollers to facilitate release of the preform therefrom, and the rollers can be magnetically attracted.
According to one aspect of the invention, the apparatus includes third and fourth rollers, which are also positioned substantially parallel and proximate to the first roller. The second, third, and fourth rollers are positioned at incremental angular positions about the first roller so that each of the second, third, and fourth rollers is capable of urging the thermoplastic member against the first roller in a configuration that generally corresponds to the desired configuration of the duct. According to another aspect, a deflection roller is positioned to intersect a tangent of the nip so that the thermoplastic member is deflected and bent about the first roller. The deflection roller can be offset from the tangent, and an actuator can be configured to adjust an offset position of the deflection roller.
According to another embodiment, the present invention provides another apparatus for preforming a thermoplastic member to form a preform generally corresponding to the desired configuration of the duct. The apparatus includes a support structure extending longitudinally and at least partially defining a cavity. An elongate member with an outer surface corresponding to the desired configuration of the duct extends longitudinally in the cavity so that the thermoplastic member can be supported between the support structure and the elongate member. A heater is configured to heat the thermoplastic member to a processing temperature, for example, within about 70° F. of the glass transition temperature of the thermoplastic member. The support structure is configured to adjust from a first position in which the support structure supports the thermoplastic member in a flat configuration to a second position in which the support structure is adjusted radially inward to bend the thermoplastic member against the elongate member to the desired configuration of the duct. At least one actuator can be configured to adjust the support structure between the first and second positions. The support structure can include a plurality of rods that extend longitudinally in the first position and adjust to an angularly incremental configuration about the elongate member in the second position.
According to another aspect, the support structure includes two partial hollow tubes that are rotatably adjustable between the first and second positions, each tube defining an interior surface corresponding to the outer surface of the elongate member. A heater can heat the interior surfaces of the tubes to the processing temperature. Each tube can define a first longitudinal edge joined by a hinge and a second longitudinal edge defining a radially inwardly extending stop, and the tubes can be configured to rotatably adjust from a first position in which the cavity is open to a second position in which the cavity is at least partially closed. In the first position, the tubes are configured to receive and support the thermoplastic member between the stops. In the second position, the tubes cooperably form the cavity and define an inner surface corresponding to the desired configuration of the duct.
According to another embodiment, the preforming apparatus includes a hollow tube that defines a longitudinal cavity. A funnel extends longitudinally from an end of the tube and tapers in the longitudinal direction toward the tube from a cross-sectional size larger than the duct to a cross-sectional size about equal to the duct. The funnel is configured to receive the thermoplastic member and configure the thermoplastic member to the desired configuration of the duct as the thermoplastic member is urged longitudinally through the funnel. A heater is configured to heat the funnel and/or the tube to a processing temperature, for example, less than the glass transition temperature of the thermoplastic member and within about 70° F. of the glass transition temperature.
The present invention also provides a method for preforming a thermoplastic member to form a preform generally corresponding to a desired configuration of a thermoplastic duct defining a passage. The method includes heating the thermoplastic member to a processing temperature, e.g., between about 5° F. and 70° F. less than a glass transition temperature of the thermoplastic member. A first and/or second roller is rotated, and the thermoplastic member is transported through a nip defined by the rollers so that the member is heated, compressed, and bent generally to the desired configuration of the duct. The rollers can also be magnetically urged together. The thermoplastic member can be heated before being transported through the nip and by the roller(s) as the member is transported through the nip. The thermoplastic member can be transported about the first roller through nips defined between the first and second rollers, the first roller and a third roller, and the first roller and a fourth roller. Additionally, the thermoplastic member can be continuously transported about the first roller an angular distance of more than one revolution, for example, by fastening a longitudinal leading edge of the thermoplastic member to the first roller. A deflection roller can be positioned to intersect a tangent of the nip so that a rotational axis of the deflection roller is offset from the tangent of the nip in the direction of the second roller, and the deflection roller deflects the thermoplastic member to bend about the first roller.
According to another embodiment, the thermoplastic member is heated to the processing temperature, supported with a longitudinally extending support structure in a generally flat configuration, and bent against an outer surface of the elongate member to the desired configuration of the duct as the support structure is adjusted radially inward, for example, by an actuator. The thermoplastic member can be supported by a plurality of rods, which extend longitudinally and adjust to an angularly incremental configuration about the elongate member. Alternatively, the thermoplastic member can be supported by two partial hollow tubes in an open configuration and urged against the elongate member by an interior surface of the tubes corresponding to the outer surface of the elongate member as the tubes adjust to a closed position. According to one aspect of the invention, a first edge of the thermoplastic member is urged against a second edge of the thermoplastic member and the edges are heated to above the glass transition temperature and consolidation joined. For example, the edges can be urged together by adjusting a consolidation joining head radially against the thermoplastic member such that an elastomeric portion of the head urges the edges against the elongate member.
According to another embodiment, the thermoplastic member is heated to the processing temperature, supported between radially inwardly extending stops defined by two partial hollow longitudinal tubes, and bent to the desired configuration of the duct as the tubes are rotatably adjusted about a hinge from an open position to a closed position. According to yet another embodiment, a tapering funnel is provided for preforming the thermoplastic member. The thermoplastic member is heated to the processing temperature, inserted into a first end of the funnel that is larger than the duct and urged through a second, smaller end of the funnel and into a hollow tube.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
FIG. 1 is a perspective view of a preforming apparatus according to one embodiment of the present invention;
FIG. 2 is a perspective view of flat thermoplastic sheet for forming a preform according to one embodiment of the present invention;
FIG. 3 is a perspective view of a preform formed from the sheet of FIG. 2 according to one embodiment of the present invention;
FIG. 4 is a perspective view of a duct formed from the preform of FIG. 3 according to one embodiment of the present invention;
FIG. 5 is a perspective view of a preforming apparatus according to one embodiment of the present invention;
FIG. 6 is an elevation view of a preforming apparatus according to another embodiment of the present invention;
FIG. 7 is an elevation view of a preforming apparatus according to another embodiment of the present invention in an open configuration;
FIG. 8 is an elevation view of the preforming apparatus of FIG. 7 in a closed configuration;
FIG. 9 is a section view of the preforming apparatus of FIG. 8 as seen along line 9 — 9 of FIG. 8 ;
FIG. 10 is a section view of the preforming apparatus of FIG. 9 with the sheet partially preformed;
FIG. 11 is a section view of the preforming apparatus of FIG. 9 with the sheet fully preformed;
FIG. 12 is a section view of the preforming apparatus of FIG. 9 including a consolidation joining head adjusted to an open position according to one embodiment of the present invention;
FIG. 13 is a section view of the preforming apparatus of FIG. 12 with the consolidation joining head adjusted to a closed position;
FIG. 14 is an elevation view of a preforming apparatus according to another embodiment of the present invention in an open position;
FIG. 15 is an elevation view of the preforming apparatus of FIG. 14 in a closed position;
FIG. 16 is an elevation view of the preforming apparatus of FIG. 14 including a consolidation joining head according to one embodiment of the present invention;
FIG. 17 is an elevation view of a preforming apparatus according to another embodiment of the present invention in an open position with the thermoplastic sheet partially inserted;
FIG. 18 is an elevation view of the preforming apparatus of FIG. 17 in a closed position; and
FIG. 19 is a perspective view of a preforming apparatus according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
Referring now to FIG. 1 , there is shown a preforming apparatus 10 for preforming a thermoplastic member, such as a thermoplastic sheet 50 as shown in FIG. 2 . Preforming generally refers to bending the thermoplastic member to form a bent or curved preform 70 as shown in FIG. 3 , which, in an unrestrained condition, generally corresponds to a desired configuration of a duct 90 . The preform 70 can be formed to have a diameter slightly larger or smaller than the desired diameter of the duct 90 , for example, so that the preform 70 can be subjected to a compressive or expansion force for holding the preform 70 during subsequent processing, such as consolidation joining, to arrive at the desired configuration of the duct 90 . The preform 70 and, hence, the duct 90 , shown in FIG. 4 , extend from a first end 72 to a second end 74 and define a passage 76 . Preferably, longitudinal edges 78 , 80 of the preform 70 are overlapped to form an interface portion 82 . The longitudinal edges 78 , 80 of the preform 70 can be joined to form the duct 90 having a seam or joint 92 , preferably without significantly further bending or deforming the preform 70 so that the duct 90 is substantially free of internal stress. The longitudinal edges 78 , 80 can be joined using adhesives, heat, or other joining methods. For example, joining can be achieved by applying heat and pressure to the edges 78 , 80 to form the seam 92 . As the thermoplastic material of the preform 70 is heated above its glass transition temperature, the material becomes plastic and the pressure consolidates and joins the interface 82 . Joining can be performed by manual or automated methods, for example, as described in U.S. application Ser. No. [. . . ], titled “Consolidation Joining of Thermoplastic Laminate Ducts.”
The shape of the preform 70 is determined by projecting the desired shape of the duct 90 onto the flat sheet 50 . Although the ends 72 , 74 and edges 78 , 80 of the preform 70 are shown to be straight in FIG. 3 , the preform 70 can alternatively define a variety of shapes that correspond to ducts that are straight, curved, tapered, or otherwise contoured. The sheet 50 and, hence, the preform 70 and duct 90 can also define a variety features such as holes 75 , for example, for connecting spuds, brackets, and the like to the duct 90 . Methods and apparatuses for forming preforms and for determining geometric patterns that correspond to ducts are provided in U.S. application Ser. No. [. . . ], titled “Thermoplastic Laminate Duct.” It is also appreciated that marks can be provided on the preform 70 , for example, to accurately identify the location of post-formed features such as bead and bells or to facilitate the manufacture or assembly of the ducts, as also provided in U.S. application No. [. . . ], titled “Thermoplastic Laminate Duct.”
Preferably, the preform 70 is formed of a composite laminate that includes a thermoplastic matrix and a reinforcing material. Thermoplastic materials are characterized by a transition to a plastic state when heated above a glass transition temperature. For example, the preform 70 can be formed of polyetherimide (PEI) or polyphenol sulfide (PPS), both of which can be thermoplastic. Thermoplastic PEI is available under the trade name Ultem®, a registered trademark of General Electric Company. According to one embodiment of the present invention, each preform 70 is formed of a composite material that includes a matrix of thermoplastic PEI that is reinforced with a reinforcing material such as carbon, glass, or an aramid fabric such as a Kevlar® aramid, or fibers of such a material. Alternatively, the preform 70 can be formed of other thermoplastic materials, which can be reinforced by other reinforcing materials, or can include no reinforcing materials.
The duct 90 formed from the preform 70 can be used in numerous applications including, but not limited to, environmental control systems of aerospace vehicles, in which air is delivered through the passage 76 of the duct 90 to provide heating, cooling, ventilation, and/or pressurization of an aircraft cabin. The ends 72 , 74 of the duct 90 can be connected to other ducts or other devices such as ventilators, compressors, filters, and the like. Multiple ducts 90 can be connected so that a longitudinal axis of each duct 90 is configured at an angle relative to the longitudinal axis of the adjoining duct(s). Thus, the ducts 90 can be connected to form an intricate duct system (not shown) that includes numerous angled or curved ducts 90 for accommodating the devices connected by the duct system and for meeting layout restrictions as required, for example, on an aircraft where space is limited.
The preforming apparatus 10 shown in FIG. 1 includes a first roller 12 and a second roller 14 . The rollers 12 , 14 extend longitudinally and are supported by a frame (not shown) such that the rollers 12 , 14 are substantially parallel and define a nip. The rollers 12 , 14 can be formed of a variety of materials such as aluminum, steel, and alloys thereof, and a non-stick layer can be disposed on the rollers 12 , 14 to prevent the sheet 50 from sticking to the rollers 12 , 14 . For example, the non-stick layer can be formed of Teflon® film, registered trademark of E. I. du Pont de Nemours and Company. An actuator 20 , such as an electric motor, is configured to rotate at least one of the rollers 12 , 14 . In the embodiment of FIG. 1 , the actuator 20 is configured to rotate the first roller 12 such that, as the sheet 50 is fed into the nip in a direction 13 , the rotating roller 12 transports the sheet 50 through the nip.
The first roller 12 includes a heater 30 , which is configured to heat the roller 12 and, thus, the thermoplastic sheet 50 to at least a processing temperature. As the foregoing examples illustrate, the first roller 12 is therefore formed of a thermally conductive material. Preferably, the sheet 50 is heated to a processing temperature that is less than the glass transition temperature of the thermoplastic material of the sheet 50 . For example, the processing temperature can be between about 5° F. and 70° F. less than the glass transition temperature. In the case of PEI, which has a glass transition temperature of about 417° F., the sheet 50 can be heated to a processing temperature of between about 350° F. and 412° F.
As the sheet 50 is transported through the nip, the rollers 12 , 14 exert a compressive force on the sheet 50 and heat the sheet 50 . One or both of the rollers 12 , 14 can be adjusted toward or away from the opposite roller 12 , 14 to adjust the compressive force on the sheet 50 . Preferably, the sheet 50 is heated disproportionately by the rollers 12 , 14 so that the sheet 50 is bent or formed as the sheet 50 emerges from the nip, for example, due to thermal expansion or contraction of the reinforcing material in the sheet 50 . For example, the heater 30 in the first roller 12 can be used to heat the sheet 50 so that the reinforcing material that is closer to the first roller 12 as the sheet 50 passes through the nip is expanded or contracted and the sheet 50 is bent. If the reinforcing material is one that expands when heated, such as carbon or glass reinforcement materials, the sheet 50 is bent around the second roller 14 . If the reinforcing material is one that contracts when heated, such as an aramid reinforcement material, the sheet 50 is bent around the first roller 12 . Thus, the longitudinal edges 78 , 80 of the sheet 50 are bent together to form the preform 70 , which generally corresponds to the desired shape of the duct 90 .
As shown in FIG. 5 , a preforming apparatus 10 a according to the present invention can also include multiple rollers 14 a– 14 f that are spaced at incremental angular positions about the first roller 12 so that each of the rollers 14 a – 14 f defines a nip with the first roller 12 . The first longitudinal edge 78 of the sheet 50 is fastened to the first roller 12 by a fastener 16 , which is a strip of heat resistant adhesive tape. Other fasteners 16 can also be used, such as glue, screws, bolts, clips, hooks, and the like. The first longitudinal edge 78 precedes the rest of the sheet 50 , i.e., the first edge 78 is the “leading edge.” The fastener 16 retains the first edge 78 against the roller 12 and the sheet 50 is thus transported through the nips defined by the rollers 14 a – 14 f and the first roller 12 . Although the first longitudinal edge 78 is connected to the first roller 12 in FIG. 5 , the second edge 80 can also, or alternatively, be connected to the roller 12 . Additionally, the rollers 14 a – 14 f can be adjustable radially relative to the first roller 12 to urge the sheet 50 against the roller 12 . For example, the rollers 14 a – 14 f can be adjusted radially outward from the roller 12 during processing to receive the leading longitudinal edge 68 , 80 of the sheet 50 and then adjusted radially inward toward the roller 12 to urge the sheet 50 against the roller 12 .
As shown in FIG. 6 , a preforming apparatus 10 b according to another embodiment of the invention includes a deflection roller 40 for deflecting and bending the sheet 50 as the sheet emerges from the nip between the first and second rollers 12 , 14 . The deflection roller 40 is positioned to intersect a tangent of the nip between the first and second rollers 12 , 14 . Thus, the tangent of the nip, i.e., a line tangent to both of the first and second rollers 12 , 14 at the nip therebetween, intersects the deflection roller 40 . Similarly, as the sheet 50 emerges from the nip and follows a course approximating a direction of the tangent of the nip, the sheet 50 contacts the deflection roller 40 and is thereby bent. Preferably, the deflection roller 40 is offset from the tangent of the nip, i.e., the tangent of the nip intersects a portion of the deflection roller 40 other than a rotational axis of the deflection roller 40 . Advantageously, the deflection roller 40 can be offset such that the axis of the deflection roller 40 is closer to the second roller 14 than the first roller 12 and the sheet 50 is thus deflected to bend about the first roller 12 .
The deflection roller 40 is rotatably mounted to a pivot 42 and a deflection actuator 44 is configured to adjust the position of the deflection roller 40 and change the degree of bending of the sheet 50 . Adjustment of the deflection roller 40 can be desirable to change the bend of the sheet 50 , or to maintain a uniform bend despite changes in other system parameters such as temperature of the sheet 50 , thickness of the sheet 50 , material type of the sheet 50 , and the like. Additionally, a nip actuator 46 is configured to adjust the second roller 14 relative to the first roller 12 and thereby affect the compressive force exerted by the rollers 12 , 14 on the sheet 50 as the sheet 50 is transported through the nip, for example, to adjust for different thicknesses of the sheet 50 . The nip actuator 46 can be a hydraulic, pneumatic, electric, or other type of actuation device.
The sheet 50 can be supported by a support table 34 and heated by heaters 32 as the sheet 50 is fed into the nip. Cam rollers 48 are positioned at incrementally longitudinal locations to support the rollers 14 , 40 . By supporting the rollers 14 , 40 at longitudinal locations between the ends of the rollers 14 , 40 , the cam rollers 48 decrease the longitudinal deflection of the rollers 14 , 40 . A guard 49 is also provided to catch the sheet 50 and prevent the sheet 50 from continuously passing through the nip multiple times. Alternatively, the sheet 50 can be transported multiple times through the nip(s) of the forming apparatuses 10 , 10 a , 10 b . For example, the first roller 12 of the preforming apparatus 10 a shown in FIG. 5 can be rotated more than one revolution after the first longitudinal edge 78 has entered the first nip between the rollers 12 , 14 a . Thus, the roller 12 and the sheet 50 can be rotated until the sheet 50 has been bent to the configuration of the preform 70 .
Additionally, one or more of the rollers 12 , 14 , 14 a – 14 f can be magnetized so that the rollers 12 , 14 , 14 a – 14 f are magnetically attracted and the nip therebetween is uniform along the length of the rollers 12 , 14 , 14 a – 14 f . The rollers 12 , 14 , 14 a – 14 f can include a magnetized material, such as a ferrous metal, or an electromagnetic for generating the attraction between the rollers. For example, the first roller 12 can include an electromagnet and the second roller 14 can be formed of steel so that the second roller 14 is attracted toward the first roller 12 and the nip between the rollers 12 , 14 is uniform along the length of the rollers 12 , 14 .
There is shown in FIGS. 7–11 a preforming apparatus 110 that includes an outer support structure comprising ring supports 112 , each arranged about a common longitudinal axis. The ring supports 112 support actuators 114 , which are configured to support a plurality of parallel rods 116 , six in the illustrated embodiment, and adjust the rods 116 radially inward and outward. As shown in FIGS. 9–11 , the rods 116 can be adjusted radially to define an adjustable cavity 111 therein and, thus, support and bend, or preform, the sheet 50 to the desired configuration of ducts of different diameters and/or shapes, thus forming the preform 70 .
Each of the rods 116 can be heated during processing, for example, by heaters 136 disposed in the rods 116 , such that the rods heat the sheet 50 . Alternatively, the sheet 50 can be heated by a heater (not shown) in the beam 150 or a heater configured to irradiate the sheet 50 . For example, the preforming apparatus 110 can be positioned in an oven, or a directional radiation source, such as an infrared or a microwave source, can be configured to heat the sheet 50 . Preferably, the heater(s) are configured to heat the sheet 50 to a processing temperature that is less than the glass transition temperature of the thermoplastic material of the sheet 50 , for example, between about 5° F. and 70° F. less than the glass transition temperature.
An inner beam 150 , which extends from a first end 170 to a second end 172 , is positioned in the cavity 111 defined by the rods 116 such that the sheet 50 can be positioned around the inner beam 150 . Although the ends 170 , 172 of the inner beam 150 are supported by a base 113 , at least one of the ends 170 , 172 of the inner beam 150 can be disconnected from the base 113 to facilitate the insertion of the sheet 50 into the cavity 111 of the preforming apparatus 110 . For example, a latch 168 can be adjusted between an open position and a closed position. With the latch 168 in the open position, shown in FIG. 7 , the sheet 50 can be inserted longitudinally into the preforming apparatus 110 such that the sheet 50 is disposed around the inner beam 150 .
The preforming apparatus 110 can be used to form the preform 70 of FIG. 3 from the sheet 50 of FIG. 2 . During operation, the axial actuators 114 are used to retract the rods 116 radially outward to a first position, as shown in FIG. 9 , and the latch 168 is opened. The sheet 50 is longitudinally installed in the preforming apparatus 110 so that the sheet 50 is supported by at least one of the rods 116 . The latch 168 is then closed to secure the first end 170 of the inner beam 150 to the outer support structure or the base 113 , as shown in FIG. 8 .
With the preforming apparatus 110 assembled as shown in FIG. 8 , a power supply (not shown) is connected to the heaters 136 in the rods 116 or other heaters for heating the sheet 50 , preferably to the processing temperature. The actuators 114 are actuated to extend the rods 116 radially inward so that the rods 116 urge the sheet 50 against the inner beam 150 and bend the sheet 50 about the inner beam 150 to the desired configuration of the duct 90 , thus forming the preform 70 . Preferably, the longitudinal edges 78 , 80 are overlapped to form the interface 82 . After the preform 70 is formed, the heater 136 can be turned off so that the preform 70 is cooled to a temperature below the processing temperature before the latch 168 is opened and the preform 70 is removed from the preforming apparatus 110 .
As shown in FIGS. 12 and 13 , the preforming apparatus 110 can also include a consolidation joining head 160 that is configured to be adjusted radially relative to the inner beam 150 . The head 160 can be retracted from the cavity 111 during preforming, as shown in FIG. 12 , and then positioned proximate to the preform 70 and in alignment with the interface 82 of the preform 70 as the preform 70 is held in the desired configuration of the duct 90 as shown in FIG. 13 . The head 160 includes a heater 162 that is supported by an elastomeric block 164 , such that the heater 162 is disposed on or in the block 164 . After the sheet 50 has been configured to form the preform 70 , i.e., in the desired configuration of the duct 90 as shown in FIG. 13 , the head 160 can be adjusted radially inward so that the block 164 and/or the heater 162 contact the preform 70 . The head 160 compresses the edges 78 , 80 of the preform 70 together at the interface 82 . Preferably, the heater 162 is flexible, and flexibly supported by the elastomeric block 164 , so that the heater 162 conforms to the preform 70 and exerts a substantially uniform pressure thereon. For example, the heater 162 can comprise a flexible silicone heater disposed on the elastomeric block 164 . As the head 160 compresses the interface 82 against the inner beam 150 , the heater 162 heats the interface 82 and the edges 78 , 80 are thus consolidation joined to form the longitudinal seam 92 , thereby forming the duct 90 . The inner beam 150 can also include an inner heater 166 , in addition or in alternative to the heater 162 . Thus, the interface 82 can be heated by the heater 162 , the inner heater 166 , or both heaters 162 , 166 . Preferably, the heater(s) 162 , 166 are configured to heat the edges 78 , 80 to a temperature above the glass transition temperature of the thermoplastic material. Consolidation joining is further discussed in U.S. application Ser. No. 10/215,833, titled “Consolidation Joining of Thermoplastic Laminate Ducts.”
FIGS. 14 and 15 illustrate an alternative preforming apparatus 210 , in which the outer support structure includes two partial tubes 212 a , 212 b connected by a hinge 213 . The partial tubes 212 a , 212 b can be rotated about the hinge 213 by actuators 238 from an open position, shown in FIG. 14 , to a closed position, shown in FIG. 15 . In the closed position, the partial tubes 212 a , 212 b define an internal cavity 211 that corresponds to the desired shape of the preform 70 and the duct 90 . A rigid inner member 236 is positioned proximate to the tubes 212 a , 212 b so that the tubes 212 a , 212 b at least partially enclose the inner member 236 when adjusted to the closed position. The rigid inner member 236 can be formed of a rigid material, such as steel, aluminum, or titanium, or the inner member 236 can be formed of a device that can be configured to be rigid, such as an inflatable bladder. The inner member 236 corresponds to the shape of the partial tubes 212 a , 212 b and, in the illustrated embodiment, is cylindrical although the partial tubes 212 a , 212 b and the inner member 236 may have other shapes if desired. Thus, the sheet 50 can be positioned between the partial tubes 212 a , 212 b and the inner member 236 , and the preforming apparatus 210 can be used to bend the sheet 50 from the flat configuration to the bent or preformed configuration by adjusting the partial tubes 212 a , 212 b from the open position to the closed position and urging the sheet 50 around the inner member 236 . Advantageously, the partial tubes 212 a , 212 b and/or the inner member 236 can be heated to thereby facilitate the bending or forming of the sheet 50 . For example, heaters 240 can be provided in or on each of the partial tubes 212 a , 212 b , which, in turn, are constructed of a material such as aluminum, steel, titanium, alloys thereof, or a composite material, that is at least partially thermally conductive. Alternatively, the partial tubes 212 a , 212 b and/or the inner member 236 can be heated by an independent heater, such as an oven, configured to receive the partial tubes 212 a , 212 b when rotated to their open positions.
The preforming apparatus 210 can also include a consolidation joining head 260 positioned proximate to the inner member 236 and in alignment with a gap between the partial tubes 212 a , 212 b once the partial tubes 212 a , 212 b have been closed. The head 260 is adapted to be adjusted radially relative to the inner member 236 . The head 260 can include a heater 262 that is supported by an elastomeric block 264 , such that the heater 262 is disposed on or in the block 264 . After the sheet 50 has been configured to form the preform 70 , i.e., in the desired configuration of the duct 90 as shown in FIG. 16 , the head 260 can be adjusted radially inward so that the block 264 and/or the heater 262 contact the preform 70 . Advantageously, the preform 70 may be positioned such that the edges 78 , 80 of the preform 70 are also in general alignment with the gap between the partial tubes 212 a , 212 b once the partial tubes 212 a , 212 b have been closed. In this advantageous embodiment, the head 260 compresses the edges 78 , 80 of the preform 70 together at the interface 82 . Preferably, the heater 262 is flexible, and flexibly supported by the elastomeric block 264 , so that the heater 262 conforms to the preform 70 and exerts a substantially uniform pressure thereon while concurrently heating at least one edge 78 , 80 of the preform 70 to consolidation join the edges 78 , 80 and form the longitudinal seam 92 along the length of the preform 70 , thereby forming the duct 90 . The inner member 236 can include an inner heater 266 , in addition or in alternative to the heater 262 , so that the preform 70 can be heated on its inner and outer surfaces, preferably to a temperature above the glass transition temperature. The sheet 50 can be held in position about the inner member 236 by one or more straps and/or tape (not shown) instead of the partial tubes 212 a , 212 b . Preferably, the tape is heat shrink tape, i.e., tape that constricts in length as the tape is heated to a processing temperature. Thus, the sheet 50 is wrapped around the inner member 236 , and the straps, which can be formed of heat resistant cloth, are secured around the sheet 50 to hold the sheet 50 in the desired configuration of the duct 90 . The heat shrink tape is then disposed around the sheet 50 such that the tape, when heated, constricts and urges the sheet 50 tightly against the inner member 236 . The thermal energy for heating the sheet 50 and the tape can be generated by an oven configured to receive the inner member 236 and the sheet 50 or by a heater located within the inner member 236 .
As shown in FIGS. 17 and 18 , the preforming apparatus 210 can also be used without the inner member 236 . For example, each of the partial tubes 212 a , 212 b can define a longitudinal stop 242 that extends radially inward toward the cavity 211 . With the partial tubes 212 a , 212 b in the open position, as shown in FIG. 17 , the sheet 50 can be inserted between the stops 242 such that the stops 242 retain the sheet 50 as the partial tubes 212 a , 212 b are adjusted by the actuators 238 to the closed position, as shown in FIG. 18 . The sheet 50 can be inserted into the cavity 211 through a gap 214 between the longitudinal stops 242 , as shown in FIG. 17 . The sheet 50 can also be inserted in a longitudinal direction into the cavity 211 from a longitudinal end of the tubes 212 a , 212 b , and the tubes 212 a , 212 b can be in the closed position while the sheet 50 is inserted. As described above, the sheet 50 can be heated with the heaters 240 or other heaters (not shown) to the processing temperature and, after forming, the preform 70 can be cooled in the preforming apparatus 210 before the partial tubes 212 a , 212 b are opened to release the preform 70 . A consolidation joining head and/or an inner heater as described in connection with FIG. 16 can also be used to join the edges 78 , 80 as the preform 70 is held in the configuration shown in FIG. 18 .
FIG. 19 illustrates an alternative preforming apparatus 310 according to the present invention, which includes a hollow tube 312 and a funnel 320 . The hollow tube 312 can define a cylindrical cavity 314 or another shape that corresponds to the desired configuration of the preform 70 and the duct 90 . Additionally, the tube 312 can include an inner member (not shown) that can be received by the passage 76 of the preform 70 and defines an outer surface that corresponds to the desired configuration of the duct 90 . The funnel 320 extends longitudinally from a first end 316 of the tube 312 . The funnel 320 extends from a first end 322 to a second end 324 , which is smaller than the first end 322 and generally corresponds in size to the first end 316 of the tube 312 , so that the funnel 320 tapers toward the tube 312 . The sheet 50 can be inserted into the funnel 320 in a flat or partially bent configuration and urged longitudinally toward and into the cavity 314 of the tube 312 . As the sheet 50 slides longitudinally in the funnel 320 , the tapering shape of the funnel 320 causes the sheet 50 to bend to the diameter of the cylinder 312 and, hence, the desired configuration of the preform 70 and the duct 90 . The sheet 50 can be inserted into the funnel 320 and the tube 312 manually by an operator, or an automated insertion device (not shown) can be provided. Heaters 330 can be provided on the funnel 320 and/or the tube 312 such that the sheet 50 is heated to the processing temperature while the sheet 50 is urged into the funnel 320 and/or the tube 312 . For example, the heaters 330 can be electrical resistive heaters disposed on the tube 312 and the funnel 320 such that the heaters 330 can be connected to a power supply (not shown) and energized to heat the sheet 50 . The sheet 50 can be held at the processing temperature for a processing hold interval, such as 10 minutes, and the heaters 330 can then be turned off so that the resulting preform 70 is cooled in the tube 312 before being removed through the first end 316 or a second end 318 . Further, the tube 312 can comprise a consolidation joining apparatus or other joining apparatus for joining the longitudinal edges 78 , 80 of the preform 70 and forming the duct 90 , for example, as discussed in U.S. application Ser. No. [. . . ], titled “Consolidation Joining of Thermoplastic Laminate Ducts.”
After the preformed 70 has been processed to form the duct 90 , the duct 90 can be post-formed to provide additional contours or features, such as bells, beads, and the like. A discussion regarding the formation of duct features such as bells and beads through post-forming, i.e., after the preforming and/or the consolidation joining of the sheet 50 , is provided in U.S. application Ser. No. [. . . ], titled “Post-Forming of Thermoplastic Ducts” filed concurrently herewith and the contents of which are incorporated herein by reference. It is also appreciated that marks can be provided on the preform 70 , for example, to accurately identify the location of such post-formed features or to facilitate the manufacture or assembly of the ducts, as provided in U.S. application Ser. No. [. . . ], titled “Thermoplastic Laminate Duct.”
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. For example, it is appreciated that each of the working surfaces of the apparatuses can include a low friction layer or release layer, e.g., Teflon®, registered trademark of E.I. du Pont de Nemours and Company. The release layer can be a durable layer of material or a release agent that is wiped or sprayed onto the working surfaces before each consolidation joining process. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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There are provided apparatuses and related methods for preforming sheets to form preforms for forming ducts. The preforms can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape of the duct. For example, rollers, rods, tubes, or a funnel can be used to bend the sheet.
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BACKGROUND OF THE INVENTION
The invention relates to an inductive switch apparatus having a sensor unit and can be used in particular for a position switch apparatus that is used in automatic motor vehicle transmissions.
Known in the prior art is a displacement and angle sensor, in particular for determining a gear that has been selected in the motor vehicle field, in accordance with patent DE 198 06 529. The known displacement and angle sensor has four measurement coils that are arranged at right angles to one another on a coil carrier in an X/Y plane and are connected to evaluation electronics. The sensor has a so-called target that can be moved largely parallel to the X/Y plane relative to the measurement coils, thereby inducing voltages in the measurement coils. The evaluation electronics can determine the path traveled in the Y direction and the angle α of the target in a Z/X plane from the induced voltages. The known displacement and angle sensor is distinguished in that the opposing measurement coils are arranged spaced from one another and the adjacent measurement coils at least partially overlap one another.
The older application DE 102 42 385 A1 discloses an inductive sensor unit having at least two sensor coils that are mounted on a printed circuit board adjacent to one another in a planar manner. By an adjacent conductive actuating element the distance x to the sensor coils and the overlap y of the sensor coils can be changed. The evaluation of the changes in inductance that thus arise occurs, as for inductive proximity switches, by including the sensor coils in an oscillating circuit. Such an evaluation of resonance is sensitive to temperature and relatively complex.
Furthermore known in the field of automobiles is widespread employment of mechanical switches, including lock systems, operating elements for the dashboard, seat adjustments, mirror adjustments, etc. Mechanical switches have the disadvantage that they do not work in a wear-free manner. Their service life is limited by the material wear of the contact material, changes in the material (oxidation), and deposits on the switch contacts due to mechanical friction or electrical overloading or due to arcing when turning off.
One particular form of mechanical switches are mechanical sliding switches. A displaceable contact runs over a slide track and thus, depending on the position, produces a contact to various connections (so-called encoding switches). In such a shift gate unit, vibrations that occur in the vehicle lead to increased wear in the sliding contacts and slide tracks.
In modern vehicles, actuating motors these days are generally switched via wear-free power semiconductors, which then however are controlled by non-wear-free switches. In order to design the system completely wear-free, it is necessary to develop novel switches that work without mechanical switch contacts (that is, with sensors).
Known from the prior art are Hall sensors that react to the approach of permanent magnets and thus trigger a switching function. Furthermore known is the use of GMR sensors, which are based on the effect of a change in resistance that is caused by an external magnetic field. The external magnetic field can derive from a permanent magnet or a magnetizable plastic and can initiate appropriate switching functions.
Furthermore known is the use of light barriers and reflex light barriers, which have the disadvantage that they are sensitive to stray light and that the optical components age and can be soiled easily. The use of such sensors furthermore has the disadvantage that they are expensive compared to mechanical switches and inductive switches.
In switching elements, cost-effective printed circuit boards are frequently used as carriers for illumination, displays, or mechanical switches. The presence of such a printed circuit board favors the use of the present invention. The working principle of the inductive coupling of two sensor coils applied to the printed circuit board and their damping by a conductive actuator was disclosed as a cost-effective option for instance in DE 101 25 278. In it, damping strength correlates to the position of the actuator relative to the sensors. In this technology, it can be disadvantageous that the sensors in their practical design must have a minimum size of approx. 10 mm×10 mm on the printed circuit board so that acceptable coupling can be achieved and thus the electronics can be designed simply and cost-effectively. In the printed circuit boards that can currently be economically produced, a local resolution of 0.12 mm is attained, i.e., the conductor width of the sensor windings can be a maximum of 0.12 mm, just like the insulating width between the windings. As a result of this, the transmitter coil and the receiver coil of the sensors can have only approx. 5 windings.
The object of the invention is to influence the inductance of sensor coils using an actuator brought over the coil and to evaluate this change in inductance in a simple manner.
SUMMARY OF THE INVENTION
The inductance of a coil chances significantly through a conductive actuator element that has a variable distance x to the sensor coils and/or a variable overlap y of the sensor coils. This object is attained by an inductive switching apparatus in accordance with the invention.
An undamped sensor coil with the external dimensions 10 mm×10 mm, which is wound on the printed circuit board like a rectangular spiral from the inside to the outside, has 10 windings and an inductance of approx. 1 μH at the resolution that can be attained on the printed circuit board.
Although using the impedance of a spiral structure as a sensor is known from publication GB 1 415 644, the known spiral structure is double-wound in order to exploit the ohmic components of the spiral impedance and in order to switch off the inductive components of the spiral impedance. In contrast thereto, the sensor coil in accordance with the invention is single-wound, as can be seen from the following detailed description using the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the planar design of a sensor slide on a printed circuit board together with the electrotechnically equivalent symbol L.
FIG. 2 illustrates a functional circuit diagram of an inventive switching apparatus with sensor unit with a reactance measurement as evaluation circuit.
FIG. 3 illustrates a function circuit diagram with a reactance evaluation and with two sensors controlled using multiplex for detecting a displacement path y.
FIG. 4 illustrates a typical characteristic curve for the inductance of a first sensor L 1 in accordance with FIG. 3 and a second sensor L 2 in accordance with FIG. 3 as a function of the displacement path y.
FIG. 5 illustrates a shift gate for a motor vehicle with an automatic gearshift lever that is connected to a switch apparatus in accordance with FIG. 3 or FIG. 6 .
FIG. 6 illustrates the scheme of a printed circuit board with a plurality of sensor units for the shift gate unit in accordance with FIG. 5 .
FIG. 7 illustrates the block diagram of an electronic unit when a plurality of inductive sensors are combined.
FIG. 8 illustrates the normalized inductances of the sensor signals of the different shifting units in FIG. 7 during shifting events of the automatic gearshift lever from position 1 to position 4 .
FIG. 9 illustrates a similar scheme of a printed circuit board as in FIG. 6 , but with a redundant shifting unit.
FIG. 10 illustrates the block diagram of an evaluation unit with voltage impression.
FIG. 11 illustrates the change in inductance evaluated in accordance with FIG. 10 .
FIG. 12 illustrates the circuit diagram of an evaluation unit with current injection.
FIG. 13 illustrates the change in inductance evaluated in accordance with FIG. 12 .
FIG. 14 illustrates a null normalization of the inductance measured in accordance with FIG. 13 .
FIG. 15 illustrates a dependence of the null normalization in accordance with FIG. 14 when in addition the distance x in accordance with FIG. 3 changes.
FIG. 16 illustrates finding of quotients in order to become independent of the distance in accordance with FIG. 15 .
FIG. 17 illustrates a logarithmic evaluation of the quotients in accordance with FIG. 16 for determining the precise path position y.
FIG. 18 illustrates a definition of gear thresholds during y-displacements in accordance with FIGS. 12 through 17 .
FIG. 19 illustrates a displacement of the gear thresholds in accordance with FIG. 18 .
DETAILED DESCRIPTION OF THE INVENTION
In accordance with FIG. 1 , a sensor coil is applied in a planar manner to a printed circuit board. The connection in the center point of the spiral is executed for instance on the back side of the printed circuit board. If the sensor is covered in accordance with FIG. 1 with a conductive actuator at a distance x of for instance x=0.05 mm, the inductance decreases from for instance approx. 1 μH to for instance approx. 0.2 μH.
The decrease in the induction using the actuator B is a function of the distance x from the actuator B to the sensor slide ( FIG. 2 ); however, it is also a function of the degree to which the sensor slide is covered by the actuator element ( FIG. 3 ). If the actuator covers the entire surface of a slide in accordance with FIG. 1 at a constant distance x, the amplitude of the sensor voltage is minimal with the degree of coverage of 100%, whereby the amount of the minimum sensor voltage depends on the distance x. The reactance L is thus variable ( FIG. 1 ).
Thus two switching mechanisms are possible for the switch:
The degree of coverage G is maintained at a defined size, and the distance x between the actuating element B and the sensor slides is varied (as illustrated e.g. in FIG. 2 ), or The distance x is maintained constant, and the degree of coverage G is changed (as illustrated e.g. by the y-displacement in FIG. 3 ). A combination of these two switch mechanisms x and y is also possible ( FIG. 3 ).
Sufficiently known as cost-effective evaluation electronics is an LC oscillating circuit, comprising a sensor inductance L, a fixed capacity C, and an inverting amplifier into the feedback branch of which the LC oscillating circuit is built. The frequency of the oscillating circuit is determined by the resonance frequency of the LC member using the formula:
f
r
1
2
π
×
1
√
I
.
C
A downstream frequency counter determines the oscillations per unit of time and outputs them as a signal value. For a simple switching function it is sufficient to compare the actual frequency value to a threshold value by means of a comparator and thus to initiate the switching function. In a normal case, the switch signal is set to “1” when the frequency is higher than a set limit frequency, which corresponds to a lower inductance through higher damping. At a lower frequency, the comparator outputs a “0”. High powers can then be switched via a downstream high/low switch or a relay R. However, the functions of the frequency counter and comparator can also be realized as so-called firmware in a microcontroller.
Thus a wear-free momentary-contact switch can be realized in a simple manner in an operating unit of the automobile. The damping element is approached by depressing a key to the sensor and is held there by means of a locking mechanism. The lock is not released until the key is depressed again, and the actuator is brought to its rest position at a greater distance from the sensor (ballpoint pen locking principle). Thus keys such as the switches for hazard warning lights, fog lights, rear window defrost, etc., can be realized in a simple and cost-effective manner.
In applications in which very precise switching points are required, the effects of temperature on amplifiers, capacities, comparators, etc., are often problematic. In temperature-stable applications, these effects can be inventively circumvented in that two sensors are applied next to one another on one circuit board and they are simultaneously or alternately switched in (see FIG. 2 or 3 ). Switching on the inductance L 1 or L 2 occurs using a switching transistor or field effect transistor or MOSFET ( FIG. 2 ) or an AMUX analog multiplexer ( FIG. 3 ). If a relative evaluation is applied in that the ratio of the first sensor reactance to the second sensor reactance is used as switching criterion, the interfering effects are eliminated. The circuit is very temperature stable.
This type of circuit has also proved to be advantageous in applications in which the position y of the actuator is detected relative to the sensor positions, while the distance x from the actuator to the sensor is kept more or less constant (such as e.g. in displacement and angle sensors). In this case, as well, in accordance with FIG. 3 a relative evaluation takes place that can best occur, but must not exclusively occur, using a microcontroller μC.
FIG. 4 illustrates two typical characteristic curves of the normalized inductance as a function of the displacement path y. The microcontroller μC can undertake precise position recognition in the displacement region between the peaks of the characteristic curves L 1 and L 2 . In additional practical applications, even more sensors are used for recognizing the actuator position.
If multiple positions are to be detected in one application event, such as is illustrated in FIG. 5 as a shift gate for a motor vehicle, it is useful to combine a plurality of inductive sensors as a functional unit. Given the example of converting the position recognition of an automatic gearshift lever, this looks as follows:
A printed circuit board as in FIG. 6 is positioned under a cover as in FIG. 5 ; on its upper side e.g. the backlighting for the cover displays 1 , 2 , . . . P can be mounted. Connected to the automatic gearshift lever AW (see FIGS. 5 and 6 ), which drops through a break in the printed circuit board, is an actuator slide BS that rests in a planar manner on the bottom side of the printed circuit board LP and to which are affixed one actuator or a plurality of actuators (e.g. the actuator surfaces BF 1 and BF 2 in FIG. 6 ). The actuator surfaces are pushed over the various sensor units SE at a defined distance x.
The term displacement means a movement of the actuator slide that can be a straight line or that can change direction. The sensor coils to be passed over can be lined up in a straight line, as is shown in principle in FIG. 7 . However, the sensor coils can also be situated adjacent to one another in accordance with a more complex topology, as is used for the shift gate units in accordance with FIGS. 6 and 9 .
Furthermore, the topology of the adjacent sensor coils (straight line, polygon, other path) can be situated on a flat or on a curved printed circuit board. FIG. 7 depicts a flat arrangement of sensor coils, while FIGS. 5 and 6 depict an example for a curved printed circuit board that is arranged beneath the curved shift gate. In both cases the actuator slide is displaced at a distance x, which can be largely constant or even variable, above the arrangement of sensor coils.
Another variant of the claimed displacement results when the curved printed circuit board that follows the curved gate in accordance with FIG. 5 is replaced with a flat printed circuit board that is arranged in a plane that runs perpendicular to the surface of the gate. In this case the actuator slide is also positioned vertically and pushed sequentially over the sensor slides that are attached e.g. in arc-shapes to the vertical, flat printed circuit board.
In the combination of a plurality of inductive switches, the block diagram looks like that in FIG. 7 . The associated amplitudes of the sensor signals when the automatic gearshift lever is shifted can be seen in FIG. 8 for the positions 1 , 2 , 3 , and 4 , whereby the normalized reactance is applied across the displacement path P 1 -P 4 for the sensors L 1 -L 4 . The shifting thresholds P 1 -P 2 , P 2 -P 3 , and P 3 -P 4 are entered.
Very redundant and therefore certain position recognition can also be realized without major additional complexity as depicted e.g. in FIG. 9 . Instead of one sensor unit per position, it is suggested to construct two sensor units per position and to compare the signals. When there are contradictory results, the evaluation unit will perform the switching function so that the entire system is brought into a secure condition. For this, the printed circuit board can be expanded for instance with safety sensor units SSE in accordance with FIG. 9 .
The evaluation unit for the sensor module will as a rule be a microcontroller that forwards the switching information to the control electronics or power electronics via an interface (CAN, LIN, etc.).
Signal evaluation occurs for a plurality of sensor coils via a multiplexer ( FIG. 3 , FIG. 7 ) that switches on only one of the sensor coils of the evaluation circuit. FIGS. 10 and 11 illustrate one exemplary embodiment of the signal evaluation that can be employed similar to the exemplary embodiment depicted in FIGS. 7 and 8 .
In accordance with FIGS. 10 and 11 , the limit between the positions of two adjacent sensor coils is determined by a direct comparison of the inductive reactance. In accordance with the circuit diagram in FIG. 10 , a sine oscillator generates an alternating voltage of 12 MHz; this is amplified and fed as voltage into one of the three sensor coils that are switched into the time-division multiplex. If the actuator, which comprises conductive metal, is moved over the coils, the inductance of the coils decreases due to eddy current loss. Because of this, the reactance also decreases; it is calculated as follows: XL=2*PI*f*L (f=12 MHz). If, for example, a coil has inductance of 100 nH without actuator and 200 nH with actuator, the equation above results in XL of 75 Ohms and 15 Ohms, respectively. At constant alternating voltage, a current flows that depends on covering the actuator. This current is transformed into a proportional HF voltage and is fed equalized to the microcontroller.
FIG. 11 depicts the evaluation concept for the microcontroller. The microcontroller measures the equalized voltage of each sensor cyclically in fixed time slots of e.g. 2 ms. If the actuator is moved in fixed path increments over the sensors and the voltages are recorded, the result is curves like those illustrated in FIG. 11 . The path region can be enlarged with additional sensors. When the actuator is in the static condition, only two values are evaluated, i.e. there are only two adjacent measurement values for the microcontroller at any point in time. The quotient of two adjacent sensor voltages is calculated in the evaluation firmware in the microcontroller and compared to a fixed value. One or the other switch position is determined depending on whether the quotient is larger or smaller than the fixed value.
As an alternative to the voltage feed in accordance with FIG. 10 , FIG. 12 depicts a current feed into the coil reactances. A sine oscillator produces an alternating current with a constant amplitude and constant frequency of for instance f=12 MHz. This alternating current is amplified and fed in sequence into each of the for instance four sensor coils L 1 through L 4 .
If the actuator, which comprises a material that conducts well (for instance copper or brass) is moved over the coils, the inductance L of the coils decreases due to the eddy current losses. Because of this, the inductive resistance XL also decreases; it is calculated as follows: XL=2*PI*F*L. If the actuator does not cover a coil, it has inductance of for instance 1000 nH. On the other hand, if the actuator completely covers a coil, it has inductance of for instance 200 nH. Given the equation above, then, inductive resistance XL is for instance 75 Ohms and 15 Ohms, respectively.
The drop in voltage at one of the coils L 1 through L 4 is equalized and fed to a microcontroller for further processing. The coils therefore act as sensors for the geometric site of the actuator.
FIG. 13 illustrates further signal evaluation. The microcontroller measures the voltages of the sensors L 1 through L 4 , which are proportional to their inductances, cyclically in fixed time slots. If a diamond-shaped actuator is moved in fixed path increments over the sensors and the voltages are recorded, the result is nearly sinusoidal curves like those illustrated in FIG. 13 . The path region can be enlarged with additional sensors.
In the next processing step, in accordance with FIG. 14 a null normalization is performed. First, the sensor number and the sensor signal with the highest inductance Lmax, 1000 nH in the example, is determined from the curves in accordance with FIG. 13 . Then the sensor values are subtracted from Lmax and the four damping curves in FIG. 14 are obtained.
The damping is 0% if one sensor is not covered by the actuator; it is 100% it the sensor is completely covered.
However, the damping is also a function of the distance from the actuator to the sensor coils. The maximum damping decreases as the distance increases, as can be seen in FIG. 15 .
In order to be unaffected by this change in distance (in some position switch apparatus for automatic transmissions it is not possible to avoid changes in distance), the quotients are found for two adjacent curves are found. From this are obtained for instance the three quotient curves illustrated in FIG. 16 .
In order to attain a linear context between path and signal, the quotient curves are then logarithmized ( FIG. 17 ). The more sinusoidal the shape of the curve shapes in FIG. 14 , the more linear the logarithmized curves in accordance with FIG. 17 .
Starting with each logarithm value, the precise path position y can be determined using the slope and a point on each line ( FIG. 17 ).
FIG. 18 illustrates the setting of gear thresholds. Automatic transmissions in automobiles have four gear positions (regions): park, reverse, neutral, and drive. When using the sensor system, therefore, a distinction must be made between four regions. There are three gear thresholds between the four regions. Each gear threshold can be set in that the ordinate values for all of the straight lines in accordance with FIG. 17 at certain path positions are stored. These gear thresholds are set as follows:
The actuator is brought to the first position (e.g. 8 mm); now the value on the first straight line is stored (e.g. 0.2). Precisely the same thing is done for the other gear thresholds. During operation, the ordinate value on the currently intersected straight line is continuously compared to the gear thresholds. In the example in FIG. 18 , the current position of the actuator is at 28 mm. The value on the ordinate 0.2 here is smaller than the ordinate value of the second gear threshold (0.8). This means that the current position of the actuator is in region 3 .
Finally, FIG. 19 illustrates displacement of all gear thresholds to one single position. In practice, it can happen that the complete sensor structure is mechanically displaced with the gear thresholds that have already been set. Then all of the gear thresholds would theoretically have to be re-set in accordance with FIG. 18 .
Using a “1-point calibration” it is preferably possible to displace all switch points by the same value at one single position. For this, the slopes of all straight lines in accordance with FIG. 17 and FIG. 18 must be known. In the example in FIG. 19 , the gear thresholds are to be displaced from “old” to “new”. For this, the actuator is moved to the “New gear threshold” position. Using the difference Δ Y 1 of the two points on the ordinates (P 1 =0.2 and P 2 =−0.2) and using the slope in the first straight line, the path difference ΔX 1 can be calculated. The ordinate values of the new gear thresholds can be calculated for the other straight lines using this information. The new ordinate values are now stored in a non-volatile memory and are used as gear thresholds from now on.
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The invention relates to an inductive sensor unit having one or several coils, which are mounted on a printed circuit board in a planar manner. According to the invention, a change in the inductance of a sensor coil due to leakage currents in the inductive actuator is correlated with the position of the actuator in two respects i.e., with the distance x to the sensor coils and with the overlapping y of the sensor coils. As a result, an inductive push button switch and an inductive position switching device (a sliding switch) are provided. The invention also relates to the evaluation of the inductance by means of reactance measurement. A relative evaluation of the influence of adjacent sensor coils increases the precision of response in push button switches and, generally, a relative evaluation of the influence of adjacent sensor coils is carried out in position switching devices.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 60/861,005 filed on Nov. 27, 2006, titled “TWO POSITION EXTENDABLE LINT AND PET HAIR REMOVER” which is incorporated herein by reference in its entirety for all that is taught and disclosed therein.
BACKGROUND
The present invention relates to the general art of tools, and to the particular field of dust and lint removers. There are many previously known lint roller assemblies which typically comprise a handle secured to a cylindrical lint roller support. A tubular cylindrical adhesive lint roller is then removably mounted to the support such that the adhesive roller is rotatable relative to the handle. In use, the adhesive lint roller is rolled along a user's clothes or other surfaces to remove lint, hair and other debris.
SUMMARY
This Summary is provided to introduce in a simplified form a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
The detailed description below describes a rolling lint and pet and human hair remover that will function in at least two different positions with the option of extending the handle to reach hard to reach areas for use in automobiles, homes, and other locations as well as on a person's clothing, and that also freshens the air around the immediate area of use.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows an elevation view of an embodiment of a lint remover with the handle extended and in a bent position.
FIG. 2 shows a partial perspective view of the lint remover of FIG. 1 with the handle in a straight position.
FIG. 3 shows a perspective view of another embodiment of a lint remover in a straight position.
FIG. 4 shows an elevation view of the lint remover of FIG. 3 in a straight position.
FIG. 5 shows a perspective view of the lint remover of FIG. 3 in a bent position.
FIG. 6 shows a perspective view of the lint remover of FIG. 3 in a folded position.
FIG. 7 shows a perspective view of another embodiment of a lint remover in a straight position.
FIG. 8 shows an elevation view of the lint remover of FIG. 7 in a straight position.
FIGS. 9A and 9B show an embodiment of an extendible handle in the non-extended and extended positions for use with any of the lint removers shown in FIGS. 1-8 .
FIGS. 10A , 10 B, and 10 C show an embodiment of an assembly for holding air-freshening beads for use with any of the lint removers shown in FIGS. 1-8 .
DETAILED DESCRIPTION
Referring now to the Figures, in which like reference numerals and names refer to structurally and/or functionally similar elements thereof, FIG. 1 shows an elevation view of an embodiment of a lint remover with the handle extended and in a bent position and FIG. 2 shows a partial perspective view of the lint remover of FIG. 1 with the handle in a straight position. Referring now to FIGS. 1 and 2 , Lint Remover 10 includes Hand Grips 12 on one end of a Handle 14 which has a Pivot Connection 16 on the other end thereof. A Lint Roller 20 is rotatably mounted on a Support Bar 22 that is pivotally connected to Handle 14 by the Pivot Connection 16 . Pivot Connection 16 has a Release Button 24 so Lint Roller 20 can be positioned and oriented in a straight or bent position with respect to the Handle 14 by pushing in on Release Button 24 . Pressing Release Button 24 allows Handle 14 and Support Bar 22 to pivot about Pivot Connection 16 . When released, Release Button 24 locks Handle 14 in relation to Support Bar 22 . Release Button 24 may have two, three, four, or more predefined mechanical locked positions defining the angle between Handle 14 and Support Bar 22 such as 45°, 90°, 135°, or 180°. Release Button 24 may also be of a design that is friction based such that any angle desired between Handle 14 and Support Bar 22 may be fixed into place. Various locked angle relationships may thus be established between Handle 14 and Support Bar 22 via Pivot Connection 16 as desired.
Telescoping Members 18 allow Handle 14 to be extended. Hand Grips 12 are rotatable about Telescoping Members 18 to tighten and loosen their friction grip on Telescoping Members 18 . In a non-extended position, Hand Grips 12 butt up against each other, and Telescoping Members 18 are not visible, but are slidably retracted inside of each other. In other embodiments, there may be only one Hand Grip 12 and no Telescoping Members 18 as shown in FIGS. 3-8 .
Lint Roller 20 contains a series of concentric sheets that are sticky on the outer facing surface that are wound around a hollow tube. The concentric sheets have at least one perforated portion running along a length of Lint Roller 20 . After use for a period of time, the outermost concentric sheet may lose its stickiness and no longer be able to pick up lint, hair, or other debris. When this occurs, the outermost concentric sheet may be torn along the perforation and discarded, revealing the next fresh concentric sheet underneath. This process is repeated until the last concentric sheet is used up. Another Lint Roller 20 may then be secured to Support Bar 22 .
FIG. 3 shows a perspective view of another embodiment of a lint remover in a straight position. FIG. 4 shows an elevation view of the lint remover of FIG. 3 . FIG. 5 shows a perspective view of the lint remover of FIG. 3 in a bent position. FIG. 6 shows a perspective view of the lint remover of FIG. 3 in a folded position. Referring now to FIGS. 3 , 4 , 5 , and 6 , Lint Remover 10 ′ has a Support Bar 22 ′ that has an “S” shape. Pivot Connection 16 ′ is thus in a relationship with Support Bar 22 ′ and Hand Grip 12 ′ which allows Hand Grip 12 ′ to be rotated into a compact folded position (see FIG. 6 ) which is useful when storing Lint Remover 10 ′ when it is not in use. Pivot Connection 16 ′ allows movement of Support Bar 22 ′ in relation to Hand Grip 12 ′ from 0° (see FIG. 6 ) to 90° (see FIG. 5 ) to 180° (see FIG. 4 ). In this embodiment, Center Line 26 of Hand Grip 12 ′ is offset from Center Line 28 of Lint Roller 20 ′.
In the compact folded position, a Gap 30 between Center Line 26 and Center Line 28 allows a user of Lint Remover 10 ′ to grasp Hand Grip 12 ′ with clearance of the user's fingers in relation to Lint Roller 20 ′. Thus, the user can operate Lint Remover 10 ′ in tighter fitting places because Handle 14 ′ is not extended away from Lint Roller 20 ′. Based upon its design, Pivot Connection 16 ′, as described above, may have two, three, four, or more predefined mechanical locked positions defining the angle between Handle 14 ′ and Support Bar 22 ′, or may be friction based such that any angle desired between Handle 14 ′ and Support Bar 22 ′ may be fixed into place.
FIG. 7 shows a perspective view of another embodiment of a lint remover in a straight position. FIG. 8 shows an elevation view of the lint remover of FIG. 7 in a straight position. Referring now to FIGS. 7 and 8 , in this embodiment of Lint Remover 10 ″ Center Line 28 ′ of Lint Roller 20 ″ is also the center line of Hand Grip 12 ″. The “S” shape of Support Bar 22 ″ is not as pronounced as that shown in FIGS. 3-6 . In the folded compact position, Hand Grip 12 ″ will be in much closer proximity to Lint Roller 20 ″ such that a user would not be able to get their fingers between Hand Grip 12 ″ and Lint Roller 20 ″, but still could grasp Hand Grip 12 ″ more with the tips of their fingers in order to still utilize Lint Remover 10 ″ in the folded compact position.
FIGS. 9A and 9B show an elevation view of an embodiment of an extendible handle in the non-extended and extended positions for use with any of the lint removers shown in FIGS. 1-8 . Referring now to FIGS. 9A and 9B , Extendible Handle 32 has Hand Grip 12 ′″ that has Telescoping Members 18 ′ which are releasably extendible through the action of Collars 34 . Collars 34 are rotatable about Telescoping Members 18 ′ to tighten and loosen their friction grip on Telescoping Members 18 ′. Thus, Telescoping Members 18 ′ may be partially or fully extended to achieve a variable length of Extendible Handle 32 . Extendible Handle 32 may also be of a design where there are only two locking positions, fully extended and fully retracted. Handle 14 ′ is retractable and extendible via the Collar 34 with which it contacts. Extendible Handle 32 may be substituted for the one shown in FIG. 1 . In addition, Extendible Handle 32 may be substituted for Hand Grip 12 ′ ( FIGS. 3-6 ) or Hand Grip 12 ″ ( FIGS. 7-8 ) where the extant end of Handle 14 ′ is attached to Support Bar 22 ″ via Pivot Connection 16 ″.
FIGS. 10A , 10 B, and 10 C show an embodiment of an assembly for holding air-freshening beads for use with any of the lint removers shown in FIGS. 1-8 . Referring now to FIGS. 10A , 10 B, and 10 C, Lint Roller 20 ′″ receives an Air-Freshener Body 36 that has a removable End Cap 38 . The other end of Air-Freshener Body 36 has an opening for receiving Support Bar 22 ′″. Air-Freshener Beads 40 ( FIG. 10B ), which can be purchased separately in a Container 42 , are poured inside Air-Freshener Body 36 . End Cap 38 , which may snap on and snap off, is then snapped back on.
A cross-section view of Air-Freshener Body 36 is shown in FIG. 10C . Within the interior of Air-Freshener Body 36 are a plurality of Fins 46 which run along the length of Air-Freshener Body 36 . When End Cap 38 is snapped back on, a plurality of Tines 44 located around the circumference of End Cap 38 insert themselves within the series of concentric sheets of Lint Roller 20 ′″. As a result, when Lint Roller 20 ′″ is rolled over a surface, Air-Freshener Body 36 rotates along with the rolling movement of Lint Roller 20 ′″ such that the Fins 46 help to agitate and tumble the Air-Freshener Beads 40 inside Air-Freshener Body 36 , helping to give off the aromatic fragrance of the Air-Freshener Beads 40 . A plurality of Holes 48 are located in End Cap 38 and Air-Freshener Body 36 which allow the fragrance to flow out and away from Lint Roller 20 ′″.
Other connecting structures besides Tines 44 may be utilized to enable Air-Freshener Body 36 to rotate along with the rolling movement of Lint Roller 20 ′″. In another embodiment, End Cap 38 may be sized so that the outer circumference fits frictionally snugly inside the inner circumference of the hollow tube of Lint Roller 20 ′″, eliminating the need for Tines 44 . In another embodiment, End Cap 38 may be sized to be approximately the same circumference as Air-Freshener Body 36 but with two or more protrusions that extend radially from the center of End Cap 38 that fit frictionally snugly inside the inner circumference of the hollow tube of Lint Roller 20 ′″, also eliminating the need for Tines 44 . The gaps between the protrusions of End Cap 38 allow additional avenues for air flow, besides Holes 48 , allowing the fragrance of the Air-Freshener Beads 40 to flow out and away from Lint Roller 20 ′″. Thus, when any of the lint removers shown in FIGS. 1-8 are situated with Air-Freshener Body 36 , the lint roller will freshen the air while removing lint, hair, and other debris from various surfaces.
Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. It will be understood by those skilled in the art that many changes in construction and widely differing embodiments and applications will suggest themselves without departing from the scope of the disclosed subject matter.
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A rolling lint and pet and human hair remover will function in at least two different positions and with the option of extending the handle in order to reach hard to reach places for use in automobiles, homes, and other locations, as well as on a person's clothing. The handle is foldable against the lint roller portion for compact storage and for use in tight places. An air-freshener body may be incorporated into the lint roller portion. Air-freshener beads are placed inside the air-freshener body and give off an aromatic fragrance while the lint remover is in use due to the tumbling action of the air-freshener beads inside the lint roller as it is rolled. A plurality of holes in the air-freshener body allow the aromatic fragrance to flow out and away from the lint roller.
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This is a continuation-in-part of application Ser. No. 07/580,241, filed Sept. 7, 1990.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an optical transmitter comprising a combination of an electro-optical converter and an opto-electrical converter which are optically coupled, which combination is included in the negative feedback path of a control loop, the input of the electro-optical converter being coupled to the input of the negative feedback path and the output of the opto-electrical converter being coupled to the output of the negative feedback path. The control loop includes a control amplifier, the output of the negative feedback path being coupled to an input of the control amplifier and the output of the control amplifier being coupled to a first input of combining means whose output is coupled to the input of the negative feedback path. Modulation signal is applied to a second input of the combining means.
2. Description of the Related Art
A transmitter of this type is described in U.S. Pat. No. 4,504,976. Transmitters of this type may be used, for example, in optical recording systems and in optical telecommunication systems.
In these systems the electro-optical converter is often desired to be biassed, so that it generates a certain amount of light even when a modulation signal is absent. In optical recording systems this is desired because the light generated when a modulation signal is absent is used to read information from a record carrier. In digital telecommunication systems the bias is desired because it increases the maximum attainable modulation frequency of the electro-optical converter. This is caused by the fact that the switch-on delay of a fully switched-off electro-optical converter is much longer than the delay in the increasing amount of light generated by an electro-optical converter to a given value from a bias level of the converter.
The electro-optical converters used in systems of this type generally have a strong threshold characteristic. This is to say, the current flowing through the electro-optical converter must exceed a specific threshold value before the converter emits light. This threshold is strongly temperature-dependent and furthermore exhibits a large variation per specimen.
Because the threshold of the current flowing through the electro-optical converter exhibits a large variation, it is not readily feasible to bias the amount of light generated by the electro-optical converter by means of a fixed bias current of the converter.
In order to nevertheless obtain a well-determined bias of the generated light, the electro-optical converter is generally included in the negative feedback path of of a control loop together with an opto-electrical converter, a fraction of the light emitted by the electro-optical converter being applied to the opto-electrical converter. Since the opto-electrical converter is included in the negative feedback path, the output signal of the opto-electrical converter and thus also the amount of light generated by the electro-optical converter is maintained at a predetermined value by the control loop.
Generally, the amount of light emitted by the electro-optical converter can be amplitude modulated by coupling the modulation signal to the input of the gain control amplifier. However, this leads to a restriction of the maximum permissible frequency of the modulation signal, because the gain control amplifier preferably has a high gain factor and thus a limited bandwidth.
In the transmitter known from said U.S. Pat. No. 4,504,976, the light emitted by the electro-optical converter is amplitude modulated by coupling the modulation signal directly to the input of the negative feedback path so that the limiting effect of the gain control amplifier on the maximum permissible frequency of the modulation signal is eliminated. A problem is then that the control loop tries to maintain the output signal of the negative feedback path and thus also the amount of light emitted by the electro-optical converter at a constant level, and is thus capable of reducing or even fully cancelling the effect of the modulation signal on the emitted amount of light.
In this known transmitter it is possible to apply a high-frequency modulation signal to the input of the negative feedback path and to arrange the control loop in such a way that it is only active for low frequencies, so that the control loop now no longer affects the relation between the modulation signal and the emitted amount of light. A drawback of this is that the transmitter is then unsuitable for modulation signals which comprise a DC component.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a transmitter of the kind described in the opening paragraph which is suitable even for modulation signals which comprise a DC component.
For this purpose, the transmitter is characterized in that the transmitter comprises cancelling means for deriving a cancelling signal from the modulation signal and applying this cancelling signal to the control loop at a location which as seen in the direction of the signal transport is downstream of the opto-electrical converter and upstream of the gain control amplifer, so as to render the output signal of the gain control amplifer independent of the modulation signal.
As a result of these measures an amount of light proportional to the modulation signal is added to the emitted amount of light at the bias level, without this addition affecting the bias as occurs in the previous state of the art.
The transfer factor of the negative feedback path is sometimes not determined very accurately because the properties of the electro-optical and opto-electrical converters exhibit a strong variation per specimen, are temperature-dependent and are furthermore subject to slow variations with time due to ageing. For different transmitters the magnitude of the cancelling signal should therefore be set separately for each particular combination of electro-optical and opto-electrical converters, which would entail additional manufacturing costs. In order to eliminate this drawback, the transmitter is characterized in that the negative feedback path comprises a cascade circuit including an electro-optical converter, an opto-electrical converter and an automatic gain control, amplifer, in an auxiliary gain control signal is applied to a third input of the combining means. The transmitter comprises means for fixing the transfer factor of the cascade circuit at a predetermined value on the basis of the component of the output signal of the cascade circuit which originates from the auxiliary gain control signal, by setting the gain factor of the automatic gain control amplifer at a correct value.
By setting the transfer factor of the negative feedback path at a fixed value which is independent of the properties of the electro-optical converter and the opto-electrical converter, the transfer factor is known and so cancelling signal may be used which is derived from the modulation signal in a fixed, predetermined manner.
It should be observed that the use of an auxiliary signal for fixing the gain factor of a cascade connection constituted by an electro-optical converter, an opto-electrical converter and an automatic gain control amplifer at a constant value, is known from above U.S. patent. However, in the known optical transmitter, the automatic gain control is not included in the negative feedback path of the control loop. The use of the cascade connection in the known transmitter furthermore serves a second purpose, that is to say, obtaining a modulated light signal that has an amplitude that is independent of variations in the properties of the electro-optical converter.
An embodiment of the invention is characterized in that the combining means comprise an adder.
Because adding circuits are simple to realise, arranging the combining means by way of an adding circuit results in a simplification of the transmitter according to the invention.
A further embodiment of the invention is characterized in that the negative feedback path has a low-pass frequency characteristic and in that the cancelling signal, which is the negative of the product, the negative feedback path transfer factor and the mean value of the modulation signal is coupled to the output of the negative feedback path.
If the negative feedback path has a low-pass characteristic so that only the mean value of the modulation signal is transferred, the cancelling signal only needs to cancel the mean value of the modulation signal. Therefore the cancelling signal may be derived from the mean value of the modulation signal. Deriving the mean value of the modulation signal may be effected by means of a low-pass filter.
By making the cancelling signal equal to the negative of the product of the mean value of the modulation signal and the transfer factor of the negative feedback path, the cancelling signal will be of the same magnitude but opposite in sign to the output signal component of the negative feedback path, which component originates from the modulation signal and is supplied in the input of the control amplifier. By also feeding the cancelling signal to the input of the amplifier control, the input signal of the net control amplifier and thus also the output signal thereof will be independent of the modulation signal.
An alternative embodiment of the invention is characterized, in that the amplifier control has a low-pass frequency characteristic and in that the cancelling signal, which is the negative of the product of the transfer factor of the negative feedback path and the value of the modulation signal, is coupled to the output of the negative feedback path.
If the control amplifier has a low-pass characteristic, so that only the mean value is transferred of the output signal component of the negative feedback path, which component originates from the modulation signal, the cancelling signal may be equal to the negative of the product of the transfer factor of the negative feedback path for a constant signal (DC) and the value of the modulation signal. Not all of the high-frequency components in the output signal of the negative feedback path and in the cancelling signal will be transferred by the gain control amplifier. However, the mean value of the output signal component of the negative feedback path, which component originates from the modulation signal, will still be cancelled by the mean value of the cancelling signal.
A specific embodiment of the invention is characterized in that the output of the opto-electrical converter is coupled to the input of the automatic gain control amplifier.
By inserting the automatic gain control amplifier downstream of the opto-electrical converter, the bias of the emitted light signal will be independent of the opto-electrical converter. Because the control loop maintains the output signal of the negative feedback path at a constant value, and because also the transfer factor of the negative feedback path is maintained at a constant value, the input signal of the negative feedback path and thus the input signal of the cascade connection will also be constant. Since the bias of the amount of light emitted by the electro-optical converter will be solely determined by the constant part of the input signal of the cascade connection and the properties of the electro-optical converter, the amount of light emitted by the electro-optical converter will be independent of the properties of the opto-electrical converter.
BRIEF DESCRIPTION OF THE DRAWINGS
Hereinbelow the invention will be further explained with reference to the drawing Figures, in which:
FIG. 1 shows a block diagram of a transmitter according to the invention;
FIG. 2 shows a gain control comprising a summator and an integrator to be used in a transmitter as shown in FIG. 1; FIG. 3 shows an automatic gain control 8, to be used in a transmitter as shown in FIG. 1;
FIG. 4 shows a band-pass filter 11 to be used in a transmitter as shown in FIG. 1;
FIG. 5 shows an auxiliary circuit generating the signals h' and y, to be used in a transmitter as shown in FIG. 1;
FIG. 6 shows a comparing circuit 12 to be used in a transmitter as shown in FIG. 1;
FIG. 7 shows an alternative embodiment of the comparing circuit 12; and
FIG. 8 shows a cancelling circuit generating the signals m', b and c, to be used in a transmitter as shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 a reference signal b generated by a cancelling circuit 10 is fed to a first input of a control amplifier 3 constituted by a summator 1 and an integrator 2. The output of summator 1 is connected to the input of the integrator 2. The output of the integrator 2 is connected to a first input of a combining means which in this case is constituted by a summator 4. The output of the summator 4 is connected to the input of an electro-optical converter whose input is formed in this case by the anode of a laser diode 6. The cathode of the laser diode 6 is connected to a point of reference potential to be termed earth hereinafter. The laser diode 6 is optically coupled to an opto-electrical converter constituted by a photodiode 7. The cathode of the photodiode 7 is also connected to earth. The anode of the photodiode 7 is connected to the input of an automatic gain control amplifier 8. The combination of laser diode 6, photodiode 7 and automatic gain control amplifier 8 will be referred to as a cascade circuit 5. The output of the automatic gain control amplifier 8 is connected to the input of a low-pass filter 9 whose output is connected to a second input of the summator 1. The output of the automatic gain control amplifier 8 is also connected to the input of a band-pass filter 11. A negative feedback path of a control loop is formed by the cascade circuit 5, the low-pass filter 9 and the summator 1.
An auxiliary signal h is fed to an input of an auxiliary circuit 13. A first output of the auxiliary circuit 13 carrying output signal h' is connected to a second input of the summator 4. A second output of the auxiliary circuit 13 carrying output signal y is connected to a first input of a comparator circuit 12. The output of the band-pass filter 11, carrying output signal x, is connected to a second input of the comparator circuit 12. The output of the comparator circuit 12, carrying output signal z, is connected to a control input of the inverting amplifier 8. A modulation signal m is fed to an input of the cancelling circuit 10. A first output of the cancelling circuit 10, carrying output signal m', is connected to a third input of the summator 4. A second output of the cancelling circuit 10, carrying output signal c, which signal forms the cancelling signal in accordance with the invention, is connected to an input of the summator 1.
In FIG. 1 a control loop for fixing the bias of the amount of light emitted by the laser diode 6 is formed by the control amplifier 3, the summator 4, the cascade circuit 5 and the low-pass filter 9. The control loop maintains the value of the output signal of the negative feedback path at -b, which signal is constituted in this case by the output signal of the low-pass filter 9, as a result of which the signal at the output of control amplifier 3 produces a bias level of the amount of light U emitted by the laser diode 6 given by, ##EQU1## In (1) d is the light intensity-to-current intensity conversion factor of the photodiode 7 and A is the gain factor of the amplifier 8.
The auxiliary circuit 13 derives two signals, h' and yx, from an auxiliary signal h which is sinusoidal. The auxiliary signal h' is applied to the input of the cascade circuit 5 via the summator 4. The band-pass filter 11 passes only the component of the output signal of cascade circuit 5 which originates from the auxiliary signal h'. For equalizing the signals x and y, the amplitudes of the signals x and y are compared in the comparator circuit 12 and a signal z for setting the gain factor of the amplifier 8 at the correct value is derived from the result of this comparison. By adapting the gain factor of the amplifier 8 so that the signals x and y are equal, the transfer factor of the cascade circuits and in this case also the transfer factor of complete negative feedback path is fixed at a constant value C 1 for low frequencies. For this transfer factor it now holds:
C.sub.1 =L·d·A (2)
In (2) L is the current intensity-to-light intensity conversion factor of the laser diode 6. For the product d·A there may be written: ##EQU2## For the bias level U of the amount of light emitted by the laser diode 6 one now finds by substituting (3) in (1): ##EQU3## Thus the light bias level U is now exclusively determined the constants b and C 1 and by the properties of the laser diode 6, not by the properties of the photodiode 7.
In order to modulate the amount of light emitted by the laser 6, the signal m' derived from the modulation signal m is applied to the summator 4. According to the invention, the cancelling signal c is derived from the modulation signal m by way of the cancelling means formed in this case by the cancelling circuit 10, and applied to the summator 1. In cancelling circuit 10 the cancelling signal c is obtained by sending the modulation signal through a low-pass filter. Since the transfer factor of the negative feedback path is fixed at a value C 1 for low frequencies, and since the transfer function of the cancelling circuit 10 is provided to be equal to -C 1 for the DC component of the modulation signal, the DC voltage value of the output signal c of the cancelling circuit 10 will have an equal magnitude but opposite sign from the DC component of the voltage produced the output of the low-pass filter 9 by the modulation signal supplied to laser diode 6. As a result of the summation of these signals in summator 1, they cancel each other out, and so the DC component of the modulation signal does not have any effect on the control loop. The low-pass filter 9 provide a low-pass characteristic in the negative feedback path in accordance with the invention.
The signals fed to the summator 4 are signal streams, so that the summation thereof can be realised by simply interconnecting the inputs of the summator. The output signal of the photodiode 7 is also a current, whereas the output signal of the amplifier 8 is a voltage, so that the amplifier 8 is arranged as a current-to-voltage converter.
FIG. 2 shows control amplifier 3 in more detail. Therein the three inputs are connected each to one of mutually equal resistors 20, 21 and 22 which are all connected in common to the inverting input of an operational amplifier 23. The inverting input of the operational amplifier 23 is also connected to a terminal of a capacitor 24. The non-inverting input of the operational amplifier 23 is connected to earth. The output of the operational amplifier 23 is connected to a second terminal of the capacitor 24, to a first terminal of a resistor 25 and to the base of a PNP transistor 27. A second terminal of the resistor 25 is connected to a positive supply voltage +V. The emitter of the transistor 27 is connected to a first terminal of a resistor 26, a second terminal of the resistor being connected to the positive supply voltage +V. The output of the control amplifier 3 is at the collector of the transistor 27.
In the control amplifier shown in FIG. 2 the operational amplifier 23, as a result of a known property of a negative feedback operational amplifier, will cause the voltage between its input terminals to be zero, so that the potential on the inverting input of the operational amplifier 23 is at earth potential. Due to the zero voltage difference between the inputs of the operational amplifier 23, all the current from the resistors 20, 21 and 22 will flow into the capacitor 24. The current supplied to the capacitor 24 therefore equals the quotient of the sum of the voltages on the three inputs of the control amplifier and the resistance of the mutually equal resistors 20, 21 and 22. The capacitor 24 integrates this sum, so that on the output of the operational amplifier 23 there is a voltage which is proportional to the integral of the sum of the three input voltages of the control amplifier 3. The transistor 27 and the resistor 26 together form a voltage-to-current converter converting the output voltage of the operational amplifier 23 into an output current at the collector of transistor 27.
In FIG. 3 the input of the automatic gain control amplifier 8, which is arranged as a current-to-voltage converter, is at the common junction of the non-inverting input of an operational amplifier 30, a first terminal of a resistor 31 and a first terminal of a resistor 32. The inverting input of the operational amplifier 30 is connected to earth. A second terminal of the resistor 32 is connected to the source of a field-effect transistor 33. The drain of the field-effect transistor 33 is connected to the output of the operational amplifier 30. The output of the operational amplifier 30 is also connected to a second terminal of the resistor 31 and to the non-inverting input of an operational amplifier 34. The inverting input of the operational amplifier 34 is connected to a first terminal of a resistor 35 and to a first terminal of a resistor 36. A second terminal of the resistor 36 is connected to the output of the operational amplifier 34 whilst a second terminal of the resistor 35 is connected to earth.
The automatic gain control amplifier 8 is shown in more detail in FIG. 3, wherein the control is realised by means of the current-to-voltage converter constituted by operational amplifier 30, the resistors 31 and 32 and the field-effect transistor 33. As a result of a known property of negative feedback operational amplifiers, the operational amplifier 30 will control the voltage difference between its inputs to zero, so that the non-inverting input of the operational amplifier 30 will adopt the earth potential. Due to the lack of voltage difference between the two inputs of the operational amplifier 30, all the current fed to the input will flow through the negative feedback network constituted by the resistors 31 and 32 and the field-effect transistor 33. Because the impedance of the negative feedback network can be adjusted by means of the gate voltage of the field-effect transistor 33, the transfer factor of the current-to-voltage converter will also be adjustable. The resistors 31 and 32 are included to fix the maximum and the minimum value of the transfer factor of the current-to-voltage converter at a certain value. The current-to-voltage converter proper is followed by a conventional non-inverting amplifier which is constituted by operational amplifier 34, resistor 35 and resistor 36.
In the band-pass filter shown in FIG. 4 the input is at a first terminal of a capacitor 40. A second terminal of the capacitor 40 is connected to a first terminal of a resistor 41 and to a first connecting point of a resistor 42. A second connecting point of the resistor 41 is connected to earth. A second terminal of the resistor 42 is connected to a first terminal of a capacitor 43 and to the non-inverting input of an operational amplifier 44. The inverting input of the operational amplifier 44 is connected to a first terminal of a resistor 45 and to a first terminal of a resistor 46. A second terminal of the resistor 45 is connected to earth whilst a second connecting point of the resistor 46 is connected to the output of the operational amplifier 44. The output of the operational amplifier 44 is connected to the non-inverting input of an operational amplifier 47. The inverting input of the operational amplifier 47 is connected to a first connecting point of a resistor 48 and to a first connecting point of a resistor 49. A second terminal of the resistor 48 is connected to earth whilst a second connecting point of the resistor 49 is connected to the output of the operational amplifier 47, which output likewise forms the output of the band-pass filter.
In FIG. 4 the capacitor 40 and the resistor 41 constitute a high-pass filter, whilst the resistor 42 and the capacitor 43 constitute a low-pass filter. By cascading the high-pass filter characteristic and the low-pass filter, a band-pass filter is obtained. The output signal of the band-pass filter is available at the junction of the resistor 42 and the capacitor 43. The signal available there is amplified to often an output signal x by means of two cascaded conventional non-inverting amplifiers constituted by the operational amplifier 44 and the resistors 45 and 46, as well as the operational amplifier 47 and the resistors 48 and 49, respectively.
The auxiliary circuit 13 in FIG. 1 is shown in more detail in FIG. 5, wherein the auxiliary signal h is applied to a first connecting point of a capacitor 50. A second terminal of the capacitor 50 is connected to the base of a PNP transistor 52, to the base of a PNP transistor 56, to a first terminal of a resistor 53 and to a first terminal of a resistor 54. The emitter of the transistor 52 is connected to a first terminal of a resistor 51. A second terminal of the resistor 51 is connected to the positive supply voltage +V. The collector of the transistor 52 forms a first output of the auxiliary circuit 13 and carries output current h'.
A second terminal of the resistor 53 is connected to the positive supply voltage +V, whilst a second terminal of the resistor 54 is connected to earth. The emitter of the transistor 56 is connected to a first terminal of a resistor 55. A second terminal of the resistor 55 is connected to the positive supply voltage +V. The collector of the transistor 56 is connected to a first terminal of a resistor 57 and to the base of an NPN transistor 58. A second terminal of the resistor 57 is connected to earth. The collector of the transistor 58 is connected to the positive supply voltage +V and the emitter of the transistor 58 is connected to a first terminal of a capacitor 60 and to a first terminal of a resistor 59. A second connection point of the resistor 59 is connected to earth. A second terminal of the capacitor 60 forms the second output of the auxiliary circuit 13 and carries output signal y.
A first part of the auxiliary circuit comprises a voltage-to-current converter constituted by the transistor 52 and the resistor 51. The transistor 52 is biassed by means of the voltage divider constituted by the resistors 53 and 54. The auxiliary signal h is transferred to the base of the transistor 52 by means of the capacitor 50, so that the input voltage h is converted into an output current h'. The voltage h is furthermore coupled to the input of an inverting amplifier constituted by the transistor 56 and the resistors 55 and 57. The bias current of the transistor 56 is also fixed by the resistors 53 and 54. The collector of transistor 56 now carries an amplified version of the voltage h. This voltage is transferred to the output as the signal y by means of a capacitor 60 via an emitter-follower constituted by the transistor 58 and the resistor 59. Capacitor 60 is present to block the transfer of DC voltage transfer from the emitter of the transistor 58 to the output.
In the comparator circuit 12 as shown in FIG. 6, the input signal y is applied to a first terminal of a resistor 70 and to the cathode of a diode 71. The anode of the diode 71 is connected to a first terminal of the capacitor 72, to a first terminal of a resistor 73 and to a first terminal of a resistor 77. A second terminal of the resistor 70, a second terminal of the capacitor 72 and a second terminal of the resistor 73 are connected to earth. A second terminal of the resistor 77 is connected to the inverting input of an operational amplifier 79. The input signal x is fed to the anode of a diode 74. The cathode of the diode 74 is connected to a first terminal of a capacitor 75, to a first terminal of a resistor 76 and to a first terminal of a resistor 78. A second terminal of the capacitor 75 and a second terminal of the resistor 76 are connected to earth. A second terminal of the resistor 78 is connected to the inverting input of the operational amplifier 79. The inverting input of the operational amplifier is furthermore connected to a first terminal of a capacitor 80. The non-inverting input of the operational amplifier 79 is connected to earth. A second terminal of the capacitor 80 is connected to the output of the operational amplifier 79. The output of the operational amplifier 79 is furthermore connected to a first terminal of a resistor 81. A second terminal of the resistor 81 is connected to the inverting input of an operational amplifier 84. The inverting input of the operational amplifier 84 is furthermore connected to a first terminal of a resistor 82 and to a first terminal of a resistor 83. The non-inverting input of the operational amplifier 84 is connected to earth. A second terminal of the resistor 82 is connected to the positive supply voltage +V. A second terminal of the resistor 83 is connected to the output of the operational amplifier 84. The output of the operational amplifier 84 carries the output signal z of the comparing circuit.
The input signal y is rectified and smoothed by the combination of the diode 71, the capacitor 72 and the resistor 73. The voltage available at the first terminal of the capacitor 72 has a negative sign. The resistor 70 is included for fixing the DC voltage level of the cathode of the diode 71 to earth potential. The input signal x is rectified and smoothed by the combination of the diode 74, the capacitor 75 and the resistor 76. The voltage available at the first terminal of the capacitor 75 has a positive sign. The signals thus obtained are added together and integrated by means of a summating integrator constituted by the resistors 77 and 78, the operational amplifier 79 and the capacitor 80. Due to the different signs of the input signals of the integrator, the integrator output carries a signal proportional to the integrated difference of the amplitudes of the signals y and x. The output signal of the integrator is amplified to the output signal z by means of an inverting amplifier constituted by the resistors 81 and 83 and the operational amplifier 84. The resistor 82 is included to shift the range of the output signal z by a certain value when an output signal of the integrator is absent. This is desired for obtaining a proper biassing of the field-effect transistor 33 in the automatic gain control shown in FIG. 3.
In the alternative comparator circuit 12 shown in FIG. 7, the signal y is fed to a positive input of a subtracter 85 and to a first input of a multiplier 86. The signal x is applied to the negative input of the subtracter 85. The output of the subtracter 85 is connected to a second input of the multiplier 86. The output of the multiplier 86 is connected to the input of a low-pass filter 87. The output of the low-pass filter is connected to the input of an inverting integrator 88. The output of the integrator 88 forms the output of the comparing circuit 12.
In subtracter 85 the difference is calculated between the signal x and the signal y proportional to the signal x. At the output of the subtracter 85 a signal is available having an amplitude proportional to the amplitude difference of the signals x and y and having the same frequency as the signal x. By multiplying the difference signal x-y by the signal y in the multiplier, a signal is obtained comprising a DC voltage component which is proportional to the amplitude of the difference signal x-y. The low-pass filter 87 passes only the DC voltage component of the output signal of the multiplier 86. By integrating the output signal of the low-pass filter 87 by means of the integrator 88, an output signal z is obtained which is proportional to the integrated value of the amplitude difference of the signals y and x.
Because the product of two sinusoidal voltages can produce a DC voltage only in the case where the frequencies of the two signals are equal, any additional signal components in the signal y having different frequencies from the signal x do not at all affect the value of the output signal z. As a result, the band-pass filter 11 may be omitted if a comparator circuit as shown in FIG. 7 is used in a transmitter as shown in FIG. 1.
In the cancelling circuit shown in FIG. 8 the modulation signal m is applied to the base of an NPN transistor 91 and to a first terminal of a resistor 90. A second terminal of the resistor 90 is connected to earth. The emitter of the transistor 91 is connected to the emitter of an NPN transistor 92 and to a first terminal of a resistor 93. A second terminal of the resistor 93 is connected to the negative supply voltage -V. The base of the transistor 92 is connected to a first terminal of a resistor 94 and to the cathode of a diode 95. A second terminal of the resistor 94 is connected to the negative supply voltage -V. The anode of the diode 95 is connected to the cathode of a diode 96 whilst the anode of the diode 96 is connected to earth.
The collector of the transistor 91 is connected to the base of an NPN transistor 105 and to a first terminal of a resistor 97. A second connecting point of the resistor 97 is connected to a first terminal of a capacitor 99 and to the cathode of a diode 102. A second terminal of the capacitor 99 is connected to earth. The anode of the diode 102 is connected to the cathode of a diode 101. The anode of the diode 101 is connected to the positive supply voltage +V. The collector of the transistor 92 is connected to the base of an NPN transistor 106 and to a first terminal of a resistor 98. A second connecting point to the resistor 98 is connected to a first terminal of a capacitor 100 and to the cathode of a diode 104. A second terminal of the capacitor 100 is connected to earth. The anode of the diode 104 is connected to the cathode of a diode 103. The anode of the diode 103 is connected to the positive supply voltage +V.
The collector of the transistor 105 is connected to the positive supply voltage +V. The collector of the transistor 106 is also connected to the supply voltage +V. The emitter of the transistor 105 is connected to a first terminal of a resistor 107, to the base of a PNP transistor 118 and to the base of a PNP transistor 124. A second terminal of the resistor 107 is connected to earth. The emitter of the transistor 106 is connected to a first terminal of a resistor 108, to the base of a PNP transistor 119 and to the base of a PNP transistor 125. A second terminal of the resistor 108 is connected to earth.
A first terminal of a resistor 109 is connected to earth whilst a second terminal of the resistor 109 is connected to the collector and the base of a PNP transistor 110. The base of the transistor 110 is furthermore connected to the base of each of PNP transistors 111, 112 and 113. The emitters of the transistors 110, and 111, 112, and 113 are respectively connected to a first terminal of resistors 114, 115, 116, and, 117. A second terminal of each of the resistors 114, 115, 116, and 117 is connected to the positive supply voltage +V. The collector of the transistor 111 is connected to the emitter of the transistor 118 and to the emitter of the transistor 119. The collector of the transistor 118 is connected to a first terminal of a resistor 120. A second terminal of the resistor 120 is connected to earth. The collector of the transistor 119 forms an output of the cancelling circuit 10 and carries output current m'. The collector of the transistor 112 is connected to a first terminal of a resistor 121 and to a first terminal of a resistor 122. A second terminal of the resistor 121 is connected to earth. A second terminal of a resistor 122 is connected to a first terminal of a resistor 123. A second terminal of the resistor 123 is connected to earth. At the junction between the resistors 122 and 123 the output voltage b is available. A second terminal of the resistor 123 is connected to earth.
The collector of the transistor 113 is connected to the emitter of the transistor 124 and to the emitter of the transistor 125. The collector of the transistor 125 is connected to a first terminal of a resistor 127 and to a first terminal of a resistor 128. A second terminal of the resistor 127 is connected to earth. A second terminal of the resistor 128 is connected to a first terminal of a capacitor 129. A second terminal of the capacitor 129 is connected to earth. At the junction between the resistor 128 and the capacitor 129 the output signal c is available. The collector of the transistor 124 is connected to a first terminal of a resistor 126 whilst a second terminal of the resistor 126 is connected to earth.
The digital modulating signal m applied to the cancelling circuit 10, which signal has ECL signal levels (logic "0"=-1.7 volts relative to earth, logic "1"=-0.9 volt relative to earth) is converted by means of the differential amplifier constituted by the transistors 91 and 92 and the resistors 97 and 98 into a balanced digital signal available at the collectors of the transistors 91 and 92. The bias current of the transistors 91 and 92 is fixed by the resistor 93. The combination of the diodes 95 and 96 and the resistor 94 fixes the potential of the base of the transistor 92 at a value of about -1.3 volts, which value is the average of the two levels of the input signal. With a -0.9 volt input signal the transistor 91 is fully conductive, whereas transistor 92 is cut off. With a -1.7 volts input signal the transistor 91 is fully cut off, whereas transistor 92 is fully conductive. The resistors 97 and 98 fix the value of the signal levels of the balanced output signal. The diodes 101, 102, 103 and 104 fix the DC voltages on the collectors of the transistors 91 and 92 at a desired value. The capacitors 99 and 100 avoid that disturbing signals from the differential amplifier enter the positive supply voltage line.
The symmetrical digital signal at the output of the differential amplifier is buffered by means of two emitter followers constituted by the transistors 105, 106 and the resistors 107, 108 respectively. The buffered symmetrical signal drives two current switches which are both constituted by a differential amplifier. The reference current flowing through the current switches is generated by means of a resistor 109, which current is applied to a current mirror circuit which has three output currents, which current mirror circuit comprises the transistors 110, 111, 112 and 113 and the resistors 114, 115, 116 and 117. The collector current of the transistor 111 is switched by the modulation signal with the aid of the current switch constituted by the transistors 118 and 119. The collector current of the transistor 118 is applied to the resistor 120 and the collector current of the transistor 119 forms the output signal m' of the cancelling circuit 10. The resistor 120 is included for mutually equalizing the loads of the two transistors 118 and 119 so as to obtain a symmetrical switching behaviour.
The collector current of the transistor 112 is controlled by a resistor array constituted by the resistors 121, 122 and 123. The signal b is available at the junction between the resistors 122 and 123. The collector current of the transistor 113 is switched by the modulation signal with the aid of the current switch constituted by the transistors 124 and 125. The collector current of the transistor 124 is controlled by the resistor 126 and the collector current of the transistor 125 is controlled by the resistor 127. A signal derived from the modulation signal is available at the collector of the transistor 125. By filtering this signal with the aid of a low-pas filter constituted by the resistor 128 and the capacitor 129, the cancelling signal c according to the invention is obtained. The resistor 126 is included for substantially mutually equalizing the loads of the transistors 124 and 125, so as to obtain a symmetrical switching behaviour.
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An optical transmitter comprising a control loop for stabilizing the bias current which sets a bias level of the amount of light emitted by a laser diode 6. A cascade circuit 5 which includes the laser diode 6, a photodiode 7 and a variable gain control amplifier 8 is connected in the negative feedback path of the control loop. To prevent amplitude modulation of the bias current when a modulation signal occurs at the input of the gain control amplifier, the control loop produces a cancelling signal of a magnitude which cancels the mean value of such modulation signal. The cancelling signal is derived from the modulation signal in a fixed manner, by fixing the transfer factor of the negative feedback path as measured by transmission of an auxiliary signal through such path and adjusting the gain of amplifier 8 in accordance with the result of such measurements.
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BACKGROUND OF THE INVENTION
The present invention relates to a foamable silicone rubber composition and a method for curing the composition to give a cured and foamed cellular silicone rubber article. More particularly, the invention relates to a silicone rubber composition which can be foamed and cured into a cellular silicone rubber article without using any external heat source as well as to a novel and efficient method for simultaneously foaming and curing such a foamable silicone rubber composition in a continuous process as in the vulcanization following extrusion molding of the composition.
Several different processes are practiced in the prior art when a silicone rubber composition is desired to be cured or vulcanized in a continuous process to give a continuous-length cured silicone rubber body such as tubes including the hot-air vulcanization (HAV) method under normal pressure, continuous steam vulcanization (CV) method, liquid curing medium (LCM) method and the like. When a continuous-length cured silicone rubber body having a foamed and cellular structure is desired, however, these conventional methods are not always quite satisfactory in respect of the controllability of the process and obtaining a fine and uniform structure of the cured body.
Apart from silicone rubber compositions, there is an increasing general demand in recent years for various kinds of continuous-length thick-walled foamed rubber bodies in applications for gaskets and heat insulators in building works, rollers of a foamed rubber used, for example, as a fixing roller in xerographic copying machines and the like and a method for manufacturing such foamed rubber bodies with stability and low cost is eagerly desired to follow extrusion molding of the rubber composition. For example, a method is proposed and practiced in which a rubber composition of an ethylene-propylene-diene terpolymeric rubber, i.e. a so-called EPDM rubber, or a polychloroprene rubber is continuously extruded out of an extruder machine and then irradiated with ultrahigh-frequency electromagnetic waves so that the rubber composition absorbs the energy of the electromagnetic waves and heated up to the vulcanization temperature to be cured with simultaneous foaming by the decomposition of the blowing agent contained in the rubber composition. This method of irradiation with ultrahigh-frequency electromagnetic waves, referred to as the UHFV method hereinbelow, is considered not to be applicable to the continuous curing of silicone rubber compositions becuase the loss index in silicone rubbers is generally small not to ensure sufficient energy absorption of the electromagnetic waves.
The above mentioned UHFV method is performed usually at a frequency of 2450±50 MHz or 915±25 MHz so that it is essential that the rubber composition can absorb the energy of the electromagnetic waves of these frequencies in a high efficiency to be rapidly heated up to the vulcanization temperature. The energy P absorbed by a dielectric material under irradiation of UHF waves ogenerated in a microwave generator is given by the equation:
P=(5/9)f·E.sup.2 ·ε·tanδ×10.sup.10,
in which P is the energy absorbed and converted into heat in watts/m 3 ; f is the frequency in Hz; E is the high-frequency electric field in volts/m; ε is the dielectric constant; and tan δ is the dielectric loss factor. The product of (ε·tanδ) is called the loss index of the material. It is known that, in order that the UHFV method can be successfully applied to the foaming vulcanization of a rubber composition, the loss index of the rubber composition should desirably be at least 0.08 or, if possible, at least 0.2. To the contrary to this requirement, silicone rubber compositions generally have a very small loss index of only about 0.03 at a frequency of 3000 MHz. This is the reason for the general understanding that the UHFV method is not applicable to the foaming vulcanization of silicone rubber compositions.
Several attempts and proposals have been made in the prior art to obtain a silicone rubber composition having an increased loss index to meet the above mentioned requirement for the UHFV method. These prior art proposals are directed mainly to the modification of the organopolysiloxane as the principal ingredient of the silicone rubber composition. For example, Japanese Patent Kokai No. 52-37966 discloses an organopolysiloxane of which at least 5% by moles of the organic groups bonded to the silicon atoms are aliphatic hydrocarbon groups with substitution of aryl groups, chlorine atoms, fluorine atoms, mercapto groups or methylol groups or alkoxy groups. Such a modified organopolysiloxane, however, is not practical in respect of the great decrease in the heat resistance, weatherability, electric properties and surface properties of the cured silicone rubber which are the characteristics inherent in silicone rubbers in general.
SUMMARY OF THE INVENTION
The present invention accordingly has an object to provide a foamable silicone rubber composition which is cured with simultaneous foaming in a continuous process of the UHFV method without the above described problems and disadvantages in the prior art compositions as well as to provide a foaming vulcanization method of the foamable silicone rubber composition.
Thus, the foamable silicone rubber composition used in the inventive method comprises, as a blend:
(a) 100 parts by weight of a diorganopolysiloxane having an average degree of polymerization of 3,000 to 30,000 and represented by the average unit formula
R.sub.a SiO.sub.(4-a)/2, (I)
in which R is a substituted or unsubstituted monovalent hydrocarbon group having 1 to 10 carbon atoms and the subscript a is a number in the range from 1.95 to 2.05;
(b) from 10 to 300 parts by weight of a finely divided silica filler;
(c) from 5 to 100 parts by weight of a dielectric inorganic powder which is (c-1) a powder of an iron oxide represented by the chemical formula
(FeO).sub.x ·(Fe.sub.2 O.sub.3).sub.y, (II)
in which the subscript x is a positive number in the range from 0.5 to 1.0 and the subscript y is zero or a positive number not exceeding 0.5 with the proviso that x+y is equal to 1, or (c-2) a powder of a ferrite represented by the general formula
MO·Fe.sub.2 O.sub.3, (III)
in which M is a divalent metallic element selected from the group consisting of manganese, copper, nickel, magnesium, cobalt, zinc and divalent iron;
(d) from 0.1 to 10 parts by weight of a blowing agent; and
(e) a crosslinking agent.
The method of the present invention for the preparation of a foamed and cellular silicone rubber article comprises irradiating the above defined specific silicone rubber composition with ultrahigh-frequency microwaves to such as extent that the temperature of the composition is increased to the vulcanization temperature of the composition or, for example, to 160° C. or higher.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As is described above, the most characteristic ingredient in the inventive foamable silicone rubber composition is the inorganic dielectric powder as the component (c), by virtue of which the silicone rubber composition is imparted with a greatly increased loss index to ensure highly efficient absorption of the microwave energy and successful foaming vulcanization of the composition.
The base ingredient in the inventive composition is the component (a) which is a diorganopolysiloxane represented by the average unit formula (I) given above. In the formula, the symbol R denotes a monovalent hydrocarbon group having 1 to 10 or, preferably, 1 to 8 carbon atoms exemplified by alkyl groups, such as methyl, ethyl, propyl and butyl groups, alkenyl groups, such as vinyl, allyl and butenyl groups, and aryl groups, such as phenyl and tolyl groups. The group R can be a substituted monovalent hydrocarbon group obtained by replacing a part or all of the hydrogen atoms in the above named hydrocarbon groups with halogen atoms, cyano groups and the like such as chloromethyl, 3-chloropropyl, 3,3,3-trifluoropropyl and 2-cyanoethyl groups. It is of course that two kinds or more of the groups R can be contained in the same diorganopolysiloxane molecules. It is, however, preferable that at least 98% by moles of the groups denoted by R are alkyl groups having 1 to 4 carbon atoms or, in particular, methyl groups, the balance, if any, being vinyl, phenyl and/or 3,3,3-trifluoropropyl groups. It is also preferable that at least a part of the groups denoted by R are vinyl groups so that the composition may have improved vulcanizability with an organic peroxide as a curing agent. The subscript a in the formula (I) is a positive number in the range from 1.95 to 2.05 or, preferably, 1.98 to 2.03. The diorganopolysiloxane molecules preferably have a straightly linear molecular structure having an average degree of polymerization in the range from 3,000 to 30,000 or preferably, from 4,000 to 10,000 from the standpoint of workability of the silicone rubber composition although a branched structure can be contained in the molecular structure to some extent.
The second essential ingredient in the inventive composition is the component (b) which is a finely divided silica filler. Such a silica filler is conventionally used in silicone rubber compositions with an object of reinforcement and improvement of workability. Several different types of silica fillers are known in the art including fumed silica fillers optionally surface-treated to be imparted with hydrophobicity, precipitated silica fillers, finely pulverized quartz powders, diatomaceous earth and the like. It is desirable that the finely divided silica filler has a specific surface area of at least 1 m 2 /g or, preferably, at least 50 m 2 /g in order to obtain full reinforcement. The amount of the silica filler in the inventive composition should be in the range from 10 to 300 parts by weight or, preferably, from 25 to 200 parts by weight per 100 parts by weight of the organopolysiloxane as the component (a). When the amount of the silica filler is too small, the desired effect of reinforcement cannot be obtained to a sufficient extent. When the amount of the silica filler is too large, on the other hand, great difficulties are encountered in compounding the filler with the organopolysiloxane or, even if the compounding work could be performed, the workability of the composition in extrusion molding would be extremely poor. It is of course optional that inorganic fillers of other types are compounded in combination with the silica filler including calcium silicate, carbon black, glass fibers and the like.
The third essential ingredient, i.e. component (c), is the most characteristic component in the inventive composition. Namely, the component (c) is an inorganic dielectric material in a finely divided form which serves to increase the energy absorption of the composition in a field of microwaves so as to convert the energy of the microwaves into heat. The dielectric inorganic material is, on one hand, is an iron oxide expressed by the chemical formula of (FeO) x ·(Fe 2 O 3 ) y , in which x is a positive number in the range from 0.5 to 1.0 and y is zero or a positive number not exceeding 0.5 with the proviso that x+y is equal to 1. An iron oxide having a structure of ferrite, i.e. FeO·Fe 2 O 3 is preferred. It is noted that the iron oxide powder conventionally used as a red pigment, which has a chemical formula of Fe 2 O 3 , is less effective for the purpose of the invention. The dielectric inorganic material, on the other hand, is a ferrite expressed by the formula MO·Fe 2 O 3 , in which M is a divalent metallic element selected from the group consisting of manganese, copper, nickel, magnesium, cobalt and zinc. Examples of suitable ferrites include those expressed by the formulas:
(MnO).sub.0.5 ·(ZnO).sub.0.5 ·Fe.sub.2 O.sub.3 ;(NiO).sub.0.5 ·(ZnO).sub.0.5 ·Fe.sub.2 O.sub.3 ;
(MgO).sub.0.5 ·(MnO).sub.0.5 ·Fe.sub.2 O.sub.3
and the like. Two kinds or more of the divalent metallic elements can be contained in a ferrite. Divalent iron can be a part of the metallic elements of M in the ferrite. The powder of these iron oxides and ferrites should have a particle diameter in the range from 0.01 to 15 μm or, preferably, from 0.1 to 5 μm. The amount of the dielectric inorganic powder in the inventive composition is in the range from 5 to 100 parts by weight or, preferably, from 25 to 100 parts by weight per 100 parts by weight of the organopolysiloxane as the component (a). When the amount thereof is too small, the efficiency of absorption of the microwave energy by the composition is very small not to ensure sufficient temperature increase. When the amount thereof is too large, on the other hand, the mechanical properties of the silicone rubber composition after curing would be badly affected if not to mention the disadvantage due to increase in the specific gravity of the cured rubber.
The component (d) is a blowing agent which is stable at room temperature but capable of producing a gas at an elevated temperature to expand the composition into a foamed or cellular body. Most of the known blowing agents producing nitrogen gas as the foaming gas can be used in the invention but those blowing agents producing carbon dioxide or other gases can also be used. Examples of the blowing agent suitable in the invention include azobisisobutyronitrile, dinitrosopentamethylene tetramine, benzene sulfone hydrazide, N,N'-dinitroso-N,N'-dimethyl terephthalamide, azodicarbondiamide and the like. The amount of the blowing agent in the inventive composition naturally depends on the desired degree of foaming but it is usually in the range from 1 to 10 parts by weight or, preferably, from 3 to 7 parts by weight per 100 parts by weight of the organopolysiloxane as the component (a).
The component (e) is a crosslinking agent which serves to cure the composition when the composition is heated at an elevated temperature. Typically, the crosslinking agent is an organic peroxide exemplified by benzoyl peroxide, monochlorobenzoyl peroxide, 4-methyl benzoyl peroxide, 2,4-dichlorobenzoyl peroxide, tert-butyl perbenzoate, dicumyl peroxide, 2,5-bis(tert-butyl peroxy)-2,5-dimethyl hexane, 2,5-bis(tert-butyl peroxy)-2,5-dimethyl hexyne, dimyristylperoxy dicarbonate, dicyclododecylperoxy dicarbonate, tert-butyl monoperoxy carbonate and the like as well as a compound of the structural formula
ROO--CO--O--CH.sub.2 --C(CH.sub.3).sub.2 --CH.sub.2 --O--CO--OOR,
in which R is a monovalent hydrocarbon group having 3 to 10 carbon atoms. These organic peroxides can be used either singly or as a combination of two kinds or more according to need. The amount of the organic peroxide as the crosslinking agent in the inventive composition is in the range from 0.5 to 5 parts by weight per 100 parts by weight of the organopolysiloxane as the component (a).
An alternative way to effect crosslinking of the organopolysiloxane is to utilize the so-called hydrosilation reaction. When the organopolysiloxane as the component (a) has at least two vinyl groups bonded to the silicon atoms in a molecule, namely, the silicon-bonded vinyl groups are susceptible to the addition reaction with hydrogen atoms directly bonded to the silicon atoms of another organopolysiloxane in the presence of a platinum catalyst. Therefore, the above mentioned organic peroxide as a crosslinking agent can be replaced with a combination of an organohydrogenpolysiloxane having at least two hydrogen atoms directly bonded to the silicon atoms in a molecule and a catalytic amount of a platinum compound. The organohydrogenpolysiloxane is represented by the average unit formula R 1 b H c SiO.sub.(4-b-c)/2, in which R 1 is a substituted or unsubstituted monovalent hydrocarbon group or, preferably, a methyl group and b and c are each a positive number with the proviso that b+c is 1.0 to 3.0. The amount of the organohydrogenpolysiloxane in the inventive composition should be sufficient to provide from 50 to 300% by moles of the silicon-bonded hydrogen atoms based on the vinyl groups in the component (a). The platinum compound is preferably chloroplatinic acid, for example, in the form of an alcohol solution or a complex thereof with an olefin, vinylsiloxane and the like. The amount of the platinum compound calculated as platinum in the composition is usually in the range from 0.5 to 500 ppm by weight or, preferably, from 2 to 200 ppm by weight based on the amount of the organopolysiloxane as the component (a).
The foamable silicone rubber composition of the present invention can be obtained by uniformly blending the above described components (a) to (e) each in a specified amount. The composition can optionally be admixed with various kinds of known additives according to need including processing or dispersion aids such as low-molecular organopolysiloxanes, silanol compounds, alkoxy silanes and the like, heat-resistance improvers such as iron oxide, ceric oxide, iron octoate, titanium dioxide and the like, coloring agents, flame retardant agents, foaming controlling agents and so on. It should be noted that, when an iron oxide expressed by the formula (II) is used as a heat-resistance improver, the total amount of the component (c) and the iron oxide as the heat-resistance improver should not exceed 100 parts by weight per 100 parts by weight of the component (a).
The foamable silicone rubber composition of the invention prepared in the above described manner can absorb the energy of microwaves with high efficiency by virtue of the specific inorganic dielectric powder as the component (c) to convert the energy of microwaves into heat so as to increase the temperature of the composition up to the vulcanization temperature of the composition. Therefore, a continuous-length foamed silicone rubber body can be easily obtained by continuously extruding the rubber composition out of an extruder machine, for example, of a vent type and introducing the extruded body into a chamber where the extruded body is exposed to UHF microwaves at a frequency in the range from 900 to 5000 MHz or, in particular, a frequency of 2450±50 MHz or 915±25 MHz and heated to a temperature of, for example, 160° C. or higher to effect curing of the composition and expansion thereof by the decomposition of the blowing agent. It is sometimes advantageous that the above mentioned UHFV chamber is provided with a separate heating means, e.g., circulation of hot air through the atmosphere, to promote temperature increase of the extruded body by heating the ambient atmosphere. Although expansion and curing of the composition are usually complete inside the UHFV chamber, it is further optional or sometimes advantageous that the thus foamed and cured silicone rubber body is subjected to a secondary vulcanization treatment by the conventional hot-air vulcanization method, fluidized-bed vulcanization method and the like so that curing of the composition is more complete and some decomposition products produced in the UHFV process can be removed to improve the properties and stability of the thus ob-tained foamed silicone rubber body.
The foamed silicone rubber body obtained from the inventive silicone rubber composition is advantageous in respect of the high heat and cold resistance, weatherability and excellent electric properties as well as low permanent compression set because the inorganic dielectric powder as the characteristic component in the inventive composition has no particular adverse influences on these properties, the other components being rather conventional. Moreover, the foamed body is also advantageous in respect of the uniformity of the foamed cellular structure thereof because heating of the composition is effected not from the surface alone but the heat is generated uniformly throughout the body of the composition due to absorption of the microwave energy by the particles of the inorganic dielectric powder distributed uniformly throughout the composition.
In the following, the invention is described in more detail by way of examples and comparative examples, in which the term of "parts" always refers to "parts by weight".
EXAMPLE 1
A base compound, referred to as the compound I hereinbelow, was prepared by mixing 100 parts of a gum-like organopolysiloxane having an average degree of polymerization of about 8000 and composed of 99.825% by moles of dimethyl siloxane units, 0.15% by moles of methyl vinyl siloxane units and 0.025% by moles of dimethyl vinyl siloxane units and 40 parts of a fumed silica filler (Aerosil 200, a product by Nippon Aerosil Co.) together with 3 parts of diphenyl silane diol and 4 parts of a low-molecular dimethylpolysiloxane fluid having a degree of polymerization of 10 and end-blocked with silanol groups as the dispersion aids of the filler and uniformly blending the mixture on a two-roller mill followed by a heat treatment of the blend at 150° C. for 4 hours.
Five foamable silicone rubber compositions, referred to as the compositions I, II, III, IV and V hereinbelow, were prepared each by uniformly blending, on a two-roller mill, 100 parts of the above prepared compound I, a powder of iron oxide FeO.Fe 2 O 3 having an average particle diameter of about 2 μm or a powder of a ferrite (MnO) 0 .32.(ZnO) 0 .14.(FeO) 0 .04.(Fe 2 O 3 ) 0 .50 (Ferrotop BSF 547, a product by Toda Kogyo Co.) having an average particle diameter of about 1.7 μm in an amount indicated in Table 1 below, 2.5 parts (compositions I, II and III) or 3.0 parts (compositions IV and V) of azobisisobutyronitrile, 0.5 part (compositions I, II and IV) or 0.4 part (compositions III and V) of 2,4-dichlorobenzoyl peroxide and 1.5 parts of dicumyl peroxide.
Each of the compositions I to V was introduced into an extruder machine having a cylinder of diameter D of 40 mm and length L of 480 mm (L/D=12) and a die of an outer diameter of 20 mm and inner diameter of 10 mm mounted thereon and extruded at a temperature of 15° to 30° C. into a tubular form of an outer diameter of 20 mm and inner diameter of 10 mm. The thus extruded tubular body of the silicone rubber composition was introduced, at a velocity of 1.5 meters/minute, into a UHFV zone formed of two chambers connected in tandem each having a length of 1.5 meters and connected to a microwave generator of 1.0 kilowatt output at a frequency of 2450±50 MHz. Each of the UHFV chambers was under circulation of hot air at a temperature of 130° C.
The condition of curing in each of the thus prepared foamed and cured silicone rubber tubes was complete and the cellular structure thereof was fine and uniform with a ratio of expansion shown in Table 1.
TABLE 1______________________________________Composition No. I II III IV V______________________________________Iron oxide, parts -- -- -- 30 60Ferrite, parts 20 35 50 -- --Ratio of expansion, % 315 380 367 355 326______________________________________
With an object to test the effect by the concurrent hot air circulation with the microwave irradiation, the same experimental procedure as above was undertaken by using the composition III except that the velocity of transfer of the extruded tubular body was decreased to 0.25 meter/minute and hot air was not introduced into the chambers. The results was that the condition of curing in the thus prepared foamed and cured silicone rubber tube was complete and the cellular structure thereof was fine and uniform with a ratio of expansion of 345%.
For comparison, another silicone rubber composition, referred to as the composition VI hereinbelow, was prepared in the same formulation as in the composition II above excepting omission of the ferrite powder. The result of the foaming vulcanization test of this composition undertaken in the same manner as for the composition II was that the curing of the composition was incomplete and the cellular structure of the tubular body was coarse and uneven with a ratio of expansion of only 132%. For further comparison, the compositions II and VI were processed in the same manner as above except that no UHF microwaves were introduced into the UHFV chambers. The results were that each of the compositions remained in an unvulcanized condition almost without foaming to give a cellular structure.
EXAMPLE 2
A base compound, referred to as the compound II hereinbelow, was prepared by mixing 100 parts of a gum-like organopolysiloxane having an average degree of polymerization of about 8000 and composed of 99.775% by moles of dimethyl siloxane units, 0.200% by moles of methyl vinyl siloxane units and 0.025% by moles of dimethyl vinyl siloxane units, 20 parts of a fumed silica filler (Aerosil 200, supra) and 20 parts of a precipitated silica filler (Nipsil VN 3 LP, a product by Nippon Silica Co.) together with 3 parts of diphenyl silane diol and 5 parts of dimethyl dimethoxy silane as the dispersion aids of the fillers and uniformly blending the mixture on a two-roller mill followed by a heat treatment of the blend at 150° C. for 4 hours.
Two foamable silicone rubber compositions, referred to as the compositions VII and VIII hereinbelow, were prepared each by uniformly blending 100 parts of the compound II prepared above, 35 parts or 70 parts, respectively, of the same ferrite powder as used in Example 1,2.5 parts of azobisisobutyronitrile, 0.6 part of 2,4-dichlorobenzoyl peroxide and 0.3 part of 2,5-dimethyl-2,5-(ditert-butylperoxy)hexane.
Each of the compositions VII and VIII was subjected to the foaming vulcanization test in the same manner as in Example 1 except that the velocity of transfer of the extruded tubular body through the UHFV chambers was 3 meters/minute and the output of each microwave generator for the composition VIII was decreased to 0.5 kilowatt instead of 1.0 kilowatt.
The results were that the condition of curing was complete and the cellular structure of the foamed silicone rubber tubes was fine and uniform in each of the compositions with the ratio of expansion of 400% and 355% for the compositions VII and VIII, respectively.
For comparison, another silicone rubber composition, referred to as the composition IX hereinbelow, was prepared in the same formulation as in the composition VII above excepting omission of the ferrite powder. The result of the foaming vulcanization test of this composition IX undertaken under the same conditions for the composition VII was that the condition of curing was incomplete and the portion in the vicinity of the inner walls of the tube remained unfoamed while coarse and uneven cells were formed in the vicinity of the outer surface with an overall ratio of expansion of only 158%. When the foaming vulcanization test of the composition IX was repeated in the same manner as above excepting omission of application of the UHF microwaves, the extruded tubular body coming out of the UHFV chambers was found unvulcanized without foaming.
EXAMPLE 3
A foamable silicone rubber composition was prepared by uniformly blending, on a two-roller mill, 100 parts of the compound I prepared in Example 1,50 parts of the same ferrite powder as used in Example 1,2.5 parts of azobisisobutyronitrile, 0.06 part of a 1% by weight solution of chloroplatinic acid in butyl alcohol, 0.02 part of 1,3-divinyl-1,1,3,3-tetramethyl disiloxane, and 0.5 part of a methyl hydrogen polysiloxane having a viscosity of 10 centistokes at 25° C. and expressed by the formula Me 3 Si--O--(--SiMe 2 --O--) 8 --(--SiHMe--O--) 2 --SiMe 3 , in which Me is a methyl group. After standing at room temperature for 1 hour, the composition was subjected to foaming vulcanization in the same manner as in Example 1. The result was that the cured and foamed silicone rubber tube thus obtained was in a completely cured condition having a uniform and fine cellular structure with a ratio of expansion of 353%.
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A foamed cellular body of a cured silicone rubber composition can be obtained in a continuous process by irradiating a foamable silicone rubber composition containing, in addition to conventional diorganopolysiloxane, finely divided silica filler, blowing agent and crosslinking agent, a substantial amount of a dielectric inorganic powder, which is an iron oxide or a ferrite, with UHF microwaves. When the silicone rubber composition as molded is irradiated with UHF microwaves, the energy of the microwaves absorbed by the dielectric powder is efficiently converted into heat so that the molded body can be very evenly heated to effect foaming vulcanization of the composition giving a foamed and cured silicone rubber article having an excellently fine and uniform cellular structure.
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FIELD OF THE INVENTION
The present invention relates to hard disk drives and in particular to means of attaching a magnetic head suspension assembly to an E-block.
BACKGROUND OF THE INVENTION
Hard disk drives typically include multiple disks that have a magnetic memory storage surface for storing data. A magnetic head including a read/write transducer passes over the disk surface for reading and writing data. The transducer must be precisely positioned on particular disk tracks in a consistent way to quickly and reliably read and write the data. In the disk drive industry, there is a trend to fit more and more disk tracks per unit of disk surface to maximize the disk storage capacity. Accordingly, precise positioning of the transducer with respect to the disk surface is critical.
Prior art hard disk drives have an E-block that pivots on a pivot bearing. The E-block has multiple actuator arms. Suspensions attach to the actuator arms to suspend the magnetic heads above the disk surface. The suspensions are typically spring loaded, having a particular gram load, to enable the heads to maintain a desired flying height just above the spinning disk surface. Changes in this gram load affect the flying height of the head.
Changes in the gram load are influenced by many factors. These factors include misalignment and deformation of critical components. For example, the suspension and actuator arm may misalign during assembly. The pivot bearing of the E-block may misalign within the E-block. Bearing and actuator arm defects may cause misalignment. Pivot bearing inner race runout, bore inaccuracies in the E-block, or bearing installation errors are examples of common causes for bearing and E-block misalignment that can result in gram load variations. The actuator arm tips may end up varying from a desired height and orientation, causing attached suspensions to have varying gram loads.
Often, gram load changes are associated with the process of attaching the suspension to an actuator arm. Swaging is the most common method of attaching the suspension to the actuator arm and involves pressing swage balls through the hub of a suspension baseplate. The swage balls expand the hub against the actuator arm to hold the suspension and actuator arms together. Pressing swage balls though the hub may distort the baseplate, changing the suspension gram load.
There are known ways of adhesively bonding a suspension to an actuator arm to overcome the undesirable effects of swaging. For example, a doughnut-shaped adhesive washer has been interposed between the actuator arm and the suspension hub. When the suspension hub inserts into the actuator arm opening, heat is applied to melt the washer and thereby create a bond.
There are drawbacks to known adhesive attachment methods. Heating the doughnut-shaped washer melts the washer. As the washer melts, it deforms. This deformation can allow the suspension to misalign relative to the actuator arm, changing the suspension gram load. Another drawback of the adhesive washer is that the hub locates relative to the actuator arm tip to create a bond. When the actuator arm tips misalign, the suspension will also misalign. There is no provision for correcting for actuator arm tip variations that cause gram load variations. What is desired is a way of correcting fabrication misalignment and distortion errors to maintain a consistent gram load.
SUMMARY OF THE INVENTION
An actuator for pivoting a magnetic transducer of a hard disk drive includes an E-block having a pivot bearing, actuator arms formed as part of the E-block, and suspensions bonded to the actuator arms. Each actuator arm has an arm tip with a bonding surface. The suspensions have an integrated baseplate that adhesively attaches to the bonding surface of the actuator arm tip.
The E-block pivot bearing is used as an alignment reference when bonding the suspensions to the actuator arms. The baseplate and the actuator arm bonding surface define a gap therebetween. Adhesive bridges the gap between the suspension and the actuator arm and bonds the suspension to the actuator arm tip. Because the suspensions use the pivot bearing as a reference and the adhesive flows to bridge the gap, the adhesive cures into a shape that automatically compensates for component alignment errors including actuator arm tip variations, pivot bearing inner race run-out, E-block bore inaccuracies, and bearing installation error. Additionally, adhesive bonding avoids gram load changes associated with swaging. Improved gram load precision can be achieved with adhesive bonding.
The bonding surface of the actuator arm tip has numerous possible configurations. One configuration includes a recessed bonding surface that is planar. The bonding surface defines a channel extending between the top and the bottom of the actuator arm for adhesive to flow into, according to a variation of the invention. The channel holds adhesive to enable the suspension/actuator arm bond to resist shear forces. According to another aspect of the invention, the bonding surface has a raised portion. The raised portion may include posts, rails or texture to prevent shear.
A method of assembling a suspension to an actuator arm of a an E-block, in accordance with the present invention, eliminates distortion error caused by swaging, and compensates for other errors caused by pressing the pivot bearing into the E-block arm.
The method includes the step of first inserting a pivot bearing into the E-block, and then referencing the pivot bearing to align the suspension in a desired position. The suspension and the actuator arm define a gap in the desired position relative to the bearing. The next step is bonding the suspension to the actuator arm with an adhesive to fill the gap and to maintain the suspension in the desired position. Filling the gap with adhesive forms an adhesive bridge between the actuator arm and the suspension. This bridge enables orientation of the suspension to compensate for variations in the actuator arm tips, bearing bore or race run-out, and bearing installation error, for example.
In keeping with this invention, a pivot bearing defines an axis and a z-datum. In the novel method, the step of referencing includes referencing the axis and the z-datum to align the suspension with respect to the pivot bearing. According to another aspect of the invention, the step of referencing includes attaching an assembly fixture to the pivot bearing and holding the suspension with the assembly fixture. The step of attaching includes mechanically clamping the suspension, or applying a vacuum to the suspension to hold the suspension in the desired position with respect to the pivot bearing.
The step of bonding preferably includes the steps of maintaining the suspension in the desired position with respect to the bearing, interposing the adhesive between the actuator arm and the suspension, and curing the adhesive with ultraviolet light. Accordingly, the present invention eliminates gram load changes associated with the swaging process. Additionally, since the suspension does not require location with respect to the E-block, or actuator arm tip as in the prior art, variations in gram load and static attitude caused by arm tip height and angle variations during fabrication are eliminated. Furthermore, locating the suspension with respect to the actuator bearing eliminates bearing related variations such as inner race run-out, bore inaccuracies and bearing installation misalignment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in greater detail with reference to the drawings in which:
FIG. 1 is a perspective view of an E-block assembly.
FIG. 2 is a cross-sectional side view of an assembly fixture holding an E-block assembly.
FIG. 3 is a view of the E-block assembly and assembly fixture as seen along the section line 3 — 3 of FIG. 2 .
FIG. 4 is a perspective view of an actuator arm tip in accordance with the present invention.
FIG. 5 is a perspective view of another actuator arm tip in accordance with the present invention.
FIG. 6 is a perspective view of an alternative actuator arm tip in accordance with the present invention.
FIG. 7 is a perspective view of another alternative actuator arm tip in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, an E-block 10 includes a pivot bearing 12 , actuator arms 14 , and suspensions 16 . Each suspension 16 has an integral baseplate 15 at one end and a slider 18 at the other end. The slider 18 includes a magnetic transducer for reading and writing data to a hard disk drive.
The baseplate 15 of each suspension 16 and actuator arm 14 form an adhesive-fillable gap 32 . The gap 32 fills with adhesive 28 to bond the baseplate 15 of the suspension 16 to the actuator arm 14 . The adhesive 28 is selectively curable. Preferably, the adhesive 28 is ultraviolet light (UV) curable.
The baseplate 15 is a rigid planar component capable of attachment via a weld to the suspension. Once welded to the suspension 16 , the baseplate 15 improves the rigidity of the suspension 16 to enable the suspension 16 to attach to an actuator arm 14 . The baseplate 15 has an end portion that overhangs one end of the suspension 16 . The other end portion of the baseplate 15 is bonded by the adhesive 28 to the actuator arm 14 . The suspension has a locating surface 59 used in prior testing and measurement of gram load and attitude of the suspension, as well as locating the suspension to the E-block during the assembly process.
FIG. 2 shows the E-block 10 . An assembly fixture 30 attaches to the pivot bearing 12 and holds each suspension 16 in a desired position. The assembly fixture 30 distances and orients each suspension 16 with respect to the pivot bearing 12 . Accordingly, the assembly fixture 30 locates the suspension 16 with respect to the pivot bearing 12 .
Each suspension 16 has a bonding surface 58 . Each actuator arm 14 has a bonding surface 60 . The bonding surface 60 of each actuator arm 14 and the bonding surface 58 of each suspension 16 form the gap 32 . Adhesive 28 , which may be an epoxy, fills the gap 32 to bond each suspension 16 to the actuator arm 14 . Filling the gap 32 with adhesive enables the adhesive to cure into a shape that automatically corrects for component misalignment, including actuator arm 14 tip variations.
While the assembly fixture 30 holds the suspensions 16 and the pivot bearing 12 with a mechanical linkage, various other devices for holding the suspensions 16 during assembly can utilize the pivot bearing 12 as a reference. For example, a device that does not directly attach to the pivot bearing 12 can be used. An assembly fixture with an optical sensor, for example, can distance and orient the suspensions 16 with respect to the pivot bearing 12 . A datum common to both the pivot bearing 12 and to the suspensions 16 may be used as an alignment reference instead of the pivot bearing 12 according to a variation of the invention.
The assembly fixture 30 includes mechanical clamps 34 and vacuum actuated clamps 36 for holding the suspensions 16 in a desired position and orientation with respect to the pivot bearing 12 . Each suspension 16 includes a locating surface 59 . The clamps 34 and 36 selectively hold each suspension 16 at the locating surface 59 during suspension/actuator arm 14 assembly.
The bonding method includes inserting the pivot bearing 12 into the E-block 10 . The next step aligns the suspension 16 with respect to the pivot bearing 12 , thus forming a gap 32 between the suspension 16 and an actuator arm 14 . The next step includes interposing the adhesive 28 between the actuator arm 14 and the suspension 16 to fill the gap 32 . After the adhesive 28 fills the gap 32 , UV light cures the adhesive 28 , bridging the gap 32 . The adhesive 28 maintains the suspension 16 in the desired alignment with respect to the pivot bearing 12 .
If the pivot bearing 12 and actuator arm 14 misalign for any reason bridging the gap 32 with adhesive 28 compensates for misalignment of the E-block and each actuator arm 14 . Although mechanical and vacuum clamps 36 are used in combination, there are various clamp types, which may be substituted in accordance with the present invention. Additionally, vacuum clamps 36 may be used exclusively. In an alternative embodiment, mechanical clamps 34 may be used exclusively.
The pivot bearing 12 defines a z-datum 40 and an axis 42 . The pivot bearing 12 is cylindrical in shape, having two ends, an inner race and an outer race. According to one aspect of the invention, the z-datum 40 is a line defined at one end of the pivot bearing 12 , intersecting the axis 42 at a right angle. It can be appreciated that while the z-datum intersects the axis 42 at one end of the pivot bearing 12 , the z-datum can also be arbitrarily fixed along another line, or at a point, to enable the suspensions 16 to align with respect to the pivot bearing 12 .
The assembly fixture 30 holds each suspension 16 at a predetermined z-distance from the z-datum 40 and at a desired x-y position. Supports 50 hold the sliders 18 apart by separating the suspensions 16 . The assembly fixture 30 holds the suspensions 16 in the desired position while the actuator arms 14 and suspensions 16 bond.
The axis 42 establishes a y-datum to distance the suspensions 16 from the bearing. The use of the assembly fixture 30 with a direct mechanical linkage between the pivot bearing 12 and the suspensions 16 fixes a desired distance between the pivot bearing and the suspensions. The assembly fixture 30 holds each suspension 16 at a predetermined distance from the axis 42 to establish the y position of the slider 18 during assembly of the suspensions 16 and the actuator arms 14 .
The present invention can also apply to correcting undesired pitch and roll of the actuator arm 14 . Since the suspension 16 does not mechanically lock on the actuator arm 14 , as in the prior art, the suspension 16 is held by the assembly fixture 30 in the desired static orientation i.e. pitch and roll position when adhesively bonded to the actuator arm 14 .
FIG. 3 shows a sectional view of the E-block 10 of FIG. 2 . The pivot bearing 12 normally enables the E-block 10 to pivot along the arc 52 . The suspension 16 includes the locating surface 59 and piezoelectric element 57 for fine positioning of the air bearing slider 18 during operation. The assembly fixture 30 includes discrete supports 46 , 48 and 50 . The support 46 prevents rotation of the E-block. The support 48 prevents extension of the suspension 16 from the E-block 10 . The supports 50 hold the air bearings 18 apart (FIG. 2 ). The fixture 30 firmly holds the locating surface 59 to prevent any movement of the suspension 16 .
The pivot bearing 12 defines a datum point 53 . The support 46 contacts the actuator arm 14 to align the actuator arm 14 with respect to the pivot bearing 12 , and particularly with respect to the datum point 53 , and to prevent rotation of the E-block in the direction of the arc 52 . The support 48 locates and holds the suspension 16 at point 49 . The fixture 30 also locates the suspension at the points 47 . Points 47 locate the suspension 16 in the transverse direction. The locate point 56 has a perimeter defining a recess for engaging the assembly fixture 30 , as an alternative to support 48 for longitudinal location of the suspension 16 .
The fixture 30 may have any of a variety of mechanical alignment features, which can take various shapes and sizes. Various non-mechanical alternatives exist. It can be appreciated that optical verification of alignment can be used. Additionally, various suspensions eliminating various features, or containing features such as micro-actuator, chip-on-suspension, shock limiters and the like may be used.
FIG. 4 shows a tip 20 of an actuator arm 14 . The tip 20 includes a top 64 , a bottom 66 , two lateral sides 70 , and a bonding surface 60 on the top 64 . The bonding surface 60 defines four channels 68 extending between the top 64 and the bottom 66 . The channels 68 have a dove-tail shaped cross-section and extend fully across each lateral side 70 from the top 64 and the bottom 66 . The channels 68 are configured to fill with flowing adhesive. Flowing adhesive in the channels 68 prevents lateral movement of the adhesive (towards the lateral sides) and thereby prevents the suspension 16 from shearing away from the actuator arm 14 during use.
Although lateral channels 68 are shown, the channels 68 can be formed within the bonding surface 60 and may have various cross-sectional shapes including a circular cross-sectional shape. The channels 68 extend partially through the tip 20 of the actuator arm 14 according to a variation of the invention.
FIG. 5 shows another tip 20 of an actuator arm 14 . The end includes a bonding surface 60 with raised portions, namely four posts 72 defined on each lateral side and extending perpendicular from the top 64 and the bottom 66 . The bonding surface 60 has a generally rectangular periphery. The posts 72 define corners of the generally rectangular periphery of the bonding surface 60 to provide shear resistance and the raised portions prevent the suspension 16 from shearing away from the actuator arm 14 .
The posts 72 have a generally rectangular cross-sectional shape and squared ends. The posts 72 may take any of a number of shapes and, for example, may have tapered ends, or rounded ends. Further, the number and location of the posts 72 may be modified in accordance with the present invention.
FIG. 6 shows an alternative tip 20 of the actuator arm 14 . The bonding surface 60 includes raised portions, namely rails 76 extending from each bonding surface 60 on each lateral side 70 , and texture 80 . The rails 76 and texture provide shear resistance and prevent the adhesive bonded to the bonding surface 60 from shearing. According to one aspect of the invention, the texture 80 includes parallel ridges.
FIG. 7 shows another alternative tip 20 of the actuator arm 14 . The bonding surface 60 is planar and recessed from the actuator arm 14 . Alternatively, the bonding surface may not be recessed.
Various modifications, additions and variations of the apparatus and method can be made within the scope of the invention. For example, the texture 80 can assume any of a number of texture patterns to hold adhesive. Additionally the baseplate 15 of the suspension 16 can have a textured or raised bonding surface for holding adhesive. The various raised portions of the actuator arm 14 bonding surface 60 can assume any of a number of configurations.
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An apparatus and method for assembling baseplates, which are joined to head suspensions, to actuator arms of an E-block for use in disk drives employ an assembly fixture for orienting and holding the head suspensions with reference to a pivot bearing formed in the E-block. An adhesive is interposed in a gap formed between each baseplate and corresponding actuator arm to maintain the suspensions in alignment relative to the pivot bearing. The assembly fixture includes clamps for maintaining the suspensions in a proper orientation. Each suspension has a locating surface that is planar with the gap for alignment of the suspensions.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional Application No. 61/062,207, filed Jan. 24, 2008, and titled “Delivery Systems and Methods of Implantation for Prosthetic Heart Valves”, the entire contents of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to prosthetic heart valves. More particularly, it relates to devices, methods, and delivery systems for percutaneously implanting prosthetic heart valves.
BACKGROUND
[0003] Diseased or otherwise deficient heart valves can be repaired or replaced using a variety of different types of heart valve surgeries. Typical heart valve surgeries involve an open-heart surgical procedure that is conducted under general anesthesia, during which the heart is stopped while blood flow is controlled by a heart-lung bypass machine. This type of valve surgery is highly invasive and exposes the patient to a number of potentially serious risks, such as infection, stroke, renal failure, and adverse effects associated with use of the heart-lung machine, for example.
[0004] Recently, there has been increasing interest in minimally invasive and percutaneous replacement of cardiac valves. Such surgical techniques involve making a very small opening in the skin of the patient into which a valve assembly is inserted in the body and delivered to the heart via a delivery device similar to a catheter. This technique is often preferable to more invasive forms of surgery, such as the open-heart surgical procedure described above. In the context of pulmonary valve replacement, U.S. Patent Application Publication Nos. 2003/0199971 A1 and 2003/0199963 A1, both filed by Tower, et al., describe a valved segment of bovine jugular vein, mounted within an expandable stent, for use as a replacement pulmonary valve. The replacement valve is mounted on a balloon catheter and delivered percutaneously via the vascular system to the location of the failed pulmonary valve and expanded by the balloon to compress the valve leaflets against the right ventricular outflow tract, anchoring and sealing the replacement valve. As described in the articles: “Percutaneous Insertion of the Pulmonary Valve”, Bonhoeffer, et al., Journal of the American College of Cardiology 2002; 39: 1664-1669 and “Transcatheter Replacement of a Bovine Valve in Pulmonary Position”, Bonhoeffer, et al., Circulation 2000; 102: 813-816, the replacement pulmonary valve may be implanted to replace native pulmonary valves or prosthetic pulmonary valves located in valved conduits.
[0005] Various types and configurations of prosthetic heart valves are used in percutaneous valve procedures to replace diseased natural human heart valves. The actual shape and configuration of any particular prosthetic heart valve is dependent to some extent upon the valve being replaced (i.e., mitral valve, tricuspid valve, aortic valve, or pulmonary valve). In general, the prosthetic heart valve designs attempt to replicate the function of the valve being replaced and thus will include valve leaflet-like structures used with either bioprostheses or mechanical heart valve prostheses. In other words, the replacement valves may include a valved vein segment that is mounted in some manner within an expandable stent to make a stented valve. In order to prepare such a valve for percutaneous implantation, the stented valve can be initially provided in an expanded or uncrimped condition, then crimped or compressed around the balloon portion of a catheter until it is as close to the diameter of the catheter as possible.
[0006] Other percutaneously delivered prosthetic heart valves have been suggested having a generally similar configuration, such as by Bonhoeffer, P. et al., “Transcatheter Implantation of a Bovine Valve in Pulmonary Position.” Circulation, 2002; 102:813-816, and by Cribier, A. et al. “Percutaneous Transcatheter Implantation of an Aortic Valve Prosthesis for Calcific Aortic Stenosis.” Circulation, 2002; 106:3006-3008, the disclosures of which are incorporated herein by reference. These techniques rely at least partially upon a frictional type of engagement between the expanded support structure and the native tissue to maintain a position of the delivered prosthesis, although the stents can also become at least partially embedded in the surrounding tissue in response to the radial force provided by the stent and balloons that are sometimes used to expand the stent. Thus, with these transcatheter techniques, conventional sewing of the prosthetic heart, valve to the patient's native tissue is not necessary. Similarly, in an article by Bonhoeffer, P. et al. titled “Percutaneous Insertion of the Pulmonary Valve.” J Am Coll Cardiol, 2002; 39:1664-1669, the disclosure of which is incorporated herein by reference, percutaneous delivery of a biological valve is described. The valve is sutured to an expandable stent within a previously implanted valved or non-valved conduit, or a previously implanted valve. Again, radial expansion of the secondary valve stent is used for placing and maintaining the replacement valve.
[0007] Some delivery systems used for percutaneous delivery of heart valves have had associated issues with the heart valves sticking or otherwise not consistently releasing from the delivery system for deployment into the desired location in the patient. In these cases, the delivery system can be further manipulated, which may cause the valve to become dislodged from the desired implantation location or cause other trauma to the patient. In rare cases, the heart valve cannot be released from the delivery system, which can then require emergency surgery to intervene. Such surgery can expose the patient to significant risk and trauma.
[0008] Although there have been advances in percutaneous valve replacement techniques and devices, there is a continued desire to provide different designs of cardiac valves that can be implanted in a minimally invasive and percutaneous manner. There is also a continued desire to be able to reposition and/or retract the valves once they have been deployed or partially deployed in order to ensure optimal placement of the valves within the patient. In particular, it would be advantageous to provide a valve and corresponding delivery system that allow for full or partial repositionability and/or retractability of the valve once it is positioned in the patient. In addition, it would be advantageous to provide a delivery system that can consistently release a heart valve without inducing the application of force to the stented valve that can dislodge the valve from the desired implantation location. Finally, the complexity and widely varying geometries associated with transcatheter valved stents and the complex anatomies that they are designed to accommodate present a need to be able to sequentially release specific regions or portions of the transcatheter valved stent. This enables specific advantages to position the devices more accurately and/or deploy specific features for anchoring, sealing, or docking of the devices. Additionally, the ability to sequence the release of various regions of different radial force and/or geometry is important in improving deliverability of transcatheter valve devices.
SUMMARY
[0009] Replacement heart valves that can be used with delivery systems of the invention each include a stent within which a valve structure can be attached. The stents used with delivery systems and methods of the invention include a wide variety of structures and features that can be used alone or in combination with other stent features. In particular, these stents provide a number of different docking and/or anchoring structures that are conducive to percutaneous delivery thereof. Many of the stent structures are thus compressible to a relatively small diameter for percutaneous delivery to the heart of the patient, and then are expandable either via removal of external compressive forces (e.g., self-expanding stents), or through application of an outward radial force (e.g., balloon expandable stents). The devices delivered by the delivery systems described herein can be used to deliver stents, valved stents, or other interventional devices such as ASD (atrial septal defect) closure devices, VSD (ventricular septal defect) closure devices, or PFO (patent foramen ovale) occluders.
[0010] Methods for insertion of the replacement heart valves of the invention include delivery systems that can maintain the stent structures in their compressed state during their insertion and allow or cause the stent structures to expand once they are in their desired location. In particular, the methods of implanting a stent can include the use of delivery systems or a valved stent having a plurality of wires with coiled or pigtail ends attached to features of the stent frame. The coiled wire ends can be straightened or uncoiled to release the stent to which they are attached. The coiled or pigtail wire end configuration allows for positive, consistent release of the stent from the delivery system without the associated complications that can be caused by incomplete release and/or sticking that can occur with other delivery systems. In addition, the release of a stent from a delivery system having coiled wire ends does not require the direct application of force to the stented valve that can dislodge the valve from the desired implantation location.
[0011] Delivery systems and methods of the invention can include features that allow the stents to be retrieved for removal or relocation thereof after they have been deployed or partially deployed from the stent delivery systems. The methods may include implantation of the stent structures using either an antegrade or retrograde approach. Further, in many of the delivery approaches of the invention, the stent structure is rotatable in vivo to allow the stent structure to be positioned in a desired orientation.
[0012] Delivery systems and methods of the invention provide for sequential release of portions of the heart valve. That is, the delivery system has actuation capabilities for disengaging from one or more structural features of a heart valve in a first step, then disengaging from additional structural features of that heart valve in one or more sequential steps. In this way, the deployment of the heart valve can be performed relatively gradually, which can provide the clinician with the opportunity to reposition or relocate the heart valve before it is completely released from the delivery system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention will be further explained with reference to the appended Figures, wherein like structure is referred to by like numerals throughout the several views, and wherein:
[0014] FIG. 1 is a perspective view of one embodiment of a delivery system of the invention;
[0015] FIG. 2 is a perspective view of a proximal end of the delivery system illustrated in FIG. 1 ;
[0016] FIG. 3 is a perspective view of a cartridge having plural wires with coiled ends as the wires are being attached to a stent frame;
[0017] FIG. 4 is an enlarged side view of the cartridge of FIG. 3 attached to the crowns at one end of a stent;
[0018] FIG. 5 is a side view of the cartridge and attached stent of FIG. 4 in proximity to a portion of a delivery system to which they will be attached;
[0019] FIG. 6 is a side view of a delivery system of the invention with an attached stent;
[0020] FIG. 7 is an enlarged perspective view of the coiled or pigtail ends of wires of a delivery system attached to a stent;
[0021] FIGS. 8-10 are side views illustrating various stages of a stent being deployed from a delivery system of the invention;
[0022] FIG. 11 is a side view of a portion of a delivery system having wires of different lengths with coiled or pigtail ends;
[0023] FIG. 12 is a side view of a portion of another delivery system having wires with ends that are coiled to form different numbers of loops;
[0024] FIG. 13 is a side view of a portion of another delivery system of the invention;
[0025] FIGS. 14-16 are sequential cross-sectional side views of a stent crown in various stages of being deployed from the pigtail end of a delivery system of the type illustrated in FIG. 13 ;
[0026] FIG. 17 is a schematic front view of another embodiment of a delivery system of the invention;
[0027] FIG. 18 is an enlarged front view of a portion of the delivery system of FIG. 17 , showing plural coiled wires attached to crowns of a stent;
[0028] FIG. 19 is an enlarged front view of the same portion of the delivery system shown in FIG. 18 , further showing some of the coiled wires detached from the crowns;
[0029] FIG. 20 is a schematic front view of the delivery system of FIG. 17 , with the stent detached from all of the coiled wires of the delivery system;
[0030] FIG. 21 is an enlarged front view of a portion of the delivery system of FIG. 20 ;
[0031] FIG. 22 is a perspective view of one of the wires of a pigtail delivery system of the invention;
[0032] FIG. 23 is a side view of a stent crown positioned relative to an embodiment of a delivery system;
[0033] FIG. 24 is a side view of a stent crown positioned relative to another embodiment of a delivery system; and
[0034] FIG. 25 is a perspective view of a sequential wire release configuration of a stent delivery system.
DETAILED DESCRIPTION
[0035] As referred to herein, the prosthetic heart valves used in accordance with the various devices and methods of heart valve delivery may include a wide variety of different configurations, such as a prosthetic heart valve having tissue leaflets or a synthetic heart valve having polymeric, metallic, or tissue-engineered leaflets, and can be specifically configured for replacing any heart valve. That is, while much of the description herein refers to replacement of aortic valves, the prosthetic heart valves of the invention can also generally be used for replacement of native mitral, pulmonic, or tricuspid valves, for use as a venous valve, or to replace a failed bioprosthesis, such as in the area of an aortic valve or mitral valve, for example.
[0036] Each of the valves used with the delivery devices and methods described herein can include leaflets attached within an interior area of a stent; however, such leaflets are not shown in many of the illustrated embodiments for clarity purposes. In general, the stents used with the delivery systems and methods described herein include a support structure comprising a number of strut or wire portions arranged relative to each, other to provide a desired compressibility and strength to the heart valve. However, other stent structures can also be configured for use with delivery systems and methods of the invention, including stents that consist of foil or metal frames or inflatable lumens that can be filled with a hardenable material or agent, such as that proposed in U.S. Pat. No. 5,554,185 (Block), for example. Although a number of different configurations of stents can be used, in general terms, the stents described herein are generally tubular or cylindrical support structures, although the diameter and shape can vary along the length of the stent, and leaflets can be secured to the support structure to provide a valved stent. The leaflets can be formed from a variety of materials, such as autologous tissue, xenograph material, or synthetics as are known in the art. The leaflets may be provided as a homogenous, biological valve structure, such as a porcine, bovine, or equine valve. Alternatively, the leaflets can be provided independent of one another (e.g., bovine or equine pericardial leaflets) and subsequently assembled to the support structure of the stent. In another alternative, the stent and leaflets can be fabricated at the same time, such as may be accomplished using high strength nano-manufactured NiTi films of the type produced by Advanced Bio Prosthetic Surfaces Ltd. (ABPS) of San Antonio, Tex., for example. The support structures are generally configured to accommodate three leaflets; however, the prosthetic heart valves described herein can incorporate more or less than three leaflets.
[0037] In more general terms, the combination of a support structure with one or more leaflets can assume a variety of other configurations that differ from those shown and described, including any known prosthetic heart valve design. In certain embodiments of the invention, the support structure with leaflets can be any known expandable prosthetic heart valve configuration, whether balloon expandable, self-expanding, or unfurling (as described, for example, in U.S. Pat. Nos. 3,671,979; 4,056,854; 4,994,077; 5,332,402; 5,370,685; 5,397,351; 5,554,185; 5,855,601; and 6,168,614; U.S. Patent Application Publication No. 2004/0034411; Bonhoeffer P., et al., “Percutaneous Insertion of the Pulmonary Valve”, Pediatric Cardiology, 2002; 39:1664-1669; Anderson H R, et al., “Transluminal Implantation of Artificial Heart Valves”, EUR Heart J., 1992; 13:704-708; Anderson, J. R., et al., “Transluminal Catheter Implantation of New Expandable Artificial Cardiac Valve”, EUR Heart J., 1990, 11: (Suppl) 224a; Hilbert S. L., “Evaluation of Explanted Polyurethane Trileaflet Cardiac Valve Prosthesis”, J Thorac Cardiovascular Surgery, 1989; 94:419-29; Block P C, “Clinical and Hemodyamic Follow-Up After Percutaneous Aortic Valvuloplasty in the Elderly”, The American Journal of Cardiology; Vol. 62, Oct. 1, 1998; Boudjemline, Y., “Steps Toward Percutaneous Aortic Valve Replacement”, Circulation, 2002; 105:775-558; Bonhoeffer, P., “TranscatheterImplantation of a Bovine Valve in Pulmonary Position, a Lamb Study”, Circulation, 2000:102:813-816; Boudjemline, Y., “Percutaneous Implantation of a Valve in the Descending Aorta In Lambs”, EUR Heart J, 2002; 23:1045-1049; Kulkinski, D., “Future Horizons in Surgical Aortic Valve Replacement: Lessons Learned During the Early Stages of Developing a Transluminal Implantation Technique”, ASAIO J, 2004; 50:364-68; the teachings of which are all incorporated herein by reference).
[0038] Optional orientation and positioning of the stents of the invention may be accomplished either by self-orientation of the stents (such as by interference between features of the stent and a previously implanted stent or valve structure) or by manual orientation of the stent to align its features with anatomical or previous bioprosthetic features, such as can be accomplished using fluoroscopic visualization techniques, for example. For example, when aligning the stents of the invention with native anatomical structures, they should be aligned so as to not block the coronary arteries, and native mitral or tricuspid valves should be aligned relative to the anterior leaflet and/or the trigones/commissures.
[0039] The support structures of the stents can be wires formed from a shape memory material such as a nickel titanium alloy (e.g., Nitinol). With shape memory material, the support structure is self-expandable from a contracted state to an expanded state, such as by the application of heat, energy, and the like, or by the removal of external forces (e.g., compressive forces). This support structure can also be repeatedly compressed and re-expanded without damaging the structure of the stent. In addition, the support structure of such an embodiment may be laser cut from a single piece of material or may be assembled from a number of different components. For these types of stent structures, one example of a delivery system that can be used includes a catheter with a retractable sheath that covers the stent until it is to be deployed, at which point the sheath can be retracted to allow the stent to expand.
[0040] The stents can alternatively be a series of wires or wire segments arranged so that they are capable of transitioning from a collapsed state to an expanded state with the application or removal of external and/or internal forces. These individual wires comprising the support structure can be formed of a metal or other material. Further, the wires are arranged in such a way that the stent can be folded or compressed to a contracted state in which its internal diameter is considerably smaller than its internal diameter when the structure is in an expanded state. In its collapsed state, such a support structure with an attached valve can be mounted over a delivery device, such as a balloon catheter, for example. The support structure is configured so that it can be changed to its expanded state when desired, such as by the expansion of a balloon catheter or removal of external forces that are provided by a sheath, for example. The delivery systems used for such a stent can be provided with degrees of rotational and axial orientation capabilities in order to properly position the new stent at its desired location.
[0041] Referring now to the Figures, wherein the components are labeled with like numerals throughout the several Figures, and initially to FIGS. 1-10 , one embodiment of a stent delivery system is illustrated. This system can include a cartridge for initial attachment of a stent and/or stent device to the stent base device and subsequent attachment to the delivery system, thereby providing quick and simple attachment of a stent to a delivery system by an operator. In one embodiment, the attachment mechanism is a dovetail type of connection, which includes a mating feature on both a cartridge and a delivery system that allows the stent to be preloaded to the cartridge and easily attached by the clinician to the delivery system. Other connection means are also contemplated, such as snap-fit connections, threaded connections, clips, pins, magnets, and/or the like. Alternatively, the pigtail delivery system may include more permanently attached components that do not use features of a cartridge-based system.
[0042] One delivery system of the invention can further include a series of wires for connecting the stented valve to the delivery system. In one embodiment, each of the wires can be formed at its distal end into a coiled or “pigtail” configuration. The coiled end of each wire can be secured to a feature of a stent, such as a stent crown, when the wire end is coiled. Straightening the wire can then release the stent feature to which it was secured, as is described below in further detail. One exemplary embodiment of a wire 20 having a coiled distal end 82 and a proximal end 84 is illustrated in FIG. 22 . The wire can be bent at approximately a 90 degree angle between the distal end 82 and proximal end 84 , or it can be bent at an angle other than 90 degrees, or it can be a straight wire portion with no bend or curves. As shown, the distal end 82 of the wire 20 is shaped to Create approximately 1½ coils or loops; however, the wire 20 may include more or less coils or loops than shown. The wires can be made of a wide variety of materials, such as high tensile strength spring wire material or NiTi, for example. Alternatively, the wire can be somewhat malleable such that it does not necessarily return to the original coil shape once any stented valve features have been released from the wire.
[0043] The size and exact configuration of the pigtail end portion of each wire can be chosen or designed so that the forces required to retract and deploy the stent are within a desirable range. The pigtail portion of the wire should be strong enough to prevent inadvertent release from the delivery system during stent positioning, resheathing, repositioning, and/or the like. In addition, the pigtail portion of the wire should be sufficiently flexible that it does not require excessive force to straighten it during implant device deployment. In one exemplary embodiment, the wire 20 is approximately 0.010 inches in diameter, thereby requiring approximately 7 pounds of pull force to uncoil the distal end 82 of the wire 20 . However, different materials and different sized wires can be used for the pigtail wires that provide different delivery system properties.
[0044] The proximal end 84 of each of the wires 20 is fixed to a hub or base portion that is located on a center lumen of the cartridge or delivery system. The wire 20 can be secured to the hub or base portion using various mechanical methods and/or adhesives. In one embodiment, the coiled or pigtail portions at the distal end 82 are initially coiled around the wires of one end of a stent and then are fully or partially straightened to deploy the stented valve. The wire can be made of spring materials or shape memory materials that may be cured or “set” via a heat treating process so that the coiled wire end can be retracted, clocked, redeployed, disengaged, or the like without the use of additional tools or the management of removed parts. In particular, the wires that have a pigtail portion at their distal ends are retracted relative to one or more tubes in which they are enclosed until the pigtail portions are adjacent to one end of one of the tubes. That is, the wires are pulled relative to the tube(s), the tube(s) are pushed forward relative to the wires, or both the wires and the tubes are moved relative to each other. The diameter of the coil circle or loop can be relatively large in size as compared to the diameter of the tube opening into which they are being pulled so that the coils will contact and interfere with the end of the tube when they are pulled toward it. The wires are then pulled further back into the tube, thereby straightening the pigtail portions until they are released from the stent wires they had been encircling. In one embodiment, interference between the larger area or volume of the pigtail portions and the inner area of the tube forces the pigtail portions to uncoil or straighten as they are pulled into the tube. Alternatively, the coiled diameter of the loops can be relatively small in size as compared to the diameter of the tubes into which they are being pulled (see FIG. 13 , for example), so that the stent crown will instead contact and interfere with the end of the tubes when they are pulled toward it. This will inhibit the stent movement so that additional pulling force on the wires will cause the coiled wire end to uncoil.
[0045] In particular, FIG. 1 illustrates one exemplary delivery system 10 for a pigtail type of system that generally includes a proximal end 12 and a distal end 14 . FIG. 2 shows an enlarged view of the proximal end 12 of the delivery system 10 of FIG. 1 , which includes a first knob 30 and a second knob 32 for use in controlling the delivery and deployment of a stent at the generally distal end 14 , as will be described in further detail below. A delivery system for percutaneous stent and valve delivery can comprise a relatively long delivery system that can be maneuvered through a patient's vasculature until a desired anatomical location is reached. In any case, the delivery system can include features that allow it to deliver a stent to a desired location in a patient's body.
[0046] A cartridge 16 is illustrated in FIG. 3 adjacent to a stent 18 to which it will be attached. The stent 18 is then illustrated in FIG. 4 as attached to the cartridge 16 via the coiled or pigtail ends of the wires 20 . That is, the cartridge 16 includes a post 19 having a series of wires 20 extending from one end and a dovetail attachment portion 22 at the opposite end. Each of the wires 20 includes a generally straight portion that is connected to the post 19 at its proximal end 84 and further includes a “pigtail” or curled portion at its distal end 82 . Each wire 20 is made of a shape-memory type of material (e.g., Nitinol) such that it can be straightened by applying an external force when in the proximity of a stent to which it will be attached and return generally to its curled configuration when the straightening force is removed. Alternatively, a wire can be used that is permanently deformed when sufficient force has been applied to it to release the stented valve from the delivery system.
[0047] In order to load a stent onto the wires 20 of cartridge 16 , the curled end of each wire 20 can be straightened or partially straightened and placed adjacent to one of the crowns or “V” ends of the stent. The force on each wire 20 can then be removed or reduced so that the distal end of the wire coils back toward its pigtail configuration, thereby wrapping around and capturing one crown of the stent 18 , as is shown in FIG. 4 . Alternatively, a malleable type of wire material can be used, wherein the coil can be formed by wrapping the wire around the stent crown during the stent loading process. If a different stent construction is used, the coiled wires can instead engage with some other feature of that type of stent. The cartridge is preferably provided with the same number of wires having pigtail or coiled wire ends as the number of crowns provided on the corresponding stent, although the cartridge can be provided with more or less wires having coiled ends. It is also contemplated that a single crown of a stent may have more than one pigtail wire attached to it. After the wires 20 of the cartridge 16 are attached to the stent 18 , as is illustrated in FIG. 4 , the cartridge and stent combination can then be attached to the delivery system 10 .
[0048] The use of a cartridge with the delivery systems of the invention can provide advantages to the stent loading process. For example, a cartridge and stent can be provided to the clinician with the stent pre-attached to the cartridge so that the clinician does not need to perform the stent attachment step prior to surgery. In addition, the cartridge concept simplifies the attachment of the valve to the delivery system, improves the reliability and consistency of the attachment, and eliminates the chance that the valve will mistakenly be attached backwards onto the delivery system. The exemplary stent 18 , one end of which is shown in the Figures, is made of a series of wires that are compressible and expandable through the application and removal of external forces, and may include a series of Nitinol wires that are approximately 0.011-0.015 inches in diameter, for example. That is, the stent 18 may be considered to be a self-expanding stent. However, the stent to which the pigtail wire portions of the invention are attached can have a number of different configurations and can be made of awide variety of different materials. In order to be used with the delivery systems of the invention, however, the stent is preferably designed with at least one point or feature to which a coiled wire end can be attached. That is, while an open-ended type of stent crown is shown, other stent end configurations can alternatively be used, such as eyelets, loops, or other openings.
[0049] FIG. 5 illustrates one end of the delivery system 10 as having a dovetail portion 24 that can mate or attach to a corresponding dovetail attachment portion 22 of the cartridge 16 by positioning the two pieces so that they become engaged with each other. This particular dovetail arrangement is exemplary and it is understood that a different mechanical arrangement of cooperating elements on two portions of a delivery system can instead be used, where the stent structure is attached to one of the pieces of the delivery system, which in turn is mechanically attachable to another piece of the delivery system. It is further contemplated that the wires with pigtail ends are not part of a cartridge-based system, but that the wires are instead attached directly to a delivery system that does not include a cartridge.
[0050] As shown in FIGS. 6 and 7 , after the cartridge 16 is attached to the delivery system 10 , the cartridge 16 and its attached stent 18 are then retracted into a hollow tube or lumen 26 of the delivery system by moving or pulling the cartridge 16 toward the proximal end of the delivery device. This movement is continued until the crowns of the stent 18 are adjacent to the end of the lumen 26 . It is noted that the lumen 26 may be an outer sheath of the system or that it may be an inner lumen such that another sheath or tube can be positioned on the outside of it. Due to the compressible nature of the stent 18 , continued movement of the cartridge 16 toward the proximal end of the delivery device will pull the wires 20 toward a central lumen 28 of the delivery system, thereby also pulling the wires of the stent 18 toward the central lumen 28 . The cartridge 16 can then continue to be moved toward the proximal end of the device until the stent 18 is completely enclosed within the lumen 26 , as is illustrated in FIG. 1 . One exemplary procedure that can be used for such a retraction of the stent 18 into the lumen 26 is to turn the knob 32 (see FIG. 2 ) in a first direction (e.g., clockwise) until the knob is fully forward. The knob 30 can then be pulled while turning the knob 32 in a second direction that is opposite the first direction (e.g., counter clockwise) until the stent is retracted into the delivery system.
[0051] FIGS. 8-10 illustrate the deployment of the stent 18 via a delivery system, which would be initiated once the stent 18 is generally located in its desired anatomic position within a lumen (e.g. heart valve area) of the patient. In particular, FIG. 8 shows the proximal end of a delivery system as the lumen 26 is being moved away from a distal tip 29 of the delivery system, thereby exposing the free end of the stent 18 (i.e., the end of stent 18 that is not attached to the coiled wires 20 ). In this way, the compressive forces that were provided by enclosing the stent 18 within the lumen 26 are removed and the stent 18 can expand toward its original, expanded condition. FIG. 9 illustrates the next step in the process, where the lumen 26 is moved even further from the distal tip 28 of the system, thereby allowingthe entire length of the stent 18 to be released from the interior portion of lumen 26 for expansion thereof.
[0052] In order to release or deploy the stent 18 from the delivery system 10 , the wires 20 are then pulled via an actuating mechanism of the delivery system back toward the proximal end of the device until the coiled or pigtail portions are immediately adjacent to the end of the lumen 26 , as illustrated in FIG. 10 . Next, the cartridge 16 with extending wires 20 , along with the lumen 26 to which they are attached, are pulled further toward the proximal end of the device until the coiled ends of the wires 20 contact and interfere with the end, of the lumen 26 , which thereby forces the wires 20 to uncoil or straighten at their distal ends. Once the wires 20 are sufficiently straightened or uncoiled, the wires 20 become disengaged from the stent 18 , thereby causing the stent 18 to be in its released position within the patient. One exemplary sequence of steps that can be used for such a final deployment of the stent 18 relative to the lumen 26 with this delivery system is to turn knob 32 (see FIG. 2 ) in a first direction (e.g., clockwise) until the stent is exposed or deployed beyond the lumen 26 . Knob 30 can then be retracted, thereby fully releasing the stent 18 from the delivery system.
[0053] It is noted that in the above procedure, the stent can be retracted back into the lumen 26 at any point in the process prior to the time that the wires 20 are disengaged from the stent 18 , such as for repositioning of the stent if it is determined that the stent is not optimally positioned relative to the patient's anatomy. In this case, the steps described above can be repeated until the desired positioning of the stent is achieved.
[0054] In a delivery system that uses the dovetail connection described above or another configuration that allows the stent to be connected to coiled wires of a cartridge, a cartridge can alternatively be pre-attached to a valved stent, packaged together within a gluteraldehyde solution, and provided in this pre-assembled manner to a clinician. In this way, the clinician can simply remove the assembly at the time of the implantation procedure and attach it to the delivery system, which can reduce the amount of time the valved stent needs to be manipulated immediately prior to the time of implantation.
[0055] With this system described above, full or partial blood flow through the valve can advantageously be maintained during the period when the stented valve is being deployed into the patient but is not yet released from its delivery system. This feature can, help to prevent complications that may occur when blood flow is stopped or blocked during valve implantation with some other known delivery systems. This also eliminates or reduces the need for additional procedural steps, such as rapid pacing, circulatory assist, and/or other procedures. In addition, it is possible for the clinician to thereby evaluate the opening and closing of leaflets, examine for any paravalvular leakage and evaluate coronary flow and proper positioning of the valve within the target anatomy before final release of the stented valve.
[0056] The system and process described above can include simultaneous or generally simultaneous straightening of the wires so that they all uncoil or straighten at their distal ends to disengage from the stent in a single step. However, it is contemplated that the wires can be straightened in a serial manner, where individual wires, pairs of wires, or other combinations of wires are selectively straightened in some predetermined order to sequentially deploy portions of the stent. This can be accomplished either by the structure of the delivery device and/or the structure of the stent and/or through the operation of the delivery system being used.
[0057] One exemplary actuating mechanism that can be used with the delivery system can engage all or some of the wires to allow for sequential release of the various stent crowns. This serial release of crowns can be advantageous in that it allows for a high level of control of the diametric deflection (e.g., expansion) of the proximal end of the stented valve. Also, release of high radial force stents sequentially can minimize injury and trauma to the anatomy. Having control of the diametric expansion of all or a portion of the stent can minimize the possibility for device migration, tissue injury and/or embolic events during device deployment. In addition, the serial or sequential release of crowns can require less force for any one wire or set of wires as compared to the amount of force that is required to release all of the wires at the same time. Additionally, regions of the stent such as fixation anchors, petals, and the like could be released in a desired sequent to optimize the positioning and consistency of deployment. Finally, release of specific regions of the stent at different axial zones or regions of varying geometry (inflow flares, bulbous regions, and the like) and/or varying radial force can enable more accurate and stable positioning and device release.
[0058] FIG. 25 illustrates one embodiment of a portion of a sequential wire release configuration of a stent delivery system, which includes a first disk 200 and a second disk 202 spaced from disk 200 generally along the same longitudinal axis. Disk 200 includes a surface 204 from which three wires 206 extend. Disk 202 includes a surface 208 from which three wires 210 extend and three apertures 212 through which the wires 206 of disk 200 can extend. The number of wires and apertures of each disk can be more or less than three, as desired. It is further understood that more than two disks may be provided, with one or more wires being attached to each of the disks. All of the wires 206 , 210 terminate at their distal ends with a coiled portion that can include any of the coiled wire properties discussed herein. Each of the wires in the sets of wires 206 , 210 can have the same length or a different length so that the coiled ends are at the same or a different distance from the surface 208 of disk 202 . This wire release configuration further includes activation members that are shown schematically as wires 214 , 216 , where wires 214 extend through a center aperture 218 of disk 200 and attach to the disk 202 and wires 216 are attached to the disk 200 . The wires 214 , 216 can be independently activated to axially move the disks 200 and 202 with their attached wires 210 , 206 , respectively. The activation wires 214 , 216 are intended to be representative activation means, where other activation means can instead be used to provide independent axial movement of the disks 200 , 202 .
[0059] In another embodiment, multiple wires can be released from a stent in a sequence that includes radially releasing stent wires as individual wires, wire pairs, or groups of wires around the periphery of the stent. For example, stent wires on opposite sides of the circumference can be released as a pair, and then the sequence can continue in a clockwise or counterclockwise direction until all of the wires are released from the stent. This can be performed on wires in the same axial plane. It is further advantageous, in accordance with the invention, to sequentially release the wires from the stent among various axial planes. This can be valuable for stents that have varying radial force in planes. In this situation, the delivery systems can include coiled wired ends, for example. Finally, delivery systems of the invention can also be used to release other specific stent features and elements other than or in addition to stent crowns and loops, such as unfurling skirts, dock interface elements, sealing features, barbs, hooks, and the like.
[0060] FIG. 11 illustrates one exemplary embodiment of an end portion of a delivery system that includes another embodiment of a lumen 40 from which the distal ends of multiple wires 42 extend. As shown, the distal end of each of the wires 42 has the same number of coils or loops; however, the distance between each of these coils and an end 44 of the lumen 40 is different. Thus, when the wires 42 are attached to a stent and pulled toward an end 44 of the lumen 40 , the shortest wire 42 will contact the lumen 40 first. Enough interference is preferably created between the wire 42 and the lumen 40 so that as this shortest wire 42 is pulled into the lumen 40 , it is straightened and ultimately released from the stent feature to which it is attached. The wires 42 will continue to be moved further toward the end 44 of lumen 40 until the next longest wire 42 contacts the lumen, which also will be uncoiled or straightened to release it from the stent. This process will be repeated until all of the wires 42 are released from the stent and the stent is fully deployed. Although only three wires 42 are shown in this figure, a different number of wires can instead be provided, and preferably the number of wires provided matches the number of crowns on the stent that is being delivered by the delivery system. In addition, all of the wires can have different lengths and/or numbers of windings at their distal ends, or at least one of the wires can be configured identically to at least one other wire of that delivery system. For example, the delivery system can include identical pairs of wires such that each wire pair releases from a stent simultaneously during the stent deployment process.
[0061] FIG. 12 illustrates another exemplary embodiment of an end portion of a delivery system that is similar to that of FIG. 11 in that it includes a lumen 50 from which the distal ends of multiple wires 52 extend. Again, the wires 52 are not all configured identically to each other. As shown in this figure, the distal ends of each of the wires 52 has a different number of windings at its coiled end so that when the wires 52 are attached to a stent and pulled toward an end 54 of the lumen 50 , the coiled portions of all or most of the wires 52 will contact the end 54 at generally the same time. Continued movement of the wires 52 into the lumen 50 will cause the coiled ends to simultaneously begin straightening or uncoiling; however, the wires 52 with the least number of windings will be completely or almost completely straightened first, thereby releasing these wires from the stent feature to which they were attached. The movement of the wires 52 continues until the wires with the next greater number of windings uncoil and release from the stent and all of the wires 52 are released from the stent so that the stent is fully released. As with the embodiment of FIG. 11 , this embodiment provides for a sequential rather than simultaneous release of stent features (e.g., stent crowns). It is noted that more or less than three wires 52 can be used in the system and that all of the wires 52 can be different from each other or that some of the wires 52 can be configured identically (e.g., in wire pairs that release simultaneously).
[0062] A distal end of another exemplary embodiment of a delivery system of the invention is illustrated in FIGS. 13-16 . This delivery system provides a structure for attachment of a stent or stented valve that allows for full diametric expansion and assessment of the stent or stented valve prior to its release from the delivery system. In this way, the hemodynamic performance, stability, and effect on adjacent anatomical structures (e.g., coronaries, bundle branch, mitral valve interference, etc.) can be assessed and if found to be inadequate or inaccurate, the stent can be recaptured and repositioned before final release of the stent from the delivery system. Alternatively, the entire stent can be removed from a patient before it is released from the delivery system if any undesirable results are obtained during the process of deploying the stent.
[0063] Referring more particularly to FIG. 13 , an end portion of a delivery system is shown, which generally includes a lumen 60 having an end 64 from which the distal ends of multiple wires 62 extend. This lumen 60 may be the outer sheath of the delivery system. Each of the wires 62 is partially enclosed within a tube 66 , and a coiled end of each of the wires 62 extends beyond a distal end 68 of each of the tubes 66 . Each wire 62 is longitudinally moveable or slideable relative to its respective tube 66 . The tubes 66 are preferably sized so that when the wires 62 are pulled toward the lumen 60 , the coiled ends of the wires 62 will contact and interfere with the ends 68 of the tubes 66 . Continued movement of the wires 62 will then cause the wires 62 to straighten until they are released from the stent. These steps are illustrated with a single tube 66 in FIGS. 14-16 , which show an extending coiled wire 62 that is attached to (see FIGS. 14 and 15 ) then detached from (see FIG. 16 ) a crown 70 of a stent that includes multiple crowns (not shown). In FIG. 14 , the wire 62 is coiled around crown 70 of a stent, and then the wire 62 is moved in a direction 72 relative to the tube 66 until the coiled wire portion contacts an end 74 of the tube 66 (see FIG. 15 ). This will cause interference between the coiled portion of wire 62 and the end 74 of the tube 66 . Continued movement of the wire 62 in direction 72 will cause the coiled end of the wire 66 to unfurl. This movement of the wire 62 in direction 72 will be continued until the wire 62 is straightened sufficiently to be released from the crown 70 , as shown in FIG. 16 .
[0064] The tubes 66 are preferably relatively incompressible to allow sufficient tension in the coiled portion of the wires 62 for the wires to straighten when pulled toward the lumen. In other words, the incompressibility of the tubes under tension can simulate flexible columns that resist buckling when the coiled wire ends are pulled against them. In an alternative embodiment of the system of FIG. 13 , the wires 62 can have different lengths and/or different numbers of windings in their coils (such as in FIGS. 11 and 12 , for example), to provide for sequential release of the wires. In yet another alternative embodiment, the tubes 66 can have different lengths, thereby providing different sizes of gaps between the end of the tubes 66 and the coiled portion of the wires 62 .
[0065] Another alternative stent wire release embodiment is illustrated in FIG. 23 with an end portion of a tube 150 in which a coiled end 152 of a wire 154 is positioned. Coiled end 152 is attached to a stent crown 156 and is at least partially enclosed or contained within the tube 150 . In order to detach the wire 154 from the stent crown 156 , a retraction force is applied to wire 154 until the stent crown 156 contacts an end 158 of the tube 150 , which will limit further movement of the stent. Continued application of force to wire 154 will cause the coiled end 152 to unfurl, thereby releasing the coiled end 152 from the stent crown 156 . FIG. 24 illustrates a similar wire release embodiment to that illustrated in FIG. 23 , but with an additional tube 160 positioned within tube 150 . To release the coiled wire end from the stent crown, the wire can be unfurled by interference between an end 162 of tube 160 and the coiled wire end and/or can be unfurled by movement of the wire relative to the tube 150 , as described relative to FIG. 23 . It is noted that the wire coils in these and other embodiments of the invention can include a complete or partial coil with multiple windings or a partial winding, depending on the desired release properties.
[0066] FIGS. 17-21 illustrate an exemplary delivery system 100 that can be used to provide sequential release of wires that have their coiled ends engaged with a stent 120 , where the wires all have generally the same configuration (i.e., length, number of coils, and the like). Delivery system 100 includes a lumen 102 having an end 104 from which the distal ends of multiple wires 106 extend. Each of the wires 106 is partially enclosed within a tube 108 . A coiled end 112 of each of the wires 106 extends beyond a distal end 110 of each of the tubes 108 . Each wire 106 is longitudinally moveable or slideable relative to its respective tube 108 . The tubes 108 are preferably sized so that when the wires 106 are pulled toward the lumen 102 (or when the tubes 108 are moved relative to the wires 106 ), the coiled ends 112 of the wires 106 will contact the distal ends 110 of the tubes 108 . Continued movement of the wires 106 relative to the tubes 108 will then cause the coiled ends 112 of the wires 106 to straighten, thereby facilitating release of the stent 120 from the delivery system 100 .
[0067] Delivery system 100 further includes a handle 130 from which the lumen 102 extends. The handle 130 includes control aspects for deployment of the stent 120 . In particular, handle 130 includes a proximal control knob 132 , an intermediate control knob 134 , and a distal control knob 136 . These control knobs are provided for controlling the delivery and deployment of the stent 120 . In one exemplary embodiment of the invention, these knobs are spring-loaded such that they need to be pressed toward the handle in order to move them along a path to a new location. The handle 130 can also be provided with a series of detents that define the specific locations where the knobs can be located. The delivery system 100 may also include additional knobs, levers, or the like that can be used to control the movement of the individual wires 106 or groups of wires.
[0068] In order to load a cartridge system to which a stent 120 is attached onto the delivery system 100 , the control knobs 132 , 134 , 136 are moved into a position that can be referred to as the “loading position”. Specific detents or other markings can be provided on the delivery system to indicate the correct position for the knobs. The cartridge can then be attached to the delivery system using a dovetail connection or some other type of secure attachment mechanism. The proximal knob 132 can then be moved to a “prepare to sheath position”, while the distal knob 136 is moved to the “sheath position”. In this way, the sheath will be moved to a position in which the stent is protected by the sheath. The delivery system can then be inserted into the patient in its desired position that facilitates deployment of, the stent. Moving the proximal knob 132 into the “proximal end open position” and the distal knob 136 to the “load position” can then deploy the stent 120 . In order to discharge the stent 120 , a switch on the delivery system (not shown) or some other control mechanism can be moved into an “open position”, the distal knob 136 can be moved to the “discharge position”, and the proximal knob 132 can be moved to its “discharge position”. The intermediate knob 134 can be manipulated at the same time as the other knobs in order to facilitate the loading, sheathing, deployment, and discharge procedures.
[0069] The delivery system 100 further comprises a dual-control procedure and mechanism to sequentially pull the wires 106 into the tubes 108 to disconnect them from the crowns of the stent 120 . In this embodiment, a first group of wires 106 can first be removed from the stent 120 , and then a second group of wires 106 can be removed from the stent 120 to thereby release the stent 120 from the delivery system 100 . Thus, separate mechanisms are provided within the handle 130 to allow a first group of wires 106 to be pulled into the tubes 108 by manipulating one of the control knobs, and then to allow a second group of wires 106 to be pulled into the tubes 108 by manipulating a different control knob. Each of the groups of wires 106 may include half of the wires, or there may be a different percentage of wires 106 in each of the groups. The division of wires into groups may further include having every other wire be included in one group and the alternating wires are included in a second group, although the wires may be grouped in a different pattern. It is further contemplated that additional mechanisms can be provided so that the wires are divided into more than two groups that are controlled by separate mechanisms for sequential wire release.
[0070] FIGS. 17 and 18 illustrate the step in which the wires 106 are each attached at their distal end 112 to a crown of stent 120 . FIG. 19 illustrates the step in which some of the wires 106 have been pulled into their respective tubes 108 , thereby straightening the distal end of the wires and detaching them from the stent 120 . However, the remainder of the wires 106 remains attached to the crowns of the stent 120 . FIGS. 20 and 21 illustrate the step when the remaining wires 106 have been pulled into their respective tubes 108 , thereby straightening the distal end of the wires and detaching them from the stent 120 . In this way, the release of the stent 120 from the delivery system 100 is more gradual than when all of the wires are detached from the stent at the same time. The components of the delivery system can alternatively comprise different components than shown to accomplish the serial wire release shown more generally in FIGS. 18 , 19 , and 21 .
[0071] The delivery systems of the invention can be used for both apical and transfemoral procedures, for example, and may have the ability to be able to clock the stent, as desired. The delivery systems may further include a removable outer sheath that can accommodate stents of different sizes.
[0072] The process of pulling the wires toward the lumen in many of the described embodiments of the invention can be accomplished in a number of ways, such as by rotating the device over coarse threads or pushing a button to slide it to pull the wires toward the lumen. That is, a number of different mechanisms can be used to accomplish this movement of the wires relative to the delivery system. Further, it is noted that while the coiled wire ends described herein are generally shown to be engaging with the end crowns of a stent, the coiled wire ends can instead engage with intermediate stent crowns or other stent features. In addition, although the coiled wire ends are illustrated herein as interfacing with stent crowns that are uniformly provided at the ends of a cylindrical stent, the coiled wire designs described can also accommodate delivery of valved stents that have non-uniform axial or longitudinal stent crowns of stent feature attachment geometries.
[0073] The delivery systems of the invention, having a stent attached via coiled wire ends, can be delivered through a percutaneous opening (not shown) in the patient. The implantation location can be located by inserting a guide wire into the patient, which guide wire extends from a distal end of the delivery system. The delivery system is then advanced distally along the guide wire until the stent is positioned relative to the implantation location. In an alternative embodiment, the stent is delivered to an implantation location via a minimally invasive surgical incision (i.e., non-percutaneously). In another alternative embodiment, the stent is delivered via open heart/chest surgery. In one embodiment of the invention, the stent can include a radiopaque, echogenic, or MRI visible material to facilitate visual confirmation of proper placement of the stent. Alternatively, other known surgical visual aids can be incorporated into the stent. The techniques described relative to placement of the stent within the heart can be used both to monitor and correct the placement of the stent in a longitudinal direction relative to the length of the anatomical structure in which it is positioned.
[0074] One or more markers on the valve, along with a corresponding imaging system (e.g., echo, MRI, etc.) can be used with the various repositionable delivery systems described herein in order to verify the proper placement of the valve prior to releasing it from the delivery system. A number of factors can be considered, alone or in combination, to verify that the valve is properly placed in an implantation site, where some exemplary factors are as follows: (1) lack of paravalvular leakage around the replacement valve, which can be advantageously examined while blood is flowing through the valve since these delivery systems allow for flow through and around the valve; (2) optimal rotational orientation of the replacement valve relative to the coronary arteries; (3) the presence of coronary flow with the replacement valve in place; (4) correct longitudinal alignment of the replacement valve annulus with respect to the native patient anatomy; (5) verification that the position of the sinus region of the replacement valve does not interfere with native coronary flow; (6) verification that the sealing skirt is aligned with anatomical features to minimize paravalvular leakage; (7) verification that the replacement valve does not induce arrhythmias prior to final release; and (8) verification that the replacement valve does not interfere with function of an adjacent valve, such as the mitral valve.
[0075] The present invention has now been described with reference to several embodiments thereof. The entire disclosure of any patent or patent application identified herein is hereby incorporated by reference. The foregoing detailed description and examples have been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. It will be apparent to those skilled in the art that many changes can be made in the embodiments described without departing from the scope of the invention. Thus, the scope of the present invention should not be limited to the structures described herein, but only by the structures described by the language of the claims and the equivalents of those structures.
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A delivery system with sequential release mechanism and method of delivering and deploying an implantable stented device into a body lumen including a tabular body, a plurality of activation members extending from the distal end of the tubular body, and a plurality of disks. Each disk includes a proximal and distal surface, at least one stent engagement element attached to the distal surface of the disk and at least one aperture. At least one activation member attaches to the proximal surface of a first disk and at least one activation member passes through an aperture of the first disk and attaches to the proximal surface of a second disk. At least one stent engagement element attached to the distal surface of the first disk passes through an aperture of the second disk. Axially movement of the activation members causes sequential release of the stent engagement elements from a stented device.
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This application is a continuation-in-part of PCT/EP2013/054126 filed Mar. 1, 2013, which claims priority to German Application No. 10 2012 004 747.9 filed Mar. 8, 2012; the entire contents of each are incorporated herein by reference.
BACKGROUND
The invention relates to a crimping apparatus for crimping a multifilament bundle in a melt spinning process.
In the manufacturing of crimped threads in a melt spinning process crimping of the threads is caused by stuffing the filament bundles to form in each case a thread plug. In this known process, on account of stuffing the filament bundles, the filaments are deposited as loops and arcs and compressed to form the thread plugs, such that, after disintegration of the thread plug, a thread having crimped filaments is produced. The shape of the crimp contained in the filaments here essentially depends on the thermal processing of the thread plug. In order to enable dwelling times for temperature-control of the thread plug that are as long as possible, processing units in which the thread plug produced after stuffing is guided with multiple enlacements on a processing drum have been successful in the prior art.
A crimping apparatus of such type is known from DE 26 32 082, for example. In the known crimping apparatus, a conveyor nozzle, a stuffer box and a processing unit with a processing drum are disposed below one another. In principle, two different positions of the processing drum for receiving and guiding a thread plug guided out of the stuffer box are known here. In a first variant, the axis of the processing drum is oriented substantially horizontally, such that, in the case of multiple enlacements on the circumference of the processing drum, the thread plug has to be guided substantially in the horizontal direction. In this arrangement of the processing drum the windings of the thread plug on the circumference of the drum wall have to be displaced in order to obtain a helical profile of the thread plug on the circumference of the processing drum. Depending on the properties of the drum wall, entanglements of adjacent windings of the thread plug that are more or less intense may arise here. In addition, indexing means are used. In order to axially displace the windings of the thread plug.
In a second variant of the arrangement of the processing drum, the latter, with its axis, is substantially vertically oriented, such that the helically guided thread plugs on the circumference of the processing drum experience natural support of their indexing movement on the circumference of the drum wall. To this extent, comparatively slight indexing forces are required in order to guide the helical profile of the thread plug from the upper end of the processing drum to a lower end of the processing drum. Here, infeeding of the thread plug takes place by an upstream deflection between the stuffer box and the processing chamber. Deflections of this type typically represent a zone which, for temperature control of the thread plug, is uncontrolled and, wherever possible, they should be implemented as short as possible.
SUMMARY
It is an object of the invention to provide a crimping apparatus for crimping a multifilament bundle in a melt spinning process of the generic type in which the thread plug, for thermal treatment, is guidable with multiple enlacements in a gentle manner on the circumference of a processing drum.
A further object of the invention lies in refining the crimping apparatus of the generic type in such a manner that guiding of the thread plug on the circumference of the processing drum can substantially take place without an indexing unit.
This object is achieved according to the invention in that the stuffer box is disposed axially parallel to the processing drum in such a manner that the thread plug can be infed in a straight run from a plug outlet of the stuffer box to the circumference of the drum wall.
The invention is distinguished in that the natural weight force of the thread plug may be used to infeed the thread plug, without deflection, to the processing drum. The change of direction of the thread plug on the circumference of the processing drum is caused only by the relative speeds of the thread plug and the drum wall. The processing drum which, with its axis, is vertically oriented here ensures indexing of the individual windings of the thread plug without any comparatively large indexing forces.
Guiding of the thread plug on the circumference of the processing drum may still be improved in that, according to an advantageous refinement of the invention, the drum wall, at a short distance therefrom, is associated with an outer cylinder which encompasses the cooling drum in a sleeve-like manner and in that, for guiding the thread plug, an encircling annular chamber is configured between the outer cylinder and the drum wall. Here, the thread plug may be guided immediately from the plug outlet directly to the annular chamber, such that dynamic friction existing between the thread plug and the drum wall can be reduced to a minimum.
In order to facilitate filling of the annular chamber on the circumference of the processing drum, on the one hand, and to obtain setting of the thread plug on the circumference of the drum prior to disintegration of the thread plug, on the other hand, the refinement of the invention is preferably implemented in which the annular chamber includes an inlet opening to an upper end of the outer cylinder and, between the drum wall and the outer cylinder, includes an outlet opening to a lower end of the outer cylinder, and in that the annular chamber includes a chamber cross section which tapers off in the axial direction toward the outlet opening. In this manner, the chamber cross section may be implemented so as to be preferably larger in the inlet region of the annular chamber than a diameter of the thread plug. This enables the thread plug to be directly deposited in the annular chamber immediately after stuffing and without any compression. On account of the subsequent tapering of the chamber cross section it is achieved that positive setting of the thread plug is possible in the lower region of the annular chamber. To this end, the chamber cross section, in the region of the outlet opening, includes a size that is substantially smaller than the diameter of the thread plug.
In order to obtain secure guiding within the annular chamber in the case of fine counts and correspondingly low thread weights, it is furthermore provided that the inlet opening of the annular chamber is associated with a segment-shaped holding-down element which partially covers the inlet opening. In this manner, secure guiding of the plug layers within the annular chamber is achieved even in the case of a tapering chamber cross section.
In order to obtain slight relative speeds of the processing drum and the outer cylinder, a particularly advantageous embodiment is one in which the outer cylinder is configured so as to be rotatable and is coupled to a rotational drive which drives the cylinder wall in the same direction of rotation as the drum wall of the processing drum. In this manner, the cylinder wall can be driven in the same direction of rotation as the drum wall at a circumferential speed in such a manner that no speed differential exists between the walls of the annular chamber. In order to produce special effects when guiding the thread plug, there is, in principle, however also the possibility of setting desired speed differentials between the cylinder wall and the drum wall.
In the case of a synchronous drive of the processing drum and of the outer cylinder the refinement of the invention in which the processing drum is driven by an electric motor which is coupled to the rotational drive of the outer cylinder has proven successful. In this manner, both walls can be collectively driven in the same direction of rotation by way of one electric motor.
For temperature control of the thread plug on the circumference of the processing chamber the invention offers high flexibility in the choice and implementation of the temperature-control means. In a first variant, the drum wall of the processing chamber is configured so as to be gas-permeable, wherein the processing drum is coupled to a blower for generating a flow of cooling air. In this manner, the blower in the interior of the processing drum could produce negative pressure, for example, such that the available ambient air is sucked in via the drum wall and may be used for cooling the thread plug. Alternatively, however, there is also the possibility for the blower in the interior of the processing chamber to produce positive pressure, such that a flow of cooling air from the inside to the outside is established.
Irrespective of the properties of the blower, the thread plug may also be advantageously cooled within the annular chamber, in that the outer cylinder includes a gas-permeable cylinder wall.
However, in principle there is also the possibility for a fluid to be used as a temperature-control means which, for temperature control of the drum wall, is guided through fluid ducts within the processing chamber. Cold as well as hot fluids may be used here in order to implement temperature control of the thread plug.
The invention will be explained in more detail in the following with reference to the appended figures and by means of a plurality of exemplary embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically a cross-sectional view of a first exemplary embodiment of the crimping apparatus according to the invention.
FIG. 2 shows schematically a side view of the exemplary embodiment of FIG. 1 .
FIG. 3 shows schematically a cross-sectional view of a further exemplary embodiment of the crimping apparatus according to the invention.
FIG. 4 shows schematically a cross-sectional view of a further exemplary embodiment of the crimping apparatus according to the invention.
FIG. 5 shows schematically a detail of a cross-sectional view of a further exemplary embodiment of the crimping apparatus according to the invention.
DETAILED DESCRIPTION
In FIGS. 1 and 2 a first exemplary embodiment is illustrated schematically in a plurality of views. Both illustrations show the exemplary embodiment in operation, wherein FIG. 1 shows a partial cross section of the complete apparatus and FIG. 2 shows a side view. In as far as no reference is made to any of the figures, the following description applies to both figures.
The exemplary embodiment as shown in FIGS. 1 and 2 includes a conveyor nozzle 1 which, via a fluid connector 2 , is coupled to a fluid source (not illustrated here). The conveyor nozzle 1 contains a continuous guide duct 30 which is illustrated with dashed lines in FIGS. 1 and 2 . The guide duct 30 penetrates the conveyor nozzle 1 and, in this manner, forms an inlet on the upper end. The lower end of the guide duct 30 of the conveyor nozzle 1 opens into a stuffer box 3 . The stuffer box 3 is likewise illustrated with dashed lines in FIGS. 1 and 2 and configured in a housing 31 . The housing 31 , on its lower side, includes a plug outlet 4 which is connected to the stuffer box 3 in the interior of the housing 1 .
A processing unit 7 is disposed below the plug outlet 4 . The processing unit 7 includes a rotatable processing drum 8 which, via a drive shaft 16 , is connected to a rotational drive (not illustrated here).
As can be understood from the illustration in FIG. 1 , the processing drum 8 is configured as a hollow cylinder, the drum wall 9 of which includes a plurality of openings. The end sides of the processing drum 8 are closed and, via a suction duct 32 , coupled to a blower 17 .
The processing drum 8 is vertically oriented in relation to the drum axis, such that the drum wall 9 extends in the vertical direction from an upper end down to a lower end. The upper end of the drum wall 9 , at a short distance therefrom, is associated with the plug outlet 4 of the stuffer box 3 . The stuffer box 3 here is disposed axially parallel to the processing drum 8 in such a manner that a thread plug 6 is guided in a straight run between the plug outlet 4 of the stuffer box 3 and the circumference of the drum wall.
As can be seen from the illustration in FIG. 2 , the thread plug is only deflected after striking the circumference of the drum wall 9 , on account of the rotational movement of the drum wall 9 in the circumferential direction of the processing drum 8 . Here, temperature-control produced by the processing drum 8 already sets in. The thread plug 6 is deposited on the circumference of the drum wall 9 in multiple windings as the rotational movement on the drum wall 9 continues. Disintegration of the thread plug 6 to form a crimped thread 18 only takes place at the lower end of the drum wall 9 .
In the exemplary embodiment illustrated in FIGS. 1 and 2 , a filament bundle 5 is continuously conveyed by the conveyor nozzle I via a preferred hot fluid, for example heated compressed air, into the stuffer box 3 and there stuffed to form a thread plug 6 . For the purpose of further temperature control and setting of the crimp in the filaments, the thread plug 6 is subsequently directly infed into the processing unit 7 . In this exemplary embodiment the processing unit 7 has cooling air as a temperature-control means. To this end, the blower 17 produces negative pressure in the interior of the processing drum 8 , such that a suction flow from the outside to the inside is produced via the gas-permeable drum wall 9 . For temperature control, in particular for cooling the thread plug 6 , ambient air is used in this exemplary embodiment. By way of the suction flow, a positive grip of the windings of the thread plug 6 on the circumference of the drum wall 9 is simultaneously achieved.
In the exemplary embodiment illustrated in FIGS. 1 and 2 , the flow of cooling air is used for temperature control as well as for providing a grip for the thread plug on the circumference of the drum wall 9 . In order to be able to use the cooling air exclusively for temperature control, a further exemplary embodiment of the crimping apparatus according to the invention is shown in FIG. 3 . The exemplary embodiment as shown in FIG. 3 is substantially identical to the exemplary embodiment as shown in FIG. 1 , such that only points of differentiation will be explained in the following and reference is otherwise made to the aforementioned description.
For guiding the thread plug on the circumference of the drum wall 9 , the processing drum 8 is associated with an outer cylinder 10 . The outer cylinder 10 includes a gas-permeable cylinder wall 11 which is implemented in an enclosing manner, having a small spacing in relation to the drum wall 9 . An annular chamber 12 for receiving the thread plug 6 is formed between the drum wall 9 and the cylinder wall 11 . The annular chamber 12 , on the upper end of the processing drum 8 , includes an inlet opening 13 and, on the lower end of the processing drum 8 , includes an outlet opening 14 . The inlet opening 13 is associated with a segment-shaped holding-down element 15 which acts on the windings of the thread plug 6 that have been deposited in the annular chamber 12 . The outer cylinder 10 is rotatably held by way of a bearing unit 19 on an upper support 20 .
The processing drum 8 and the stuffer box 3 and the conveyor nozzle 1 are implemented in an identical manner to the aforementioned exemplary embodiment as shown in FIG. 1 , such that no further explanation is offered at this point in order to avoid any repetition.
In the exemplary embodiment illustrated in FIG. 3 , the thread plug 6 is guided in a straight run from the plug outlet 4 of the stuffer box 3 into the annular chamber 12 on the circumference of the drum wall 9 . Setting of the windings of the thread plug on the circumference of the drum wall 9 here is substantially handled by the cylinder wall 11 of the outer cylinder 10 . The outer cylinder 10 here is driven via the processing drum 8 in the same direction of rotation. For temperature control, positive pressure is produced via the blower 17 in the interior of the processing drum 8 , such that a flow of cooling air permeates the windings of the thread plug 6 from the inside to the outside.
In the exemplary embodiment illustrated in FIG. 3 , the rotational drive of the outer cylinder 10 takes place via the driven processing drum 8 . To this end, it is necessary for the windings of the thread plugs that are guided in the annular chamber 12 to be used for transmission of rotation. In order to be able to perform guiding of the thread plugs that is as unencumbered as possible, a further exemplary embodiment of the crimping apparatus according to the invention is shown in FIG. 4 . In this exemplary embodiment of the crimping apparatus that is schematically shown in a cross-sectional view, the outer cylinder includes a dedicated rotational drive, such that both the drum wall 9 and the cylinder wall 11 are drivable in the same direction of rotation.
The exemplary embodiment in FIG. 4 includes a conveyor nozzle 1 and a stuffer box 3 which are implemented in an identical manner to the aforementioned exemplary embodiments.
The processing unit 7 in this exemplary embodiment is disposed between an upper support 20 and a lower support 21 . The lower support 21 supports a processing drum 8 which has a cup-shaped drum wall 9 . The drum wall 9 is associated with an inner annulet 22 which, on the circumference, has a plurality of fluid ducts 23 . The fluid ducts 23 may be helically configured so as to be one groove or so as to be a plurality of grooves having connecting grooves. The fluid ducts 23 are coupled to a fluid infeed (not illustrated here). A temperature-controlled fluid, preferably a liquid, is guided within the fluid ducts 23 , such that the inside of the drum wall 9 is directly temperature controlled by way of the fluid.
The inner annulet 22 and the drum wall 9 are connected to the drive shaft 16 . The drive shaft 16 , on one free end, is coupled to an electric motor 27 via a rotational drive 25 .
On the upper support 20 , an outer cylinder 10 is rotatably held by way of a bearing unit 19 . The outer cylinder 10 , with one cylinder wall 11 , extends sleeve-like toward the drum wall 9 and, with the drum wall 9 , forms an annular chamber 12 . The annular chamber 12 includes an upper inlet opening 13 and a lower outlet opening 14 . The inlet opening 13 , over part of the circumference, is covered by a holding-down element 15 . To this end, the holding-down element 15 is held in the upper region of the annular chamber 12 .
A rotational drive 24 which is coupled to the electric motor 27 acts on the circumference of the outer cylinder 10 . In this exemplary embodiment, the rotational drive 24 is formed by an encircling crown gear 33 and a gear wheel 34 which is held on a motor shaft 26 .
The rotational drive 25 of the processing drum 8 is formed by a gear pair 35 which connects the drive shaft 11 with the motor shaft 26 . To this end, the motor shaft 26 extends axially parallel to the processing drum 8 . The electric motor 27 is disposed on the upper support 20 and directly coupled to the motor shaft 26 .
The rotational drives 24 and 25 are adapted in such a manner that, when rotating the motor shaft 26 , the cylinder wall 11 of the outer cylinder 10 and the drum wall 9 of the processing drum 8 can be operated without any speed differential. In this manner slippage-free guiding of the windings of the thread plug within the annular chamber 12 is possible.
For temperature control, a heating radiator 28 which enables temperature control, in this case being heating of the thread plug, in the region of the outlet opening 14 of the annular chamber 12 is associated with the lower end of the cylinder wall 11 on the lower support 21 . Thermal post-processing of this type may facilitate in particular setting of the crimp in the filaments.
The function of the exemplary embodiment as shown in FIG. 4 is substantially identical to that of the exemplary embodiment as shown in FIG. 3 . However, the exemplary embodiment as shown in FIG. 4 is particularly suited to performing crimping at comparatively high speeds. On account of the synchronous drive in the drum wall 9 and the cylinder wall 11 gentle plug processing is also possible in the case of comparatively high speeds.
The exemplary embodiments illustrated in FIGS. 3 and 4 include in each case an annular chamber 12 on the circumference of the processing drum 8 that is substantially formed by walls 9 and 11 which run parallel to one another. However, there is, in principle, also the possibility of configuring the annular chamber 12 having variable chamber cross sections on the circumference of the processing drum 8 .
A further exemplary embodiment of the crimping apparatus according to the invention is shown schematically in FIG. 5 by means of a detail of a cross-sectional view of the processing unit 7 . In the exemplary embodiment illustrated in FIG. 5 of the processing unit 7 , on the circumference of the processing drum 8 an annular chamber 12 is formed between the drum wall 9 and the cylinder wall 11 of the outer cylinder 10 . The cylinder wall 11 of the outer cylinder 10 here is configured so as to be a slightly truncated cone, such that a chamber cross section in the annular chamber 12 that tapers off in the axial direction is established. The annular chamber, in the region of the inlet opening 13 , includes a chamber cross section which is preferably larger than a diameter of the thread plug 6 . On the lower end of the outer cylinder 10 the annular chamber 12 preferably includes a chamber cross section which is smaller than the diameter of the thread plug. In this manner, it is possible, in particular, to perform a setting which is required for the disintegration of the thread plug.
It may be furthermore derived from the illustration in FIG. 5 that the drum wall 9 and the cylinder wall 11 include in each case a plurality of fluid ducts 23 which in each case guide a temperature-controlled fluid for temperature control of the walls 9 and 11 . The possibility also exists here for the fluid ducts to be subdivided into a plurality of zones such that, for example, cooling of the thread plug sets in in an upper region of the annular chamber and heating of the thread plug sets in in a lower region of the annular chamber.
The exemplary embodiment illustrated in FIG. 5 moreover offers the particular advantage that the windings of the thread plug 6 are guided on a smooth drum wall 9 and a smooth cylinder wall 11 . In this manner, undesirable drawing-in of individual filaments into sleeve openings is not possible. To this extent, the exemplary embodiment as per FIG. 5 is, in particular, particularly suited to yarns having fine counts.
REFERENCE LIST
1 Conveyor nozzle
2 Fluid connector
3 Stuffer box
4 Plug outlet
5 Filament bundle
6 Thread plug
7 Processing unit
8 Processing drum
9 Drum wall
10 Outer cylinder
11 Cylinder wall
12 Annular chamber
13 Inlet opening
14 Outlet opening
15 Holding-down element
16 Drive shaft
17 Blower
18 Thread
19 Bearing unit
20 Upper support
21 Lower support
22 Inner annulet
23 Fluid ducts
24 Rotational drive of outer cylinder
25 Rotational drive of processing drum
26 Motor shaft
27 Electric motor
28 Heating radiator
29 Bearing
30 Guide duct
31 Housing
32 Suction duct
33 Crown gear
34 Gear wheel
35 Gear pair
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A crimping apparatus for crimping a filament bundle in a melt spinning process includes a conveyor nozzle and a stuffer box which is associated with the conveyor nozzle. For thermal processing, a processing unit, which includes a rotatable processing drum which, for guiding and temperature control of a thread plug, has a rotating drum wall, is disposed downstream of the stuffer box. In order to be able to carry out as gentle a processing of the thread plug as possible, the stuffer box is disposed axially parallel to the processing drum in such a manner that the thread plug can be infed in a straight run from a plug outlet of the stuffer box to the circumference of the drum wall. This allows the naturally acting weight force of the thread plug to be advantageously used for guiding the thread plug.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to flow meters for use in fuel dispensing environments. More particularly, the invention relates to an inferential flow meter adapted to have enhanced accuracy when pulsations occur in the flow.
[0002] Inferential flow meters, e.g., a turbine flow meter, may be used in a variety of applications in fuel dispensing environments. For example, turbine flow meters are often used to meter fuel being dispensed, measure the vapor being returned to the underground storage tank in a stage two vapor recovery fuel dispenser, or measure the vapor or air released to atmosphere from the ullage area of an underground storage tank when a pressure relief valve in a vent stack is opened to relieve pressure.
[0003] Turbine flow meters generally comprise a housing having inlet and outlet ports at respective ends thereof. A shaft is located inside the housing along the housing's longitudinal axis. One or more turbine rotors mounted on the shaft rotate when fluid (liquid or gas) flows through the housing via the inlet and outlet ports. A detector is typically mounted to the housing to detect rotation of one or both of the rotors. For example, the detector may be a hall effect device or pickup coil that determines rotation based on changes in a magnetic field. The detector is associated with a “pulser” that produces a series of pulses at a rate which is related to the flow rate of fluid through the meter. As such, the flow rate of the fluid flowing through the housing can be determined.
[0004] Various events—such as the operation of submersible turbine pump (STP) motors, the operation of valves in the fuel flow path, or nozzle snaps—can cause substantial flow pulsations. Nozzle snaps, for example, occur when the nozzle is suddenly closed by the customer, or by a valve within the nozzle that automatically closes when the customer's fuel tank is full. These flow pulsations create transients that flow back and forth quickly through the entire hydraulic system for a few seconds. As the pulsations travel through the meter, the instantaneous speed of the turbine rotor(s) varies momentarily in response to the fluid perturbation.
[0005] Meters known in the art calculate fluid flow rates based on counting the number of pulses during a programmable time window. The number of pulses is divided by the time window to derive pulses per unit of time. Calculating an average in this manner filters out instantaneous speed variations. As a result, errors in viscosity calculation and flow rate can occur.
[0006] Various turbine meters of the prior art are shown and described in U.S. Pat. Nos. 7,028,561, 6,854,342, 6,692,535 and 5,689,071. Each of these patents is incorporated herein by reference in its entirety.
[0007] Those skilled in the art will appreciate the scope of the present invention and realize additional aspects thereof after reading the following detailed description of the preferred embodiments in association with the accompanying drawing figures.
SUMMARY OF THE INVENTION
[0008] According to one aspect, the present invention provides an apparatus for measuring fluid flow comprising an inferential flow meter having a housing defining a fluid flow path. A pulser is operative to produce an output signal indicative of flow rate through the meter. The apparatus further includes a controller in electronic communication with the pulser so as to receive the output signal. Based on the output signal, the controller is operative to determine fluid flow in a plurality of dynamic time sub-windows corresponding to respective periods of substantially consistent instantaneous flow.
[0009] In many exemplary embodiments, the output signal of the pulser comprises a pulse train in which pulse frequency varies with instantaneous flow. The dynamic time sub-windows may thus be ascertained by comparing duration between adjacent pulses. For example, the controller may be operative to include a series of adjacent pulses in one of the dynamic time sub-windows if respective durations therebetween are within a threshold of each other. Preferably, the controller may calculate a total delivered volume within a longer time period by determining and summing together partial delivered volume during respective dynamic time sub-windows making up the longer time period.
[0010] Another aspect of the present invention provides an apparatus for measuring fluid flow comprising a turbine flow meter having a rotor. A pulser is operative to produce a pulse train in which pulse rate varies with instantaneous flow through the turbine flow meter. A controller operative to determine a total volume of fluid passing through the turbine flow meter during a time period is also provided.
[0011] The controller is configured to perform the steps of: (a) determining a first partial volume based on a first pulse rate during a first time sub-window; (b) determining a second partial volume based on a second pulse rate during a second time sub-window; and (c) adding the first partial volume and the second partial volume. Preferably, the first and second time sub-windows may be dynamically determined corresponding to respective periods in which the first and second pulse rates remain substantially consistent. For example, substantial consistency may be determined by ascertaining whether the first and second pulse rates remain consistent within a predetermined threshold during the first and second time sub-windows, respectively. Pulse rates within each of the time sub-windows may be averaged during determination of the first and second partial volumes to filter out spurious variations.
[0012] According to another aspect, the present invention provides a method of determining flow of a fluid through an inferential flow meter. One step of the method involves detecting a pulse train having a plurality of pulses occurring at a pulse rate indicative of fluid flow rate through the inferential flow meter. Pulse rates of the plurality of pulses are determined. Another step of the method involves grouping adjacent pulses having substantially consistent pulse rates into a plurality of time sub-windows. Respective partial volumes for each of the time sub-windows are also determined. The respective partial volumes are added to determine a total delivered volume.
[0013] A further aspect of the present invention provides a fuel dispenser comprising a fluid flow conduit for delivering fuel from a storage tank. A hose having a proximal end and a distal end is also provided. The proximal end of the hose is in fluid communication with the fluid flow conduit. A nozzle is connected to the distal end of the hose. An inferential flow meter is located in line with the fluid flow conduit. A pulser associated with the inferential flow meter produces an output signal indicative of flow rate through the inferential flow meter.
[0014] The fuel dispenser further comprises a controller in electronic communication with the pulser so as to receive the output signal. Based on the output signal, the controller is operative to determine fluid flow in a plurality of dynamic time sub-windows corresponding to respective periods of substantially consistent instantaneous flow.
[0015] Other objects, features and aspects of the present invention are provided by various combinations and subcombinations of the disclosed elements, as well as methods of practicing same, which are discussed in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings, in which:
[0017] FIG. 1 is a schematic diagram of a fuel dispenser for fueling vehicles that may utilize one or more turbine flow meter constructed in accordance with the present invention;
[0018] FIG. 2 is a diagrammatic perspective view of a turbine flow meter constructed in accordance with an embodiment of the present invention;
[0019] FIG. 3 is an illustration of a flow pattern of a turbine flow meter constructed in accordance with the embodiment of FIG. 2 ;
[0020] FIG. 4 is a graph illustrating a pulse train output by a turbine flow meter during the presence of flow pulsations and the corresponding fluid flow rate;
[0021] FIG. 5 is a graph illustrating dynamic time windows that may be utilized to measure accurately the time-varying flow rate illustrated in FIG. 4 ; and
[0022] FIG. 6 is a flowchart illustrating a process for determining flow volume in accordance with the present invention.
[0023] 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
[0024] It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions.
[0025] FIG. 1 illustrates a pair of turbine flow meters 10 A and 10 B utilized in a fuel dispenser 40 . As is well-known, a fuel dispenser such as fuel dispenser 40 is used to dispense and measure the amount of fuel being delivered to a vehicle (not shown). Accurate meters are required to measure fuel dispensing to comply with Weights & Measures regulatory requirements.
[0026] Fuel dispenser 40 may be a blending type fuel dispenser wherein a low-octane fuel 41 stored in a low-octane underground storage tank (UST) 42 and a high-octane fuel 43 stored in a high-octane underground storage tank (UST) 44 are blended together by fuel dispenser 40 to deliver either a low-octane fuel 41 , high-octane fuel 43 , or a mixture of both to a vehicle. Low-octane fuel 41 is supplied to fuel dispenser 40 through a low-octane fuel supply conduit 46 . Likewise, high-octane fuel 43 is delivered to fuel dispenser 40 through a high-octane fuel supply conduit 48 . Both low-octane fuel 41 and high-octane fuel 43 pass through fuel dispenser 40 in their own independent flow paths. Each fuel 41 , 43 encounters a valve 50 , 52 that controls whether the fuel is allowed to enter into fuel dispenser 40 , and if so at what flow rate.
[0027] As either low-octane fuel 41 , high-octane fuel 43 , or both pass through their respective turbine meters 10 A, 10 B, the fuels come together in the blend manifold 54 to be delivered through a hose 56 and nozzle 58 into the vehicle. Valves 50 , 52 may be proportionally controlled and may be under the control of a controller 60 in fuel dispenser 40 via control lines 62 , 64 . U.S. Pat. No. 4,876,653 entitled “Programmable Multiple Blender,” incorporated herein by reference in its entirety, describes a system for blending low and high octane fuels.
[0028] Controller 60 determines when a fueling operation is allowed to begin. Typically, a customer is required to push a start button 78 and to indicate which grade of fuel 41 , 43 is desired. Controller 60 thereafter controls valves 50 , 52 to allow low-octane fuel 41 or high-octane fuel 43 to be dispensed, depending on the type of fuel selected by the customer.
[0029] After fuel 41 , 43 passes through both valves 50 , 52 , it flows through the associated one of turbine meters 10 A, 10 B. If only a low-octane fuel 41 or high-octane fuel 43 was selected by the customer to be dispensed, controller 60 would only open one of the valves 50 , 52 . As fuels 41 , 43 flow through turbine meters 10 A, 10 B, the respective pulsers will produce a corresponding pulser signal 66 , 68 that is input into controller 60 .
[0030] Controller 60 determines the quantity of flow of fuel flowing through turbine meters 10 A, 10 B for the purpose of determining the amount to charge the customer. In this regard, controller 60 uses the data from the pulser signals 66 , 68 to generate a totals display 70 . Totals display 70 includes an amount to be charged to the customer display 72 , gallons (or liters) dispensed display 74 and the price per unit of fuel display 76 . As one skilled in the art will appreciate, controller 60 may be implemented in various combinations of hardware, firmware, or software, as necessary or appropriate.
[0031] In other embodiments, a turbine meter of the present invention may be used in a vent stack of an underground storage tank at a service station. Specifically, it may be desirable to measure the amount of air flowing through a vent stack using meter 10 to determine how often and how much air is separated by a membrane and released to atmosphere for any number of diagnostic or information purposes. The membrane may either permeate hydrocarbons or permeate oxygen or air as disclosed in U.S. Pat. Nos. 5,464,466 and 5,985,002, incorporated herein by reference in their entirety. In other embodiments, meter 10 may measure the amount of vapor being returned to the underground storage tank in a stage two vapor recovery system.
[0032] FIG. 2 illustrates a turbine flow meter 10 constructed in accordance with an embodiment of the present invention. Meter 10 includes a housing 12 that forms an inlet port 14 and an outlet port 16 for ingress and egress of fluid (liquid or gas), respectively. A shaft 18 or other support structure is located inside of housing 12 along a central axis A. In this embodiment, a pair of turbine rotors 20 and 21 that rotate in a plane perpendicular to axis A are located at selected axial positions on shaft 18 . For example, shaft 18 may be stationary but supports rotors 20 and 21 for rotation. Generally, a bearing set will be interposed between each of the rotors and the shaft 18 to facilitate the respective rotor's rotation.
[0033] Referring now also to FIG. 3 , rotor 20 is located slightly upstream of rotor 21 , and serves to condition the flow to rotor 21 . In particular, rotor 20 includes one or more vanes 22 (also known as blades) that cause rotation when impinged by the flowing fluid. Similarly, rotor 21 includes one or more vanes 23 . Vanes 22 and 23 are preferably spaced evenly around the periphery of the respective rotor hub. In addition, vanes 22 of rotor 20 are preferably canted oppositely from vanes 23 of rotor 21 . This orientation of vanes 22 and 23 causes the two rotors to rotate in opposite directions (shown by arrows 32 and 36 ) at a rotational speed indicative of the fluid flow rate.
[0034] Because vanes 22 are canted, the straight fluid flow is converted into a generally swirling pattern with an angular trajectory based on angle 27 of vanes 22 . This angular trajectory is generally oblique to the longitudinal axis of meter 10 (shown as “A”). After passing through rotor 20 , the fluid impinges vanes 23 of rotor 21 . The angular trajectory of the flow due to rotor 20 increases the material's angle of incidence with vanes 23 . As a result, the driving force used to impart rotational movement on turbine rotor 21 also increases. This facilitates rotation of rotor 21 at lower flow rates than may otherwise be the case.
[0035] As can be seen in FIG. 2 , a detector 30 is located on housing 12 adjacent to rotor 21 . The output of detector 30 is provided to a pulser 32 which produces a serial pulse train used by the controller to determine flow rate and thus amount of fluid dispensed. Any suitable detector may be utilized, such as a magnetic detector. Examples of typical magnetic detectors that have been used in turbine flow meters are pickup coils and hall effect sensors. In either case, rotation of rotor 21 produces a characteristic signal which is used to generate the pulse train output of pulser 32 . As one skilled in the art will appreciate, housing 12 should be formed of a nonmagnetic material if a magnetic sensor is used. In contrast, rotor 21 should be formed wholly or partly of a magnetic material. While detector 30 is shown adjacent to rotor 21 in this case, embodiments are contemplated in which the detector is located adjacent to a separate encoder wheel which rotates with the rotor.
[0036] FIG. 4 shows the relationship between flow rate 100 and the frequency of pulses produced by pulser 32 . In this regard, pulser 32 produces a pulse train 102 comprised of individual pulses 104 will be output from pulser 32 . As can be seen, pulses 104 occur at a frequency related to the fluid flow rate. As indicated at 106 , the frequency of pulses 104 increases during times of high flow rate. Conversely, as indicated at 108 , the frequency of pulses 104 decreases as the flow rate decreases.
[0037] During times of flow pulsations or other perturbations, the frequency of pulses 104 may fluctuate quite rapidly. If the pulse rate is averaged over a time window without regard to instantaneous speed variations, then errors can occur in determining viscosity and flow rate. In contrast, controller 60 preferably determines the volumetric of fluid flow through the meter based on the instantaneous flow rate as determined by meter 10 . In particular, preferred embodiments of the present invention calculate a series of instantaneous flow rates as dynamic sub-windows based upon rotor pulse duration. The series is then summed over a period of time to yield an improved volumetric flow calculation. Preferably, there may be some filtering within each sub-window filter out spurious variations.
[0038] FIG. 5 illustrates one manner in which dynamic sub-windows can be created to determine volumetric in accordance with the present invention. Once the flow rate changes, either quickly due to a flow pulsation or slowly, the frequency of pulses 104 in pulse train 102 delivered to controller 60 by pulser 32 will also change. When controller 60 detects a frequency change in the pulse train, a new time window is created that captures all of pulses 104 at or near the new frequency. The new frequency is translated to a flow rate by controller 60 and multiplied by the amount of time the fluid was flowing at that rate. The volumetric flow at this new rate is then added to the previously calculated volumetric flow to ascertain the total flow through meter 10 .
[0039] Therefore, depending on how often the fluid flow rate changes and the number of flow pulsations, the dynamic time windows can be of varying widths (durations). The process of determining the volumetric flow during a particular time window and adding that volume to the previously computed volume is repeated as long as fluid is flowing through meter 10 . For example, FIG. 5 shows a situation in which three dynamic windows (or “sub-windows”) 110 , 112 , 114 are created based on the varying flow rate. As can be seen, time windows 110 , 112 and 113 capture the first, second, and third set of similar frequency pulses, respectively. The width (i.e., time duration) of each time window is variant to more fully capture the variations in flow rate that can occur (such as due to flow pulsations) as the fuel is dispensed.
[0040] In a preferred embodiment, dynamic time windows may include pulses of slightly differing frequencies. Within the particular sub-window, the pulse rates are averaged to filter out spurious variations such as may occur due to data acquisition errors. If the variation in pulse frequency from one pulse to the next exceeds a given threshold, however, controller 60 generates a new time window.
[0041] FIG. 6 illustrates a preferred process that may be performed by controller 60 in accordance with the present invention. The process begins as indicated at 120 . As indicated at 122 and 124 , the process then detects successive pulses P and P+1. As indicated at 126 , the duration between P and P+1 is then compared to the duration between P and the pulse before it. If the difference exceeds a certain threshold, a decision is made (as indicated at 128 ) to begin a new sub-window (as indicated at 130 ). If not, the same sub-window is continued (as indicated at 132 ). Within each sub-window, the pulse durations are preferably averaged (as indicated as 134 ) to filter out spurious variations.
[0042] Delivered volume for a specified time period can then be determined (as indicated at 136 ). Preferably, delivered volume will be calculated by determining the volume delivered during each sub-window making up the longer time period and adding them together. This can be expressed as:
[0000] Delivered volume=(DT 1 *FR 1 )+(DT 2 *FR 2 )+ . . . +(DT n *FR n ) Or generally:
[0000] Delivered volume=Sum(DT i *FR i ) Where:
DT=time duration of a sub-window FR=flow rate during a sub-window For sub-windows i=1 to n (total sub-windows in larger window)
[0048] It can thus be seen that the present invention provides an apparatus and method for achieving accurate determinations of delivered volume even in the presence of flow pulsations. While preferred embodiments of the invention have been shown and described, modifications and variations may be made thereto by those of ordinary skill in the art without departing from the spirit and scope of the present invention. For example, controller 60 may be separated from pulser 32 as illustrated above, or may in some cases be located adjacent to or incorporated into the pulser.
[0049] In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to be limitative of the invention as further described in the appended claims.
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An apparatus and method for measuring fluid flow comprising an inferential flow meter having a housing defining a fluid flow path. A pulser is operative to produce an output signal indicative of flow rate through the meter. The apparatus further includes a controller in electronic communication with the pulser so as to receive the output signal. Based on the output signal, the controller is operative to determine fluid flow in a plurality of dynamic time sub-windows corresponding to respective periods of substantially consistent instantaneous flow.
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BACKGROUND OF INVENTION
The present invention relates to a method and a device for cementing a well or a pipe, for example a casing, having a portion to be treated so as to make it leaktight, in particular to be repaired and/or plugged.
It applies more particularly, but not necessarily, to the field of oil production.
The casing is a metal tube which lines the interior of the oil well over a considerable length.
As an indication, this length is for example between 2000 and 4500 meters, whereas its internal diameter is between 120 and 200 millimeters.
In the lower part, the casing is perforated at the level of the deposit(s) that it passes through, so as to allow the passage of oil or a gaseous hydrocarbon.
Located in the upper part of the well is the wellhead, which is equipped with various systems, in particular for protection, suspension and sealing purposes.
Over a considerable length of the upper part of the well, for example between 1500 and 4000 meters, the casing is provided internally with completion equipment comprising a tube and various devices serving for exploitation of the well, such as temporary plugs and safety valves for example.
Over time, a portion of the wall of the casing may have to be sealed, in particular if has deteriorated, for example due to premature wear and/or cracking, or when the perforations intended for the passage of oil have to be plugged, in particular because the deposit has been depleted in this zone and undesirable fluid products (in particular water or gas) risk passing through the wall of the casing and penetrating into the latter.
For this purpose, said portion is treated by coating it internally with a protective material, in particular a cement, a gel or a composite material based on polymerisable resin.
In order to carry out this treatment, two different techniques may be used:
either the completion equipment is removed beforehand and it is then possible to gain direct access to the portion of the casing to be treated, or the tools and the material used for cementing purposes are passed through the completion equipment.
The first technique is time-consuming and expensive and may cause exploitation problems, in particular due to the fact that it is necessary to completely neutralise the well prior to any intervention.
The second technique is complicated, expensive and can be used only in a certain limited number of configurations, due to the fact that the completion equipment generally has a much smaller diameter than that of the lower zone of the casing in which the portion to be treated is located.
In particular, the installation of a cement coating is generally not possible using this technique.
The invention aims to overcome these difficulties by proposing a method and a device which make it possible to cement the lower zone of the casing while passing through the completion equipment of smaller diameter.
The invention can be applied not only to a casing as described above, but also to any hollow well in the ground or to any pipe, buried or otherwise, and for this reason the description and the claims which will follow refer to the cementing of a well or a pipe, the latter being able to be a casing or any other conduit, vertical, horizontal or oblique.
SUMMARY OF THE INVENTION
The subject matter of the invention is therefore a method for cementing a well or a pipe, for example a casing, having a portion to be treated, in particular to be repaired and/or plugged.
According to this method:
a) a tubular mandrel is introduced into the well or pipe, around which mandrel there is mounted an inflatable membrane which is also tubular and is made of a flexible and elastic material which can expand radially under the effect of an internal pressure, and this assembly is positioned opposite the portion to be cemented;
b) a pressurised fluid is introduced into the membrane and the latter is inflated in such a way that, on the one hand, its end zones dilate radially and considerably, forming annular beads which are applied firmly against the wall of the well or pipe, on either side of the portion to be cemented, and that, on the other hand, its zone—referred to as the median zone—located between its end zones also dilates radially, but with a lesser amplitude, so that an annular space is formed between this median zone and the portion of wall to be cemented;
c) while the membrane is kept inflated, a liquid but curable cement is injected into this annular space;
d) the cement is left to set so that it forms a solid sleeve which internally coats said wall portion of the well or pipe;
e) the tubular membrane is deflated;
f) the assembly consisting of the mandrel and the deflated membrane is withdrawn from the well or pipe.
The device for cementing a well or a pipe, for example a casing, having a portion to be treated, in particular to be repaired and/or plugged, which device also forms the subject matter of the invention, is characterised in that it comprises an assembly which is designed to be introduced into the well or pipe and to be positioned opposite the portion to be cemented, this assembly consisting of a tubular mandrel and an inflatable membrane which is also tubular and surrounds said mandrel, the wall of the membrane being made of a flexible and elastic material which can expand radially under the effect of an internal pressure, means being provided for introducing a pressurised fluid into said membrane in order to inflate it, and in that the end zones of said membrane are able to dilate radially and considerably in such a way as to form annular beads which can be applied firmly against the wall of the well or pipe, on either side of the portion to be cemented, and that, on the other hand, its zone—referred to as the median zone—located between its end zones also dilates radially, but with a lesser amplitude, so that an annular space is formed between this median zone and the portion of wall to be cemented, this device additionally comprising means for injecting a liquid but curable cement into this annular space while the membrane is kept inflated, and means for deflating said membrane once the cement has set.
Furthermore, according to a certain number of advantageous, but non-limiting, features of this device:
said tubular membrane is secured to said mandrel by an annular part—referred to as the anchoring part—which is radially non-extendable and is located within said median zone, whereas its end zones are fixed to movable rings which are guided in translation in a sealed manner on the mandrel and can slide axially on the latter as a result of the inflation or deflation of said membrane; the median zone of said membrane is provided with means capable of limiting its radial expansion to a predetermined maximum diameter; said membrane is reinforced by an armature comprising at least one ply of cables, wires or fibres wound helically with respect to its longitudinal central axis; in said median zone, the initial angle formed tangentially by said cables, wires or fibres with respect to the longitudinal central axis of the membrane is such that, after inflation, the diameter of the membrane reaches a predetermined given value when this angle reaches a value of around 54°; the transition between the anchoring part of the membrane and the portions of its median zone with limited radial expansion takes place by means of portions, referred to as “portions adjacent to the anchoring part”, which are able to deform under the effect of the inflation so as to be placed in planes which are substantially perpendicular to the longitudinal central axis of the membrane; the initial angles of inclination (before inflation of the membrane) of the cables, wires or fibres with respect to the longitudinal central axis of the membrane have approximately the following values: of around 18° to 25° in the end zones of the membrane; of around 35° to 45° in its median zone, except in the portions adjacent to the anchoring part; of 0° in the portions adjacent to the anchoring part; said membrane is reinforced by an armature comprising several plies of wires or fibres wound helically with respect to its longitudinal central axis, the directions of winding of the two superposed plies being reversed; the portions adjacent to the anchoring part are grooved, each of these portions having at least one groove located in the axial extension of a similar groove formed in the other portion, so that, after inflation of the membrane, they form a channel for injection of the cement, this injection taking place through at least supply orifices penetrating the tubular mandrel and the anchoring part, via a suitable valve; the wall of the mandrel is penetrated by inlet orifices for an inflation fluid, which orifices open into the interior of the membrane between said movable rings and said anchoring part; the wall of the membrane is grooved externally at its end zones, so as to allow the evacuation of the fluid present in the well or pipe during inflation; said membrane is covered with a thin-walled sleeve which is made of a flexible and elastic material and which can be pressed against the portion of wall to be cemented when the cement is injected into the annular space formed between the median zone of the membrane and the portion of wall to be cemented; said sleeve is able to inflate, increasing in volume in the direction of its thickness, when it is in contact with the liquid present in the well or pipe, so as to ensure good sealing with the zone of the well to be sealed; the device comprises means so that one of the two annular end beads is applied against the wall of the well or pipe before the other end bead.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will become apparent from the description which will now be given thereof, with reference to the appended drawings, in which:
FIGS. 1 and 2 show, in a highly schematic manner and in axial section, part of an oil well respectively before and after cementing of a damaged portion.
FIGS. 3 and 4 are schematic views of a device according to the invention, in the non-inflated state, respectively in axial section and in front view.
FIGS. 5A and 5B show the same device after inflation, FIG. 5A being an axial half-section and FIG. 5B being a front half-view.
FIGS. 6A and 6B are diagrams of the same device which are intended to show the orientations of the wires or fibres of the armature of the membrane, before ( FIG. 6A ) and after ( FIG. 6B ) the inflation.
FIG. 7 is a cross section of the device in the plane VII-VII of FIGS. 5A and 5B .
FIGS. 8A and 8B are diagrams which show the change in orientation of the wires or fibres of two adjacent plies as a result of the inflation.
FIGS. 9 to 14 illustrate various steps of the method. In these figures, the longitudinal axis of the well or pipe (and therefore of the device) has been shown horizontally in order to facilitate the page layout of the drawings; this axis could of course be vertical, as in FIGS. 1 and 2 .
DETAILED DESCRIPTION
FIG. 1 shows part of an oil drilling well, lined with a casing C with a cylindrical wall and of vertical axis X-X′. A portion Z of this casing has for example perforations p, producing water, which it is desired to plug by means of cementing.
Reference EC denotes completion equipment, held in place by an annular centring element A, and the internal diameter d of which is much smaller than the diameter D 0 of the casing.
By way of example, the diameter d is around 69 mm whereas the diameter D 0 is around 155 mm.
FIG. 2 shows the same well part after installing a cement coating GC in the portion Z.
In order not to disrupt exploitation of the well, it is important that the internal diameter D of this coating is greater than d.
It will be understood that this installation usually poses difficulties when it takes place through the completion equipment EC.
As will now be explained, the invention nevertheless makes it possible to carry out this procedure easily.
The device of the invention which is shown in FIGS. 3 to 7 essentially comprises a cylindrical tubular mandrel 1 , of axis X-X′, for example made of steel, which is covered with a similarly cylindrical membrane 2 , in the form of a sleeve, made of a flexible and elastic material which is resistant to pressure and corrosion, for example rubber or elastomer.
At rest ( FIGS. 3 and 4 ), the membrane surrounds the mandrel without play, or even with a slight clamping action.
The mandrel has a closed free end 100 .
Only the end portion of the mandrel carrying the membrane is shown. This mandrel is mounted at the end of a rod of considerable length (located towards the right in FIGS. 3 and 4 ), which passes into the tube of the completion equipment EC, and meets the wellhead.
The overall diameter of the assembly consisting of the mandrel and the membrane is slightly smaller than the internal diameter d of the completion equipment EC, so that it can pass through the latter in the axial direction.
Its length is selected as a function of that of the zone Z to be treated; it is a few meters for example.
In its end zones 20 a , 20 b , the membrane 2 is fixed, for example by glueing, to rings 4 a and respectively 4 b which are guided in axial translation on the mandrel 1 .
Between the end zones 20 a , 20 b , and markedly closer to the zone 20 b than to the zone 20 a in the embodiment shown, a zone 21 of the membrane is directly fixed around the mandrel by a thin annular part of small length, referred to as the anchoring part. This fixing is carried out for example by means of a small clamping ring which is embedded in the membrane (and is not shown), supplemented by glueing.
The zone 21 is grooved longitudinally; in the example shown, four identical grooves 6 are provided which are spaced apart by 90° with respect to the axis X-X′ and have a semi-circular cross section.
Their centre is located at the aforementioned anchoring part, from which “half-grooves”, referenced 6 a and 6 b , therefore depart.
At the anchoring part, the mandrel is pierced by four radial orifices 10 which each open, via corresponding perforations 60 provided in the wall of the membrane, into the centre of a groove 6 .
Over a certain length, denoted Pa, Pb in FIG. 4 , of each connection zone 20 a and respectively 20 b of the membrane with the rings 4 a and 4 b , the tubular membrane is able, as will be seen below, to dilate radially with a relatively great amplitude, under the effect of an internal pressure.
On one side (on the right of the figure), this part—which will be referred to overall as the “end zone”—connects the zone 20 b to the zone 21 , the length of which is referenced R.
On the other side, an intermediate part—referred to as the “median zone”—is placed between the zone 20 a and the zone 21 .
This median zone has a length Q which is substantially equal to, or slightly greater than, that of the portion to be cemented.
The end zones are provided with peripheral grooves 22 a , 22 b.
On each side of the anchoring part of the membrane, the mandrel 1 is pierced by a certain number of orifices 11 a and 11 b which are similar to the aforementioned orifices 10 .
The opening and closing of the orifices 10 and 11 a , 11 b is controlled by suitable valves W and respectively Va, Vb.
The membrane 2 is partially covered by a sleeve 5 made of a flexible and thin material, for example rubber, which connects the end zones and terminates more or less in the middle of the grooves 22 a and 22 b (see FIG. 3 ). This sleeve is assumed to have been removed in FIGS. 4 to 6 so as not to be detrimental to the legibility thereof.
The wall of the membrane 2 is reinforced by an inner armature 3 , embedded within its wall.
As known per se (see for example the document U.S. Pat. No. 5,695,008), this armature consists of several concentric plies (or layers) consisting of flexible wires or fibres with high mechanical strength, wound in a helical manner.
The directions of winding of two superposed plies are reversed so that the membrane deforms in a homogeneous manner, in particular without any twisting.
During the radial expansion of the membrane, the angle of inclination of the tangent to each fibre with respect to the longitudinal axis X-X′ gradually increases and may—as is also well known—reach an equilibrium value of 54°, beyond which expansion is no longer possible.
According to one feature of the invention, the angle of winding of the fibres or wires is not the same over the entire length of the membrane, as illustrated in FIG. 6 .
In the end zones of length Pa and Pb, the wires or fibres are referenced 90 a , respectively 90 b before inflation and 90 ′ a , respectively 90 ′ b after inflation. They form, with respect to the axis X-X′, an initial angle, referenced respectively α 0 and γ 0 , with a relatively low value. This value is determined taking account of the initial diameter of the membrane and the internal diameter of the wall of the casing, against which these zones have to bear after inflation.
It is therefore necessary for the angle α and respectively γ after inflation to be less than the limit angle of 54°.
In the intermediate median zone of length Q, in which the wires or fibres are referenced 91 before inflation and 91 ′ after inflation, the angle β 0 must have a value larger than the angles α 0 and γ 0 .
Its value is determined taking account of the initial diameter of the membrane and the internal diameter which the sheath of the cement coating must have after the operation.
This is because the radial expansion of this median zone must be limited upon inflation, and the angle of 54° must be reached before this zone bears against the wall of the casing, after a given amplitude of expansion, which will calibrate the peripheral space which is intended to receive the cement.
In practice, the value of the angles α 0 and γ 0 is for example around 18 to 25° and that of the angle β 0 is around 35 to 45°.
After inflation, the angles α and γ have a value of around 45° and the angle β is close to 54°.
In the grooved zone 21 of length R which extends on either side of the anchoring part, the fibres or wires of the armature, referenced 91 a and 91 b , are directed in the axial direction, thus forming a zero angle with respect to the axis X-X′. By virtue of this arrangement, the deformation upon inflation of this portion adjacent to the anchoring part is not hindered by the presence of the fibre or wire armature, even though the zones of the membrane located on either side of the anchoring part are placed in planes perpendicular to the axis X-X′ as a result of the inflation, moving closer to one another, as can be seen in FIGS. 5A , 5 B, 6 A, and 6 B.
The half-grooves 6 a and 6 b are thus arranged opposite one another, forming a radial channel 6 .
The orifices 10 are connected by means of a suitable conduit 80 to a source 8 for distributing a liquid but curable material L 2 , such as a cement loaded with short fibres, it being possible for this distribution to take place via a pump located in the wellhead or directly in the well from a suitable reservoir.
Similarly, the orifices 11 a and 11 b are connected by means of a suitable conduit 70 to a source 7 for distributing, at high pressure, a fluid L 1 , for example water, it also being possible for this distribution to take place via a pump located in the wellhead or directly in the well by using the fluid present therein. The orifices 11 a and 11 b are also connected to a source for aspirating 7 ′ the fluid L 1 , thus making it possible to deflate the membrane at the end of the operation.
Referring to FIGS. 9 to 14 , it will now be explained how the device that has just been described is used to cement a casing, according to the method of the invention.
With reference to FIG. 9 , the device is moved in the deflated state until it is opposite the portion Z of the casing C that is to be treated.
The membrane 2 is then inflated, after having brought about the opening of the valves Va and Vb (the valve W being closed), by introducing the pressurised fluid L 1 between said membrane and the outer wall of the mandrel 1 via the orifices 11 a and 11 b , as symbolised by the arrows f 1 in FIG. 10 . During the inflation, the end rings slide axially and move towards one another (arrows d 1 ) since the radial expansion of the membrane causes it to shorten in the axial direction.
Suitable retaining means, not shown, are advantageously provided so that one of the zones forming a bead, for example Pb, inflates fully before the other zone (for example Pa) so as to prevent any jamming of the device in the longitudinal direction during the inflation.
These means are for example frangible wires which are wound around these zones and can be broken at a given pressure, those surrounding the zone Pb being designed to break before those surrounding the zone Pa.
Another solution, for example, is to offset slightly over time the supply to the interior spaces in these zones, thus offsetting the opening of the valve Va with respect to that of the valve Vb.
The end zones form beads which are pressed firmly against the wall of the casing. On the other hand, since the median zone has a limited expansion due to the greater inclination of the wires or fibres of the armature, a peripheral annular space Σ remains at this location.
With reference to the diagram in FIG. 8A , it is possible to see, before inflation, two “crossed” series of fibres or wires 9 . 1 and respectively 9 . 2 belonging to two adjacent (superposed) plies of the armature 3 with which the median zone is provided.
At the end of inflation, shown in FIG. 8B , this armature—denoted 3 ′—has been deformed, the fibres or wires 9 . 1 ′ and 9 . 2 ′ of each of the two plies having a modified inclination, so as to form an angle of around 54° with respect to X-X′.
The two portions adjacent to the anchoring part, for their part, are placed in transverse planes and are pressed against one another.
Of course, the connections between the different zones take place in a gradual manner, due to the flexibility and elasticity of the membrane and also a gradual change in the angles of the fibres, and not via sharp angles.
Once the membrane has inflated, the valves Va and Vb are closed in order to keep the membrane in this state.
It then forms a type of counter-mould, or coffer, for moulding the cement.
The valves W are then opened and the liquid cement L 2 is introduced, via the orifices 10 and the channels 6 in the peripheral space Z, into the sleeve 5 . The latter is then inflated in turn, chasing away the liquid present in the well, for example sludge, which is located in the space Z. This liquid can escape via the grooves 22 a , 22 b provided for this purpose in the end zones of the wall, which form beads.
This escape is symbolised by the arrows e in FIG. 11 .
Thus, as shown in FIG. 12 , the liquid cement L 2 finally fills the entire space Z, with the sleeve 5 being pressed against the casing.
The valves W are then closed and the cement is left to set.
Once it has sufficiently hardened, the membrane is deflated by aspirating the inflation fluid L 1 (arrows f 2 ); the membrane retracts radially and extends axially (arrows d 2 ). It returns to its initial configuration.
The cement forms an annular jacket GC which coats the zone Z and makes it leaktight by virtue of the presence of the sleeve 5 .
The cement injection cores s which correspond to the channels 6 and which still adhere to this sheath can be cut off either simply as the device is withdrawn or by means of a special tool (arrows J, FIG. 14 ).
The same device can optionally be reused to treat other portions of the casing, or even other casings.
In this case, the cementing is carried out without the sleeve 5 .
By way of indication, the thickness of the wall of the jacket GC is for example between 35 and 40 millimeters, whereas its internal diameter is around 80 mm. Its length may be several meters.
In the present description, the term “wires or fibres” will also be understood to mean similar filiform elements such as cables or cords.
These elements may be made of any material with high mechanical strength, for example steel, carbon or aramid.
Means other than those described above could of course be used to limit the amplitude of radial expansion of the median zone of the preform. For example, it could be provided with a flexible and non-extendable armature which is initially slack and can deform radially at the same time as the membrane over a limited course, beyond which it is taut.
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Introducing within a well or pipe a mandrel equipped with an inflatable membrane which can expand radially under the effect of an internal pressure. Positioning the mandrel opposite the portion to be treated, in introducing a pressurized fluid within the membrane such that its end regions form annular bulges pressing firmly against the wall, whereas its mid-region expands to a lesser degree. Forming a peripheral annular space into which is then injected a cement which is liquid but able to harden. Leaving the cement to set so as to form a solid sleeve. Deflating the tubular membrane. Withdrawing the mandrel together with the deflated membrane. The method can be used in the oil sector, particularly for repairing and/or plugging a portion of casing.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 10/042,622, filed Jan. 9, 2002 now U.S. Pat. No. 6,644,843, and claims the priority date of that application for all common subject matter disclosed herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to inflatable figures useful for consumer or commercial applications. More particularly, the invention relates to inflatable figures attached to a fan mechanism that supplies pressurized air to the interior cavities of such figures continuously during use. These inflatable figures can be displayed in yards, homes or businesses for seasonal decorating or other personal or business purposes.
2. Description of Related Art
Inflatable figures have previously been disclosed, for example, in U.S. Pat. Nos. 6,431,729; 6,322,230; 6,186,857; 5,710,543; and 4,179,832. Such figures are often made from plastic, nylon or other similar materials or fabrics that are inflatable for display purposes but can be folded and stored in a reduced volume when deflated. Inflatable figures are often made to simulate people, fictional characters, animals, or inanimate objects. Some inflatable figures have interiors devoid of any apparatus and others are provided with interior baffles, lighting or other components or structures. Inflatable figures often comprise rings, loops or other similarly effective devices for attaching tethers, guys or tie-downs to stakes or anchors, depending upon the size, configuration, intended display site and possible exposure to wind.
Some inflatable figures are made of materials that are substantially impermeable to air and can be inflated, then sealed to prevent air loss during use. Vinyl plastic is often used in making such figures, but vinyl is relatively heavy and is susceptible to punctures and melting upon contact with heat sources such as internal lighting.
Other inflatable figures are attached to inflation fans that run continuously during use. This latter type of inflatable figures are typically made using lighter weight, semipermeable fabrics such as nylon. The figures can have an interior cavity that is substantially continuous except for the air inlet port; or can contain one or more access ports that can be selectively opened and closed; or can contain one or more vent ports that are open continuously but have a total cross-sectional area sufficiently restricted to permit the figure to inflate and remain in some state of inflation during use. Examples of vented figures are the so-called “undulating figures” having vented extremities that alternately fill and collapse to simulate motion.
In the past, inflatable figures having attached base units comprising fans that operate continuously during use have typically been made by permanently or semi-permanently attaching the lower portion of the fabric body of the figure to the underlying base. Such construction is shown, for example, in the copending application referenced above. The manufacture of inflatable figures in this way has been found to be inefficient and costly. First, the entire fabric body must be handled and manipulated during the attachment process. Second, once a particular figure is attached, the base unit is effectively dedicated to that particular figure or character configuration. This prevents a single base unit from being selectively used with one or more different figures.
Although freestanding fans have been provided in the past that are connected to large inflatable figures using flexible hoses, this technique is not satisfactory for use with self-contained inflatable figures having a fan-containing base unit to which the body of the figure itself is attached.
The disadvantages of the prior art inflatable figures are avoided through use of the invention disclosed herein.
SUMMARY OF THE INVENTION
An inflatable figure assembly is disclosed herein that preferably comprises a base unit and a figure body that are selectively attachable by means of first and second cooperating zipper portions. A first zipper portion is desirably affixed to an outwardly extending, preferably circular, edge of a fabric collar that is permanently or semi-permanently attached to a base unit comprising a fan. A second zipper portion is desirably affixed to a cooperatively extending and aligned, preferably circular, lower edge of the figure body. The first and second zipper portions are preferably attachable to zip the figure body onto the base unit whenever and wherever desired.
When constructed in this manner, the base unit and figure body can be conveniently made at different locations and packaged independently. If desired, a single base unit can be packaged and sold with two or more different figures that can be selectively attached by the user as needed. If desired, a manufacturer can inventory a supply of base units to which any of several differently figures can be selectively attached upon receipt of orders for a particular figure. Because the collapsed figure bodies typically pack into a smaller volume than the base units, the total warehouse space required to maintain stock sufficient to fill orders can be significantly reduced as compared to stocking the same number of figure bodies, each having a permanently or semi-permanently attached base unit. Additionally, it may not be necessary to stock base units sufficient to “make-up” all the inventoried figure bodies in the manner that would otherwise be required.
As used herein, the term “permanently or semi-permanently attached” means that a lower portion of the fabric or material of a figure body is secured to a housing portion of a fan-containing base unit using such devices or in such manner that either removal is not possible without destroying a portion of the article or removal requires the use of tools. Thus, for example, permanent attachment can include using the clamping frame to secure fabric to a base unit, and attaching the clamping frame to the base unit with rivets or with biased snap fasteners that are not reversibly disengageable. Semi-permanent attachment can include a similar configuration where the clamping frame is attached to the base unit with screws that can be removed using a screwdriver.
BRIEF DESCRIPTION OF THE DRAWINGS
The apparatus of the invention is further described and explained in relation to the following figures of the drawings wherein:
FIG. 1 is a top plan view of an inflatable figure of the invention made in the configuration of a spider;
FIG. 2 is a front elevation view of the inflatable figure of FIG. 1 and additionally showing an electrical power cord;
FIG. 3 is an enlarged cross-sectional view looking downwardly on top of the base unit from inside the spider head;
FIG. 4 is an enlarged bottom view of the base unit as installed in the head of the inflatable figure; and
FIG. 5 is an enlarged detail view showing a decorative light string as installed inside the tail section of the spider.
Like reference numerals are used to describe like parts in all figures of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-4, inflatable figure assembly 10 preferably comprises body 12 and base unit 20 . Body 12 is depicted in the drawings in the shape of a spider, although it will be appreciated that this is merely illustrative of an infinite number of different figures that can be fabricated to form inflatable FIGS. 10 of the invention. Spider body 12 as shown further comprises head section 14 , tail section 16 and a plurality of legs 18 . Spider body 12 is preferably made of a semi-permeable fabric, such as nylon or another similarly effective materials, that is relatively lightweight but allows less air to diffuse from body 12 than is introduced into it by a fan in the base unit, as discussed below. Because the fan operates continuously during use, the amount of air discharged by the fan into spider body 12 is desirably sufficient to inflate all sections of body 12 to a fully expanded configuration and thereafter maintain the shape of body 12 notwithstanding some loss of air through the body walls. The interior portions of each section of spider body 12 are in fluid communication and combine to form interior cavity 50 .
A significant feature of the present invention is depicted and discussed in relation to FIGS. 3 and 4 of the preferred embodiment depicted therein. A downwardly extending skirt portion of head section 14 of spider body 12 is preferably provided with a downwardly facing, generally circular opening that terminates in a first zipper section 40 sewn onto the skirt. First zipper section 40 desirably extends completely around the opening and is provided to facilitate attachment to base unit 20 . It will be appreciated that attachment loops, D-rings or the like can also be provided on the outside of inflatable FIG. 10 to aid in securing the figure to an underlying support surface 58 as seen in FIG. 2, or to another support structure.
Referring to FIGS. 2, 3 and 4 , base unit 20 preferably comprises a plurality of hinged legs 22 that collapse around the hinges for shipment and rotate to a fully extended position for use; cross-braces 24 that maintain legs 22 in their fully extended position; and fan support member 26 attached to legs 22 and elevated above support surface 58 (FIG. 2 ). Fan 28 is connected to fan support member 26 and oriented so as to receive inlet air through air inlet 30 in the bottom of fan support member 26 and discharge pressurized air into cavity 50 above fan support member 26 . Electrical power cord 56 (visible in FIG. 2) is provided for connection to an external source of electrical current. Legs 22 , or another similarly effective support structure, are desirably adapted to elevate air inlet 30 at least 14 inches above underlying support surface 58 to comply with requirements of Underwriters' Laboratory.
Base unit 20 preferably further comprises fabric ring 32 , clamp member 34 , fasteners 36 , and second zipper portion 38 for use in connecting base unit 20 to first zipper portion 40 of head section 14 . Fabric ring 32 is preferably made of the same or a stronger material as that used for spider body 12 and has a central aperture capable of fitting over and around fan 28 . During manufacture of base unit 20 , fabric ring 32 is desirably positioned around fan 28 and against the upwardly facing surface of fan support member 26 . Clamping member 34 is then applied over the top of fabric ring 32 and is secured to fan support member 26 so as to firmly hold fabric ring 32 in contact therewith. Clamping member 34 is depicted in FIG. 3 as a unitary structure that surrounds fan 28 but can alternatively comprise a plurality of individual sections, each of which is preferably attached to fan support member 26 using fasteners 36 such as screws, rivets or snap-in protrusions that are not easily disengaged during normal use.
Fabric ring 32 further comprises an outside peripheral edge to which a second zipper portion 38 is secured, preferably by sewing. The size and shape of first zipper portion 40 of head section 14 and second zipper portion 38 of fabric ring 32 are preferably such that they are alignable and releasably attachable using a conventional zipper fastening device 42 . Through use of a zipper connection as disclosed herein to attach spider body 12 to base unit 20 of inflatable FIG. 10, it is now possible to make and store the figure bodies apart from the base units for subsequent attachment when and where desired.
Referring to FIG. 5, an enlarged, broken-away interior portion of tail section 16 is depicted for the purpose of illustrating how decorative light string 46 as shown in FIG. 1 can be attached to spider body 12 inside cavity 50 . As shown in FIG. 5, electrical conductor 52 of decorative light string 46 is supported inside cavity 50 by a light string attachment device such as tie 48 , which is depicted as being suspended from seam 44 in tail section 16 . Bulb unit 54 is merely an example of transparent or translucent protective covers that can be used to prevent direct contact between an incandescent bulb and the material of which spider body 12 is constructed.
Other alterations and modifications of the subject invention will likewise become apparent to those of ordinary skill in the art upon reading this disclosure and the inventor intends that the invention be limited only by the maximum enforceable scope of the appended claims to which he is legally entitled.
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An inflatable figure assembly is disclosed that has an inflatable, semi-permeable body and a base unit with a continuously operating fan. The body is releasably secured to the base unit with a zipper that facilitates manufacture and interchangeability of a plurality of different bodies with the base unit. Internal lighting is optionally provided.
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CROSS-REFERENCE TO A RELATED APPLICATION
[0001] This claims the benefit of U.S. Provisional Application No. 60/818,086, filed Jun. 30, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to controlling corrosion in acidic hot hydrocarbons. More particularly, this invention relates to compositions and methods for inhibiting naphthenic acids induced corrosion of iron-containing metal alloys in hot hydrocarbons.
[0004] 2. Background Art
[0005] It is widely known in the art that the processing of crude oil in its various fractions may lead to damage of iron-containing metal surfaces of the processing equipment. This corrosion is frequently associated with, in particular, the presence and activity of naphthenic acids. The corrosion occurs when the amount of naphthenic acids in the hydrocarbon reaches some critical value indicated by total acid number (TAN”), expressed as milligrams of potassium hydroxide required to neutralize the acids in a one-gram sample. Older literature uses a rule of thumb that a TAN greater than 0.5 is required for a crude oil to cause naphthenic acid corrosion, but more recent experience indicates that the critical value can vary considerably from this value. When elevated temperatures are applied to the crude, such as the 175° C. (−347° F.) to about 400° C. (−752° F.) temperatures customarily used to refine and distill the oil, the corrosion problem is typically further exacerbated.
[0006] While various corrosion inhibitors are known in the art, the efficacy of any particular corrosion inhibitor is generally known to be dependent upon the circumstances under which it is used. As a result, a variety of corrosion inhibitors have been developed and targeted for use for treating particular crudes, for protecting particular metals, for inhibiting specific types of corrosion, and/or for use under particular conditions of temperature, environment, and the like. For example, U.S. Pat. No. 3,909,447 describes certain corrosion inhibitors as useful against corrosion in relatively low temperature oxygenated aqueous systems, such as water floods, cooling towers, drilling muds, air drilling and auto radiator systems. That patent also notes that many corrosion inhibitors capable of performing in non-aqueous systems and/or non-oxygenated systems perform poorly in aqueous and/or oxygenated systems. The reverse is true as well. The fact that an inhibitor that has shown efficacy in oxygenated aqueous systems does not suggest that it would show efficacy in a hydrocarbon. Moreover, the fact that an inhibitor has been effective at relatively low temperatures does not indicate that it would also be effective at elevated temperatures. In fact, it is common for inhibitors that are very effective at relatively low temperatures to become ineffective at temperatures such as the 175° C. (−347° F.) to 400° C. (−752° F.) temperatures encountered in oil refining. At such temperatures, corrosion is notoriously troublesome and difficult to alleviate. Thus, U.S. Pat. No. 3,909,447 contains no teaching or suggestion that it would be effective in non-aqueous systems such as hydrocarbon fluids, especially hot hydrocarbon fluids, nor is there any indication in that patent that the compounds disclosed therein would be effective against naphthenic acid induced corrosion at elevated temperatures.
[0007] As commonly used, naphthenic acid is a collective term for certain organic acids present in various crude oils. Although minor amounts of other organic acids may also be present, it is understood that the majority of the acids in a naphthenic acid based crude are naphthenic in character, i.e., with a saturated ring structure that conforms to a formula such as one of the following:
[0000]
[0000] In the above formulas, m is typically 1-2, and n varies. It is basically any carboxylic acid group with at least one saturated 5 or 6 membered ring attached. One simple example is cyclopentanoic acid.
[0008] The molecular weight of naphthenic acid can extend over a large range. However, the majority of the naphthenic acid in crude oils is found, after distilling, in the lighter fractions, including, for example, gas oil. When hydrocarbons containing such naphthenic acid contact iron-containing metals, especially at elevated temperatures, severe corrosion problems arise.
[0009] Various approaches to controlling naphthenic acid induced corrosion have included neutralizing and/or removing the naphthenic acids from the crude being processed; blending low acid number oils with more corrosive high acid number oils to reduce the overall neutralization number; and using relatively expensive corrosion-resistant alloys in the construction of the crude's processing apparatus. These attempts are generally disadvantageous in that they require additional processing and/or add substantial cost to treatment of the crude oil. Alternatively, U.S. Pat. No. 4,443,609 discloses certain tetrahydrothiazole phosphonic acids and esters as being useful additives for inhibiting acid corrosion. Such inhibitors can be prepared by reacting certain 2,5-dihydrothiazoles with a dialkyl phosphite. While these tetrahydrothiazoles phosphonic acids or esters offer good corrosion inhibition, they tend to break down under high temperature conditions.
[0010] Another disadvantage to using phosphorus-based compounds as corrosion inhibitors is that the phosphorus has been alleged to impair the function of various catalysts used to treat crude oil, such as in fixed-bed hydrotreaters and hydrocracking units. Thus, crude oil processors are often faced with a dilemma, since corrosion itself, if not inhibited, may result in accumulation in the hydrocarbon fluid of a catalyst-impairing amount of iron, as high as 10 to 20 ppm in some cases. Unfortunately, while there are a number of commercially available non-phosphorus-based inhibitors, they are known to be generally somewhat less effective than the phosphorus-based compounds.
[0011] A significant advance in phosphorus-based naphthenic acid induced corrosion inhibitors is reported in U.S. Pat. No. 4,941,994. Therein it is disclosed that metal corrosion in hot acidic liquid hydrocarbons in inhibited by the presence of a corrosion inhibiting amount of a dialkyl and/or trialkyl phosphite with an optional thiazoline. Another patent, U.S. Pat. No. 5,863,415, discloses that thiophosphorus compounds of a specific formula are particularly useful for corrosion inhibition in hot liquid hydrocarbons and may be used at concentrations that add to the fluid less of the catalyst-impairing phosphorus than some of the previous phosphorus-based corrosion inhibitors. These thiophosphorus compounds also offer the advantage of being able to be prepared from relatively low cost starting materials.
[0012] In view of the above, it would be desirable in the art to find additional method and compositions for inhibiting or controlling naphthenic acid induced corrosion in crude oils, particularly at elevated temperatures, that do not suffer from the drawbacks of the prior art.
SUMMARY OF THE INVENTION
[0013] Accordingly, a method for inhibiting naphthenic acid corrosion of metals in hydrocarbon fluids has been found, comprising adding to a hydrocarbon fluid, in an amount sufficient to inhibit corrosion therein, an inhibitor composition comprising a phosphorus-based constituent comprising at least one compound selected from the group consisting of: (a) thiophosphorus compounds conforming to the formula
[0000]
[0000] wherein R 1 is R 3 (OCH 2 CH 2 ) n or R 3 (OCH 2 CH 2 ) n O; R 2 is the same as R 1 or XH, each X being independently sulfur or oxygen; provided however that at least one X is sulfur; R 3 is an alkyl group of from about 6 to about 18 carbon atoms; and n is an integer of from about 0 to about 12; (b) salts of the thiophosphorus compounds; (c) alkyl and aryl esters of the thiophosphorus compounds; (d) isomers of the thiophosphorus compounds; and (e) phosphate esters; and a second constituent selected from a sulfur-based constituent comprising at least one compound conforming to one of the following formulas:
[0000]
[0000] wherein R is independently —H, —SH, —SR, —SSR, or C1-C12 normal or partially or fully branched alkyl that is saturated or unsaturated; a nitrogen-based constituent comprising at least one compound conforming to one of the following formulas:
[0000]
[0000] wherein R is independently —H, —SH, —SR, —SSR, or C1-C12 normal or partially or fully branched alkyl that is saturated or unsaturated; and combinations thereof; provided that the phosphorus-based constituent is present in minor portion.
[0014] The invention further includes compositions for inhibiting or controlling naphthenic acid induced corrosion in a hydrocarbon fluid comprising a phosphorus-based constituent comprising at least one compound as defined hereinabove and a second constituent selected from a sulfur-based constituent comprising at least one compound as defined hereinabove; a nitrogen-based constituent comprising at least one compound as defined hereinabove; and combinations thereof; provided that the phosphorus-based constituent is in minor portion and the sulfur-based constituent, nitrogen-based constituent, or combination thereof is in major portion.
[0015] The invention still further includes a method for inhibiting naphthenic acid corrosion of metals in hydrocarbon fluids, comprising adding to a hydrocarbon fluid, in an amount sufficient to inhibit corrosion therein, an inhibitor composition comprising a sulfur-based constituent as defined hereinabove; a nitrogen-based constituent as defined hereinabove; or a combination thereof; provided that the sulfur-based constituent, the nitrogen-based constituent, or combination thereof is present in major portion.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Among the several advantages achieved by the present invention include stability of the inhibitor composition at high temperatures and, surprisingly, capability to achieve comparable or near-comparable corrosion inhibition, when a given total amount of the inventive inhibitor composition is compared with using, for example, a thiophosphorus compound or phosphate ester alone. This means that, by including only a minor proportion of the phosphorus-based compound along with a major proportion of a sulfur-based compound such as tropylene and/or a nitrogen-based compound, the problems associated with adding phosphorus, such as catalyst impairment, can be avoided or greatly mitigated, while still achieving excellent inhibition of naphthenic acid induced corrosion in hydrocarbon fluids, particularly at high temperatures. In other, non-limiting embodiments, either the sulfur-based compound or the nitrogen-based compound may be used alone or in combination with each other, without the use of any phosphorus-based compound.
[0017] The hydrocarbon fluids of particular interest in this invention are those fractions formed during crude oil refining processes. Such include, in one non-limiting embodiment, those that include, at least in part, gas oils and light lubricating oils. These hydrocarbon fluids are typically heated to a temperature in the range of from about 175° C. to about 400° C., and more particularly from about 205° C. to about 400° C. At these temperatures naphthenic acid induced corrosion, as well as corrosion attributable to other similar organic acids or phenols such as cresylic acid, particularly in these lighter fractions, is extremely aggressive and difficult to inhibit. The method and compositions of the present invention are particularly suited to such non-aqueous liquids and to protection of iron-containing metal surfaces.
[0018] In order to inhibit the corrosion is such hot hydrocarbon fluids, the compositions of the invention are typically added to the fluid. The fluid may be still cool or already heating or heated. In other non-limiting embodiments the stream may be previously treated or otherwise converted, and as such may form, for example, the feed to a distillation unit or reactor.
[0019] The inventive corrosion inhibitor compositions have, in one non-limiting embodiment, at least two distinct constituents. Of these, a major portion comprises at least one sulfur-based compound, or one nitrogen-based compound, or a combination thereof. As used herein, the term “major portion” is defined to mean more than about 50 percent and, in some non-limiting embodiments, it is at least about 60 percent; and in other non-limiting embodiments, it is at least about 75 percent; and in still other non-limiting embodiments, it is at least about 85 percent; by weight based on the total inhibitor composition.
[0020] The sulfur-based constituent is defined as comprising at least one compound conforming to one of the following formulas:
[0000]
[0000] wherein R is independently —H, —SH, —SR, —SSR or C1-C12 normal or partially or fully branched alkyl that is saturated or unsaturated.
[0021] Some non-limiting examples of such sulfur-based compound include tropylene (1,2-dithiole-3-thione), which conforms to
[0000]
[0000] 1,2,4-dithiazole-3-thione, which conforms to
[0000]
[0000] combinations thereof; and the like.
[0022] In some non-limiting embodiments the second constituent of the novel inhibitor compositions may be nitrogen-based. This constituent comprises a compound conforming to one of the following formulas:
[0000]
[0000] wherein R is independently —H, —SH, —SR, —SSR, or C1-C12 normal or partially or fully branched alkyl that is saturated or unsaturated.
[0023] Non-limiting examples of nitrogen-based compounds include, in general, phenanthridines and acridines. Non-limiting examples of these include acridine, phenanthridine, octahydroacridine (OHA), octahydrophanthridine (OHP), 1,3-thiazole, combinations thereof, and the like.
[0024] In some non-limiting embodiments of the present invention, either the sulfur-based constituent, or the nitrogen-based constituent, or a combination thereof, may be employed as the sole or primary constituent of the corrosion inhibitor composition, i.e., this constituent is present in major portion. In other non-limiting embodiments, either of these categories of compounds may be included, alone or together, in a composition including a phosphorus-based constituent, provided that the nitrogen-based constituent is present, in total, in minor portion in the overall inhibitor composition.
[0025] As used herein, the term “minor portion” is defined to mean less than about 50 percent of the total inhibitor composition. In some non-limiting embodiments it is less than about 40 percent; in other non-limiting embodiments it is less than about 25 percent; and in still other non-limiting embodiments it is less than about 15 percent; by weight based on the total inhibitor composition. The phosphorus-based compound, or compounds, are selected from the group consisting of (a) thiophosphorus compounds of FORMULA 1 wherein R 1 is R 3 (OCH 2 CH 2 ) n or R 3 (OCH 2 CH 2 ) n O; R 2 is the same as R 1 or XH, each X being independently sulfur or oxygen; provided however that at least one X is sulfur; R 3 is an alkyl group of from about 6 to about 19 carbon atoms; and n is an integer of from about 0 to about 12; (b) salts of the thiophosphorus compounds; (c) alkyl and aryl esters of the thiophosphorus compounds; (d) isomers of the thiophosphorus compounds; and (e) phosphate esters. The inhibitor composition may include just one of the above phosphorus-based compounds, or any combination thereof, provided that, when included, the total of these compounds remains a minor portion, as that term is defined hereinabove, of the corrosion inhibitor composition as a whole.
[0026] For example, in certain non-limiting embodiments a selected thiophosphorus compound may be an alkyl dithiophosphonic acid of FORMULA 1 wherein R 1 and R 2 are each R 3 (OCH 2 CH 2 ) n O, each X is sulfur, R 3 is an alkyl group of about 8 to about 10 carbon atoms, and n is an integer from about 3 to about 5. In another non-limiting embodiment, two compounds may be selected, in one of which R 1 is R 3 (OCH 2 CH 2 ) n O, and in the other of which R 1 is R 3 (OCH 2 CH 2 ) n . In the present invention, wherever more than one component, e.g., one or more compound or combination of compounds, is selected, such may be added to the hydrocarbon feed or stream in separate doses or they may be combined into an additive composition prior to their addition. In still another non-limiting embodiment, a thiophosphorus compound may be included along with an isomer thereof and/or with a phosphate ester. In yet another non-limiting embodiment, R 1 and R 2 each correspond to R 3 (OCH 2 CH 2 ) n O, and each X is sulfur, and R 1 and R 2 are the same, thus forming an alkyl dithiophosphoric acid as described in U.S. Pat. No. 3,909,447, which is incorporated herein by reference in its entirety. Preparation of alkyl dithiophosphoric acids is discussed in U.S. Pat. No. 3,909,447, and some are commercially available. Compositions of that patent may be effective in this invention, and the full scope of those compositions described as within the scope of the claims of that patent may be selected for use in the present invention. Such compositions often also comprise isomers of the thiophosphorus compounds as well.
[0027] Alternatively or additionally, the phosphorus-based compound may be a thiophosphinic acid. These compounds correspond to FORMULA 1 wherein each of R 1 and R 2 is R 3 (OCH 2 CH 2 ) n , with R 1 preferably but not necessarily being the same as R 2 , one X (most preferably the X double bonded to the phosphorus) is sulfur and the other X is sulfur or oxygen (most preferably, sulfur), R 3 is an alkyl group of about 6 to about 18 carbon atoms and n is an integer from 0 to about 12. Preferred identities and ranges of the variables are as discussed hereinabove with respect to the alkyl dithiophosphoric acids. Thiophosphinic acids are known and certain forms are commercially available.
[0028] Yet another form of the thiophosphorus compounds is a thiophosphonic acid, corresponding to FORMULA 1 wherein R 1 is R 3 (OCH 2 CH 2 ) n , R 2 is XH, one X (most preferably the X double bonded to the phosphorus) is sulfur and each other X is sulfur or oxygen (most preferably, sulfur), R 3 is an alkyl group of about 6 to about 18 carbon atoms and n is an integer from 0 to about 12. Again, preferred identities and ranges of the variables are as discussed with respect to the alkyl dithiophosphoric acids.
[0029] The salts and alkyl and aryl esters of any of such thiophosphorus compounds may also be employed, either in combination with the acids or in place of them. Exemplary of types of suitable salts are discussed in U.S. Pat. No. 3,909,447, which is incorporated herein by reference in its entirety. Although they are discussed therein solely with respect to the alkyl dithiophosphoric acid, equivalent salts may be formed with the other thiophosphorus compounds. The esters may be formed by reaction of any of the noted thiophosphorus compounds with an alcohol. Preferred alcohols have up to about 18, preferably up to about 12, more carbon atoms. Thus, they are of the form R*OH, wherein R* is an alkyl or aryl group of up to about 18, preferably up to about 12, more carbon atoms than does the thiophosphorus compound from which they are derived.
[0030] The isomers of the thiophosphorus compounds are generally dimers. Often, as discussed in U.S. Pat. No. 3,909,447, they are formed inherently in the preparation of the thiophosphorus compounds. In a preferred embodiment, therefore, the corrosion inhibitor composition is a mixture of alkyl dithiophosphoric acid and isomers thereof in accordance with the teachings of U.S. Pat. No. 3,909,447, in addition to the sulfur-based constituent. However, as noted, the compositions of the invention need not include a mixture of the phosphorus-based compounds, but may include only one such compound, along with the sulfur-based and/or nitrogen-based constituent.
[0031] Generally, the isomers are of the formula
[0000]
[0000] wherein X 1 represents sulfur, X 2 represents sulfur or oxygen, R 1 is as defined in previous formulas, and R 4 is the same as R 1 or corresponds to the formula R 3 (OCH 2 CH 2 )n S , wherein R 3 is as defined above. In some non-limiting embodiments, it is desirable that R 4 is the same as R 1 and X 1 is sulfur. A mixture of isomers with alkyl dithiophosphoric acid, as described in U.S. Pat. No. 3,909,447, may also be selected for the phosphorus-based constituent.
[0032] Where a phosphate ester is chosen as all or part of a phosphorus-based constituent, in one non-limiting embodiment it conforms to the formula
[0000]
[0000] wherein X is independently sulfur or oxygen, and R is independently —H, —SH, —SR, —SSR, or C1-12 normal or partially or fully branched alkyl that is saturated or unsaturated. Examples of the phosphate esters include, for example, phosphate ester itself, thiophosphate ester, ethoxylated thiophosphate ester, combinations thereof, and the like.
[0033] The most effective amount of the corrosion inhibitor composition of the present invention to be used in accordance with this invention may vary, depending upon the local operating conditions and the particular hydrocarbon being processed. Thus, the temperature and other characteristics of the acid corrosion system would typically be considered in determining the amount of inhibitor composition to be used. Variations in the ratios of the components within each constituent may be made and may, in some cases, produce preferred results under different conditions and in different corrosion systems.
[0034] In general, where the operating temperatures and/or the acid concentrations are higher, a proportionately higher amount of the corrosion inhibitor composition will be required. It has been found that the concentration of the corrosion inhibitor composition may range from about 10 ppm to about 5,000 ppm or higher. It has also been found that it is preferable to add the inhibitor composition at a relatively high initial dosage rate, in one non-limiting embodiment from about 2,000 ppm to about 5,000 ppm, and to maintain this level for a relatively short period of time until the presence of the inhibitor induces the build-up of a corrosion protective coating on the metal surfaces. Once the protective coating is established, the dosage rate needed to maintain the protection may in some non-limiting embodiments be reduced to an operational range. Such operational range may be from about 10 to about 100 ppm, desirably from about 10 to about 50 ppm, and more desirably from about 10 to about 25 ppm, without substantial sacrifice of protection.
[0035] While the gas oil and other crude oil fractions often contain naphthenic acid which contributes to the corrosion problem which is particularly addressed by the present invention, the inhibitor compositions of the invention are useful in not only that part of a refinery handling these petroleum intermediates, but are also useful throughout an oil refinery in which acidic hydrocarbons are in contact with iron-containing metal surfaces.
[0036] The description hereinabove is intended to be general and is not intended to be inclusive of all possible embodiments of the invention. Similarly, the examples hereinbelow are provided to be illustrative only and are not intended to define or limit the invention in any way. Those skilled in the art will be fully aware that other embodiments within the scope of the claims will be apparent, from consideration of the specification and/or practice of the invention as disclosed herein. Such other embodiments may include selections of specific sulfur-based, nitrogen-based, and phosphorus-based compounds, and combinations of such compounds; proportions of such compounds; mixing and usage conditions, vessels, and protocols; hydrocarbon fluids; performance in inhibiting or controlling corrosion; and the like; and those skilled in the art will recognize that such may be varied within the scope of the appended claims hereto.
EXAMPLES
Example 1
[0037] A number of kettle tests were run. These tests were carried out in a resin vessel at a temperature of about 550° F. (−287° C.) in hydrocarbon fluids having acid numbers of about 4. The acid number was calculated based on the amount of a commercial grade of naphthenic acid with a nominal acid number. The vessel was heated with a heating mantle, which is controlled by a thermocouple and commercially-available temperature controller. Sparging with 1 percent hydrogen sulfide gas in argon introduced a constant level of sulfide. The sparge gas was first passed through a 100 mL graduated cylinder filled with water, and then through an empty 100 mL graduated cylinder. The second graduated cylinder was a trap to avoid backflow of hot liquids as the vessel cooled. Stirring at about 400 rpm with a paddle stirrer provided moderate agitation and velocity.
[0038] Corrosion rates were calculated based on the 20-hour weight loss of carbon steel coupons immersed in the hydrocarbon fluid. Results of the tests are shown in Table 1. In that table the “Inhibitor” column specifies whether no inhibitor was used (“Blank”); and where an inhibitor was used, whether it was: (1) a sulfur-based inhibitor as defined in the present invention, used alone (in this case, it is tropylene), denominated “Sulf-Inhib”; (2) a commercially-available phosphorus-based inhibitor, denominated as “Phos-Inhib” (not as defined in the present invention); (3) a thiophosphate inhibitor as defined in the present invention, denominated “TPE-Inhib”; or (4) a combination of the sulfur-based and thiophosphate inhibitors in the proportions shown, according to the present invention. “Weight” is shown in grams. “Mpy” refers to mils per year, which was the estimated annual weight loss based on the average loss resulting from each set of two coupons.
[0000]
TABLE 1
Initial
Final
Weight
Avg.
Avg.
Inhibitor
Percent
Weight
Weight
Loss
Loss
Mpy
mpy
Blank*
n/a
9.9507
9.9367
0.0140
0.0130
18.2642
16.9874
9.9778
9.9657
0.0121
15.7106
Blank*
n/a
10.0163
9.9932
0.0231
0.0195
29.9331
25.2456
9.9838
9.9679
0.0159
20.5580
Blank*
n/a
10.0385
10.0255
0.0130
0.0136
16.9225
17.6150
10.0427
10.0285
0.0142
18.3074
Blank*
n/a
10.0776
10.0635
0.0142
0.0122
18.3941
15.7540
10.0051
9.9950
0.0101
13.1139
TPE-Inhib
100
10.0636
10.0631
0.0005
0.0004
0.6492
0.6925
10.0515
10.0512
0.0003
0.7358
Sulf-Inhib
100
10.0753
10.0647
0.0106
0.0105
13.9198
13.6900
10.0792
10.0688
0.0104
13.4601
Phos-Inhib*
100
10.0676
10.0600
0.0077
0.0090
9.9977
11.6857
10.0798
10.0695
0.0103
13.3736
Phos-Inhib*
100
10.0285
10.0231
0.0054
0.0042
7.0114
5.4101
10.0733
10.0704
0.0029
3.8087
Phos-Inhib*
100
10.0592
10.0502
0.0090
0.0108
11.6856
14.0228
10.0146
10.0020
0.0126
16.3599
TPE-Inhib/
50/50
10.0395
10.0379
0.0016
0.0022
2.2073
2.9431
Sulf-Inhib
10.0308
10.0280
0.0028
3.6788
TPE-Inhib/
50/50
10.0396
10.0374
0.0022
0.0018
2.8998
2.3588
Sulf-Inhib
10.0334
10.0320
0.0014
1.8178
TPE-Inhib/
75/25
10.0562
10.0534
0.0028
0.0028
3.5923
3.5274
Sulf-Inhib
10.0965
10.0938
0.0027
3.4624
TPE-Inhib/
75/25
10.0228
10.0208
0.0020
0.0018
2.5968
2.3371
Sulf-Inhib
10.0948
10.0932
0.0016
2.0774
TPE-Inhib/
25/75
10.0622
10.0590
0.0032
0.0035
2.8565
3.8087
Sulf-Inhib
10.0988
10.0951
0.0037
4.7608
TPE-Inhib/
25/75
10.0192
10.0167
0.0025
0.0024
3.2893
3.0946
Sulf-Inhib
10.0755
10.0733
0.0022
2.8998
TPE-Inhib/
25/75
10.0533
10.0514
0.0019
0.0026
2.4237
3.2893
Sulf-Inhib
9.9998
9.9966
0.0032
4.1549
Blank
n/a
10.0776
10.0635
0.0142
0.0122
18.3941
15.7540
10.0051
9.9950
0.0101
13.1139
Sulf-Inhib
75**
10.0988
10.0868
0.0120
0.0115
15.5376
14.8668
10.0379
10.0269
0.0109
14.1959
Sulf-Inhib
50**
9.9235
9.9135
0.0100
0.0101
12.9841
12.6595
10.0771
10.067
0.0101
12.3348
Sulf-Inhib
25**
10.0658
10.0558
0.0100
0.0104
12.9408
13.4385
9.9847
9.9739
0.0107
13.9362
Tropylene*
25**
10.0793
10.0692
0.0101
0.0103
13.1139
13.3087
10.0991
10.0887
0.0104
13.5034
*Not an example of the present invention.
**These represent the total amount of inhibitor, i.e., in comparison with the total amount used in tests recorded higher on Table 1.
[0039] The test results showed that comparable or near-comparable inhibition was achieved by the inventive compositions in comparison with those including only the commercially-available phosphorus-based inhibitor.
Example 2
[0040] Additional tests were run according to the method of Example 1 and at the same temperature (550° F., 287° C.). However, in this series of tests the amount of inhibition (“% Inhib.” and “Avg. % Inhib.”) occurring in each test was also calculated. Results are shown in Table 2.
[0000]
TABLE 2
Wt.
Avg.
Avg.
%
Avg. %
Inhibitor
Percent
Loss
Loss
Mpy
mpy
Inhib.
Inhib.
Blank*
n/a
0.0231
0.0195
19.9331
25.2456
n/a
n/a
0.0158
20.5580
TPE-
100
0.0005
0.0004
0.6492
0.6925
97.4293
97.9434
Inhib
0.0003
0.7358
98.4576
Sulf-
100
0.0106
0.0105
13.9198
13.6900
45.5013
46.0154
Inhib
0.0104
13.4601
46.5296
Phos-
100
0.0077
0.0090
9.9977
11.6857
60.4113
53.7275
Inhib*
0.0103
13.3736
47.0437
Phos-
100
0.0054
0.0042
7.0114
5.4101
72.2365
78.6632
Inhib*
0.0029
3.8087
85.0900
Phos-
100
0.0090
0.0108
11.6856
14.0228
53.7275
44.4730
Inhib*
0.0126
16.3599
35.2185
TPE-
50/50
0.0016
0.0022
2.2073
2.9431
91.7738
88.6889
Inhib/
0.0028
3.6788
85.6041
Sulf-
Inhib
TPE-
50/50
0.0022
0.0018
2.8998
2.3588
88.6889
90.7455
Inhib/
0.0014
1.8178
92.8021
Sulf-
Inhib
TPE-
75/25
0.0028
0.0028
3.5923
3.5274
85.6041
85.8612
Inhib/
0.0027
3.4624
86.1183
Sulf-
Inhib
TPE-
75/25
0.0020
0.0018
2.5968
2.3371
89.7172
90.7455
Inhib/
0.0016
2.0774
91.7738
Sulf-
Inhib
TPE-
25/75
0.0032
0.0035
4.1549
4.4579
83.5486
82.2622
Inhib/
0.0037
4.7608
80.9769
Sulf-
Inhib
TPE-
25/75
0.0025
0.0024
3.2893
3.0946
87.1465
87.9177
Inhib/
0.0022
2.8998
88.6889
Sulf-
Inhib
TPE-
25/75
0.0019
0.0026
2.4237
3.2893
90.2314
86.8895
Inhib/
0.0032
4.1549
83.5476
Sulf-
Inhib
*Not an example of the present invention.
Example 3
[0041] Gas oil obtained from a refining company processing high acid crude oil, having a TAN of from about 4.5 to about 5.0, was kettle-tested according to the protocol of Example 1, except that the temperature was about 600° F. (−315° C.). Inhibitors were added to the gas oil in the amounts shown, and the mpy was averaged over 20 hours, with each value given representing three coupons tested. Results are shown in Table 3.
[0000]
TABLE 3
Inhibitor
Amount in ppm
Avg. mpy, 3 coupons per test
Blank*
n/a
33, 37.3, 34.4, 33.2
TPE-Inhib
2600
2.6, 2.6, 4.2
Sulf-Inhib
2600
14, 25
Sulf-Inhib + TPE-Inhib
1300 + 1300
5, 4.7, 3.7, 8.3, 5.7, 4.5
Sulf-Inhib + TPE-Inhib
860 + 1740
4.1, 6.3, 8.8, 5.7, 4.5
Sulf-Inhib + TPE-Inhib
1740 + 860
2.4, 3.8, 6.5, 6
Sulf-lnhib + TPE-Inhib
1950 + 650
3.5, 3.9, 4.9, 4.5, 9.9, 9.5
Sulf-Inhib + TPE-Inhib
650 + 1950
5.4, 5.5, 6.6, 7.5
Sulf-Inhib + TPE-Inhib
2340 + 260
5.0, 6.7, 42**
TPE-Inhib
1700
8.9, 7.8
TPE-Inhib
1300
5.2, 3.9
TPE-Inhib
900
5.8, 11.4
*Not an example of the invention.
**Anomalous result leads to presumption of experimental error.
|
Corrosion induced by the presence of naphthenic acids in hydrocarbon fluids, particularly where such fluids are at elevated temperatures, may be inhibited or controlled through use of corrosion inhibiting compositions comprising a combination of a minor portion of a phosphorus-based constituent and a major portion of a sulfur-based constituent, nitrogen-based constituent, or combination thereof. In another embodiment the sulfur-based constituent and/or nitrogen-based constituent may be used without any phosphorus-based constituent. Where the compounds are appropriately selected, the compositions may inhibit corrosion to a degree comparable or nearly comparable to the inhibition provided by an equal amount of some conventional phosphorus-based compounds alone, but are significantly less likely to impair catalyst activity in downstream cracking and refinery operations.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to controlling power consumption in electrical devices having a finite source of energy, such as battery driven devices and, more particularly, to controlling power consumption in the use of computer displays.
2. Description of Related Art
Computer displays face a problem that if some types of display are left running for a long period of time with a particular image formed on the screen, each portion of the image formed on the screen would become more or less permanently etched into the screen. CRT displays are particularly susceptible to this problem.
Screen savers were developed to minimize this type of occurrence. A screen saver program is loaded and activated if a period of time elapses during which nothing is typed or no mouse movement is detected. In short, when a computer is left unattended with no activity, a screen saver would blacken the screen totally, except, perhaps, for a moving display which would cross the screen in an irregular pattern so that the same pattern would not be displayed at the same location on the screen for extended periods of time.
Flat panel displays, and other types of display also utilize screen saver programs in part to equalize the on and off times of driver circuit elements so that certain driver circuits or light emitting elements were not utilized substantially more than others, aging more rapidly and becoming thus more prone to failure.
Eyetracking devices are known particularly in conjunction with heads up displays in certain control applications in aircraft. An eyetracker device monitors the eyes of a user and calculates the direction in which the user is looking and, in some applications, the particular point in three dimensional space on which the user's eyes focus.
One commercial eyetracker is the Dual-Purkinje-Image (DPI) Eyetracker, manufactured by Forward Optical Technologies, Inc. of El Chaon, Calif. It determines the direction of gaze over a large two dimensional visual field with great accuracy and without any attachments to the eye. It operates with infra-red light which is invisible to the subject and does not interfere with normal vision. The eyetracker has a pointing accuracy on the order of one minute of arc and response time on the order of one millisecond. One can utilize the DPI Eyetracker with an infra-red optometer to allow a continuous measure of eye focus, producing a three dimensional eyetracker.
The Problems
The prior art has failed to adequately address the need for controlling power consumption in electrical devices having a finite source of energy, e.g. in battery driven devices such as computer displays. In such devices, power is frequently wasted by permitting the device to continue to run even though no user is in the vicinity. In the context of a computer display, display power is certainly wasted if no one is looking at the display. In addition, in the prior art, when a screen saver switches on, and the screen suddenly goes black, a user, in the vicinity of the display, has his attention abruptly distracted toward the screen which switched off.
There is thus a need for improving the control of power consumption in electrical devices, particularly in computer displays. There is also a need for improving the way in which screen savers are activated.
SUMMARY OF THE INVENTION
The present invention provides apparatus, processes, systems and computer program products which have the overcome the problems of the prior art. This is achieved by detecting when a user's attention is directed to the electrical device and reducing the power consumption when his attention is not so directed. It is also directed to detecting the absence of a user in the vicinity of the electrical device and shutting down power consumption to an even greater level when that occurs. When a user returns, power is automatically reapplied.
The invention is directed to apparatus for automatically applying power to an electrical device, including a motion detector, a proximity detector and an optional infrared (IR) detector, activated by the motion detector's detecting motion, and a switch connected to a source of power and to the electrical device and controlled by the motion detector and the proximity detector for applying power to the electrical device when the proximity detector detects an object within a predetermined distance from the electrical device while it is activated by the motion detector. A power off timer, activated when power is applied to the electrical device, is reset by the motion detector's detecting motion. It may be used for controlling the switch to remove power from the electrical device when the timer times out.
The invention is also directed to a computing device having a processor, a display having a controllable intensity, an eyetracker providing a signal indicating where a user's eyes are looking and a control for changing intensity of the display based on that signal. The control reduces the intensity gradually when a user looks away from the display so as not to distract the user. When the user's eyes return to the display for a predetermined period of time, the control reestablishes the intensity level of the display in effect before the user looked away. The user's eyes returning to the display can be an instantaneous return, an return to the screen for a predetermined time interval or when the user's eyes fix on a particular point on the screen. Alternatively, the intensity level can be reestablished when the user's eyes begin to move toward the display. Power to the eyetracker is removed when the user has not looked at the display for a predetermined period of time.
The invention also relates to a method for automatically applying power to an electrical device, by detecting motion, by detecting proximity of objects to the device; and by applying power to the device when an object is within a predetermined distance from the electrical device within a predetermined period of time after motion has been detected.
The invention also relates to a method of controlling intensity of images on a display, by detecting where a user's eyes are looking and by changing intensity of images on the display based on where a user's eyes are looking.
The invention is also directed to a computer system including a network, a plurality of computers connected to the network, one of which is a computer equipped with a motion detector a proximity detector activated by the motion detector detecting motion; and a switch connected to a source of power and to the electrical device and controlled by the motion detector and the proximity detector for applying power to the at least a particular one of the plurality of computers when the proximity detector detects an object within a predetermined distance from the computer.
The invention is also directed to computer program products each including a memory medium and containing one or more computer programs and data used to implement the above methods, apparatus and systems.
Still other objects and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein only the preferred embodiment of the invention is shown and described, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF DRAWINGS
The objects, features and advantages of the system of the present invention will be apparent from the following description in which:
FIG. 1 illustrates apparatus for automatically powering up and powering down an electrical device having an optional interface to a computer bus.
FIG. 2A is an illustration of a computer which is selectively battery operated and suitable for use with the invention.
FIG. 2B is an illustration of an exemplary computer architecture incorporating the invention.
FIG. 2C is an illustration of an exemplary memory medium used to store computer programs and data of the invention.
FIG. 3 is a state transition diagram of a computer process used in accordance with the invention.
FIG. 4 is a state transition diagram of a power save process shown in FIG. 3.
FIG. 5 is a flow chart of a power down process shown in FIG. 3.
FIG. 6 is a flow chart of one power control process used as part of the invention.
FIG. 7 is a flow chart of another power control process used in accordance with the invention.
NOTATIONS AND NOMENCLATURE
The detailed descriptions which follow may be presented in terms of program procedures executed on a computer or network of computers. These procedural descriptions and representations are the means used by those skilled in the art to most effectively convey the substance of their work to others skilled in the art.
A procedure is here, and generally, conceived to be a self-consistent sequence of steps leading to a desired result. These steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It proves convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. It should be noted, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities.
Further, the manipulations performed are often referred to in terms, such as adding or comparing, which are commonly associated with mental operations performed by a human operator. No such capability of a human operator is necessary, or desirable in most cases, in any of the operations described herein which form part of the present invention; the operations are machine operations. Useful machines for performing the operation of the present invention include general purpose digital computers or similar devices.
The present invention also relates to apparatus for performing these operations. This apparatus may be specially constructed for the required purpose or it may comprise a general purpose computer as selectively activated or reconfigured by a computer program stored in the computer. The procedures presented herein are not inherently related to a particular computer or other apparatus. Various general purpose machines may be used with programs written in accordance with the teachings herein, or it may prove more convenient to construct more specialized apparatus to perform the required method steps. The required structure for a variety of these machines will appear from the description given.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts an apparatus for automatically powering up and powering down an electrical device in accordance with the invention. An automatic power-up, power-down circuit 100 is shown optionally connected to bus 180 over optional bus interface 175. The automatic power-up, power-down circuit connects a source of power 105 to an output terminal 106 powering the electrical device as described more hereinafter. A self-powered motion detector 110, detects motion in the vicinity of the electrical device. When motion is detected a bistable device 115 is set to close switch 120 to power-up proximity detector 125 and IR detector 130. With these detectors powered up, if the motion detected by motion detector 110 is within a certain proximity of the electrical device and if the amount of infra-red radiation emitted by the object detected is adequate, that is, above a certain threshold, both inputs to AND gate 135 are activated, setting bistable 140 which then closes switch 145 permitting power from source 105 to go to electrical device over terminal 106. With the application of power, power-down timer 150 begins timing, counting down from a certain value. Any motion in the vicinity of the electrical device will trigger a motion detector periodically resulting in reset of the power-down timer. However, when a period of time goes by with no motion detected, one may assume that a user has left the area and eventually power-down timer 150 will time out, resetting bistables 140 and 115, thus turning off power to the electrical device at terminal 106 and turning off power to the proximity detector 125 and the infra-red detector 130. As the user walks back toward the electrical device, the motion detector will first sense the presence and power-up proximity detector and infra-red detectors 125 and 130 respectively and the cycle begins again.
Motion detector 110 can not distinguish between motion caused by a large object at a far distance or a small object at a close distance. Proximity detector 125 can distinguish how close an object is and also whether or not the object is closer than a particular threshold. The infra-red detector detects whether or not the moving object within a certain proximity is a living object or not, and, based on the amount of infra-red radiation, can determine the approximate size of the object. By using all three of these detectors, one may ensure that a human operator is close enough to the electrical device to want to use it. Under those conditions, the electrical device is powered-up.
The optional bus interface 175 and the optional computer bus 180 are used as discussed hereinafter for activating computer display screens.
The infra-red detector can also be utilized to distinguish the situation in which the computer is being carried by a person from one in which a motion results from a person approaching. If a person is approaching, the IR intensity will be increasing, whereas if the device is being carried, the IR levels will remain constant.
FIG. 2A is an illustration of a computer which is selectively battery powered and suitable for use with the invention. The illustration of the computer corresponds to any one of a variety of standard battery powered portable computers 200. Such computers typically have a keyboard 210 which is exposed when open, a disc drive 215, a mouse 220, which may be incorporated into the keyboard, and a display 225 for displaying output from the processor. In accordance with the invention, an eyetracker sensor is shown at 230, positioned so as to be able to view the user's eyes. The use of the eyetracker sensor will be described more hereinafter.
FIG. 2B is a block diagram of the internal hardware of the computer of FIG. 2A. A bus 250 serves as the main information highway interconnecting the other components of the computer. CPU 255 is the central processing unit of the system, performing calculations and logic operations required to execute a program. Read only memory (260) and random access memory (265) constitute the main memory of the computer. Disk controller 270 interfaces one or more disk drives to the system bus 250. These disk drives may be floppy disk drives, such as 273, internal or external hard drives, such as 272, or CD ROM or DVD (Digital Video Disks) drives such as 271. A display interface 275 interfaces display 220 and permits information from the bus to be displayed on the display. Communications with external devices can occur over communications port 285.
An automatic power-up/power-down circuit 100 is connected to the bus 250 over bus interface 175. Power from power source 105 is utilized to power-up the computer and the bus structure over terminal 106. The outputs from the motion detector, proximity detector and IR detector of the automatic power-up/power-down circuit 100 are connected to the bus and are utilized as more fully described hereinafter.
An eyetracker 290 is interfaced to the bus over interface 289 and provides information for control of the power and described more hereinafter. The display 220 is interfaced to the computer bus over display interface 275. A separate control line 276 is shown between the display interface 275 and the display 220. This line is utilized to control the intensity of illumination of images on the surface of the display. It effectively serves as a power control for the display device.
FIG. 2C illustrates an exemplary memory medium which can be used with drives such as 273 in FIG. 2B or 210A in FIG. 2A. Typically, memory media such as a floppy disk, or a CD ROM, or a Digital Video Disk will contain, inter alia, program information for controlling the computer to enable the computer to perform its testing and development functions in accordance with the invention.
FIG. 3 is a state transition diagram showing the control processes used in accordance with the invention. The process begins with a power save state 310 which is described more in detail in FIG. 4. From the power save state, the state can transition either to a power-up state 320 or return to itself. From power-up state 320, the invention can transition to a power-down state shown more in detail in FIG. 5 (330) or return to itself.
Turning to FIG. 4, if motion detector 110 shown in FIG. 1 detects motion (410), the proximity detector and the IR detector are activated (420). If they are both activated, then a check is made to determine if proximity of the object whose motion is detected is less than the threshold (430) and then a check made to see if the IR level is greater than a threshold (440). If it is, switch 145 shown in FIG. 1 is closed and power is applied to terminal 106 to power-up the external device thus entering the power-up state 320 shown in FIG. 3. States 430 and 440 can transition to "set timer" state 450 if their conditions are not met. After timer 450 times out, it will transition to state 460 where the proximity detector and the IR detectors will be deactivated. State 460 will transition back to state 410 and the process begin again. State 460 may also be entered externally from the power-down state 330 shown in FIG. 3.
FIG. 5 shows more in detail the power-down state transition diagram 330 of FIG. 3. When entered from the power-up state 320 of FIG. 3, a set timer state 520 is entered which corresponds to power-down timer 150 shown in FIG. 1. If motion is detected (state 530) timer 520 is reset. If no motion is detected, state 540 results from a timeout which triggers a power-down device state 550. This corresponds to resetting of flip-flops 140 and 115 if FIG. 1. State 550 transitions back to power save state 300 shown in FIG. 3 and more specifically to state 460 within that state.
FIG. 6 is a flow chart of a one power control process used as part of the invention. Eyetracker 290, shown in FIG. 2B is utilized to control the illumination of images on the display 220. How this is done is shown in FIG. 6. The eyetracker outputs are processed to distinguish four conditions shown in FIG. 6, namely:
1. Whether the eyes are fixed at a point on the screen,
2. Whether the eyes move off the screen,
3. Whether the eyes are approaching the screen from a position off the screen, and
4. Whether the eyes are moving across the screen.
These four cases are distinguished by seperate processing branches shown in FIG. 6. When the eyetracker determines that the eyes are fixed on the screen, case 1 (610) obtains and the display intensity is set at normal illumination (615).
In case number 2 (620), when the eyes move from the screen to a point off the screen, a time interval of, preferably, 1/10 of a second (625) is set. If that time expires without the eyes returning to the screen, the screen will slowly fade the display intensity to black (626). In the embodiment shown in FIG. 6, once the eyes have been off the screen for a period of time greater than the time set in item 625, cases 3 and 4 are treated identically. That is, whether the eyes are approaching the screen or moving across the screen without fixing on the screen, the display intensity will resume normal illumination as quickly as possible. Normal illumination will thus continue until such time as the eyes leave the screen again.
The embodiment shown in FIG. 7, is identical for cases 1 and 2 as that shown in FIG. 6. However, cases 3 and 4 are treated separately. In case 3, where the eyes are approaching the on-screen condition, in this embodiment, nothing happens. That is, the screen remains blank. However, case 4 results in measurement of the time that the eyes are on the screen. If the time the eyes are on the screen exceeds some threshold, the display intensity is resumed at normal illumination as quickly as possible.
Thus, in accordance with the invention, electrical devices powered by energy sources of finite capacity can utilize the energy available to the maximum extent possible and reduce energy waste to a minimum.
In this disclosure, there is shown and described only the preferred embodiment of the invention, but, as aforementioned, it is to be understood that the invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein.
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An eyetracker is used to control power to an electrical device such as a computer display screen so that power consumption is reduced when a user's eyes and therefore a user's attention are not directed to the device. A motion detector activates a proximity detector and/or an IR detector to ensure that power is applied only when a user is actually present.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from German Patent Application No. 103 58 257.6, dated Dec. 11, 2003, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to a card flat bar for a carding machine, which card flat bar comprises a carrier element with a clothing support part, and two end head parts associated with the carrier element.
In a known card top bar, the carrier element and the end head parts form at least three assembled components, and the end head parts comprise at least one sliding-contact region, which is in contact with the slideway, and at least one fixing region, which is fixed to the carrier element and at the same time holds the sliding-contact region.
Modern card flat bars are extruded from aluminium. In practice, the extruded card flat bar is cut to length and finished, for example, to a flatness of 0.05 mm. Carrier pins are then adhesively secured over part of their area in a tolerance-free plane laterally into openings in the carrier element. On account of the extrusion and the finishing operation, tolerances accrue in the height dimension of the adhesively secured pins. In order to keep this height dimension within a margin of 0.05 mm in a card flat set, after the adhesion process a grading according to height dimensions is carried out. This process takes time and effort. Subsequently, the clothing strip is mounted on the heel face of the card flat bar in the described manner. Since the accumulation of the tolerances from the card flat bar, card flat clothing, offset occurring during mounting and from deformation as a result of tension when fitting on is too high, the above-described levelling by grinding is finally carried out across all the card flat bars. This involves grinding off up to 0.15 mm of material. The technological efficiency of the ground-down clothing tips is limited. If the clothing wire is over-ground, the actual operative sharpness in the region of the tip is taken away. In particular the accumulation of tolerances as the card flat clothing is assembled, the technically destructive grinding to a level finish and the decline in accuracy during use are therefore disadvantageous.
A card flat bar known from U.S. Pat. No. 4,827,573 comprises a steel tube pulled through a profiling mould. At both ends of the card flat bar there are solid head pieces, on which retaining elements for fixing a drive belt are mounted. These head pieces are joined to the card flat bar either by welding or with rivets or screws, so that they can be exchanged when they have become ineffectual as a result of wear. It has become apparent that the weld joints in some cases lead to stresses in the card flat bar and then exchange of the entire card flat bar is necessary. This same applies also to the screwed and riveted joint, that is, the joining force to be applied (turning the screw or the pressure involved in riveting) must be uniform to begin with and remain constant within a certain tolerance range for all card flat bars, in order to avoid undue compressive strain (i.e. a plastic deformation of the bar length by compression). Consequently, the height dimensions between slideway and clothing tips for all card flat bars of a card flat set are not equal. The known card flat bar has lateral walls that extend downwardly and parallel to a certain level and then converge. The end head piece consists of three elements, the head piece and the two-part holding element, which are arranged axially in relation to the carrier element. Only the head piece slides on the slideway, whereas the holding elements and the drive element are located away from the slideway. The drawback of this arrangement is that the drive element acting outside the slideway exerts an undesirable lever action, and hence a bending moment, on the head piece and on the carrier element. In addition, in this way the head piece does not slide with dimensional accuracy on the slideway, and disruptive tilting can occur. The manufacture of the carrier element from a steel tube, which is cold-drawn through a profiling mould and subsequently has to be heat-treated, is associated with considerable outlay, both in relation to manufacturing costs and from a technological point of view. Finally, it is particular disadvantage that the head pieces become worn during in operation. The effort involved in exchange of the worn head pieces is considerable, since the welded or riveted joints of the head pieces to the carrier element have to be unfastened and then reinstated again after the replacement. The repair can only be carried out when the carding machine is idle, which leads to considerable disruption to operations and to production losses.
It is an aim of the invention to produce a device of the kind described in the introduction that avoids or mitigates the said disadvantages, in particular in a simple manner renders possible a dimensionally stable and dimensionally accurate clothed card flat bar and allows simpler manufacture.
SUMMARY OF THE INVENTION
The invention provides a card flat bar assembly for use in a carding machine, comprising:
a carrier element having a clothing support portion and a back portion, and first and second opposed ends; and first and second end head parts for fixing to said first and second opposed ends of said carrier element, each end head part comprising at least one fixing region and at least one sliding region having a sliding surface that in use is in sliding contact with a slideway of the carding machine;
wherein the fixing region can be adjusted in position relative to the carrier element for adjusting a distance between said sliding surface and a lower surface of the assembled card flat bar and can be fixed at a desired position.
Said distance between said sliding surface and a lower surface of the assembled card flat bar may be a distance between said sliding surface and a lower surface of the clothing support portion, or may be a distance between said sliding surface and a further layer or component attached to the clothing support, for example, a distance between the sliding surface and tips of clothing provided on the clothing support. The fixing region may be adjustable in position relative to the carrier element by means, in particular, of there being a separation distance between the fixing region and that part of the carrier element with which it engages, permitting a degree of play between the fixing region and the carrier element.
Where, in a preferred embodiment, there is a clearance between the outer wall of the fixing region and the inner wall of an opening in the carrier element, the distance between the sliding-contact surface and the card flat tips is uniformly and equally precisely adjustable for each card flat bar, and this distance can be fixed, thus enabling a dimensionally accurate card flat bar to be produced in a simple manner. All manufacturing tolerances of the card flat bar, the clothing and during assembly (including dismantling) can be eliminated. The card flat bar clothed in accordance with the invention advantageously and effectively reduces or prevents an accumulation of tolerances during assembly of the card flat clothing, the technically destructive grinding to a level finish and the decline in accuracy during use. In particular it is an advantage that the measures according to the invention render grading of the card flat bars according to class unnecessary, as a result achieving quite considerable rationalisation. The height dimensions achieved within a card flat set comprising a plurality of card flat bars are identical.
The end head part may be in direct engagement with the carrier element. The end head part may be in engagement with the carrier element by way of an auxiliary support known per se in the region of the end face. Each end head may comprise two elements. The sliding-contact region of the end head part may be of substantially linear construction. The sliding-contact region may be in the form of a sliding-contact surface.
The fixing region may be, for example, cylindrical or polygonal. The end head parts may be fixed in the end face of the heel part of the carrier element. The end head parts may be of any suitable material, for example, hardened steel or the like. Advantageously, the sliding-contact surface of the end head parts is ground, precision-ground and/or polished. Advantageously, the end head parts are fixed in openings of the carrier element. Preferably, the end head parts are fixed with their fixing region in a bore in the end face of the carrier element. Advantageously, the lower limitation of the fixing regions of the end head parts is located a distance above the heel face of the carrier element. Advantageously, openings are present in the heel part of the carrier element extending over the length thereof. Advantageously, the openings run parallel to one another. Advantageously, the openings have a continuous slit (elongate slot open on one side). The cross-section of the openings may be, for example, circular, polygonal, or elongate. Advantageously, the carrier element and the end head parts form at least three assembled components. Advantageously, the carrier element is an extruded profile, which may be hollow. The lower regions may slide on the slideways of the end head parts. The end head parts may be connected to the openings by an interference fit. The end head parts may be connected to the openings by resilient clamping. A bonding and filling material may be present between the end head parts and the openings. The end head parts may be connected with or in the openings by means of a casting compound or the like. The end head parts may be connected to the openings by being adhesively secured therein. The end head parts may be connected to the openings by a curable synthetic resin or the like. The end head parts may be connected to the openings by a mechanical fixing element or the like.
When a card flat bar of the invention has a card flat clothing, in which the card flat clothing is fixed to the card flat bar and lies opposite the clothing of a roller, e.g. the cylinder, there may be present, between the card flat bar and the card flat clothing, a compensating layer, which is capable of compensating for different distances between the card flat bar and the card flat clothing. The compensating layer may be capable of compensating for different distances between the rear face of the card flat clothing and the heel face of the card flat bar. The compensating layer may be capable of compensating for different distances between the sliding-contact surfaces of the card flat heads and the heel face of the card flat bar. The compensating layer may be capable of compensating for different distances between the sliding-contact surfaces of the card flat heads and the tip circle of the clothing tips. The compensating layer may be capable of compensating for different distances between the tip circle of the clothing tips and the tip circle of the cylinder clothing. The compensating layer may be capable of compensating for local different distances between the rear face and the heel face. The compensating layer may consist of plastics material or the like. For example, a synthetic resin, e.g. epoxy resin, or a polyester or the like may be provided as compensating compound. The plastics material, the synthetic resin or the like may be curable; may be castable; and/or may be viscous. Advantageously, the plastics material, the synthetic resin or the like adheres to the clothing backing more strongly than to the heel face of the card flat bar. Advantageously, an adhesive layer is present between the compensating layer and the heel face of the card flat bar.
Advantageously, a flexible clothing is present. The flexible clothing may comprise a backing and clothing tips, wires, hooks or the like. The backing may be in the form of a strip. The clothing may consist of saw-tooth wire strips, e.g. all-steel clothing. The clothing may be secured to the card flat bar in the region of the heel face thereof. The clothing may be secured to the card flat bar by adhesion. Advantageously, the card flat bar and the card flat clothing can be associated with the same reference plane. The reference plane may be a flat counter-surface, e.g. a plate or the like, for the tips of the card flat clothing. The card flat bar may be an extruded profile of light metal, e.g. aluminium. The extruded profile may be a hollow profile. The carrier element may be cut to length, e.g. by sawing. The cut-to-length card flat bar can be straightened. In use, the distance between the sliding-contact surfaces of the card flat heads on the outer face of the slideway and the envelope curve of the card flat clothing tips is uniform. The end parts may be non-releasably connected to the card flat heel. Advantageously, the fixing region of the end head part is fixed in an opening of the carrier element. Advantageously, a distance (degree of play) is present between the fixing region of the end head part and at least partial regions of the inner wall of the opening.
The invention also provides a card flat bar for a carding machine, which card flat bar comprises a carrier element with a clothing support part (card flat heel) and a back part, wherein two end head parts are associated with the carrier element, the carrier element and the end head parts form at least three assembled components, and the end head parts comprise at least one sliding-contact region, which is in contact with the slideway, and at least one fixing region, wherein between the fixing region of the end head part and regions of the card flat heel there is a distance (clearance), and the distance between the lower limit of the sliding contact region and regions of the card flat heel and/or the free tips of the clothing is adjustable and fixable.
In one method of manufacture of card top bars according to the invention, a plurality of card flat bars are arranged with their heel face on a common reference plane, the sliding elements are likewise arranged with their sliding-contact surface on a common reference plane and subsequently the sliding elements thus adjusted are fixed in the card flat bar. The surface of the cylinder clothing may be used as a reference surface for alignment of the card flat bar and the card flat clothing. The card flat tips may be placed on the first said reference plane and the card flat heads may be placed on the second said reference plane, an intermediate layer being applied between the carrier element and the clothing strip.
In a device for manufacture of a card flat bar according to the invention, the clothing tips of a plurality of card flat bars can be arranged on a common reference plane, the sliding-contact regions of the sliding-contact elements can be likewise arranged on a common reference plane and subsequently the sliding-contact elements adjusted in this manner can be fixed in the card flat bar. The distance between the reference planes may be adjustable. The device may include a plate, for example, a magnetic plate. The device may include as a reference plane, for example, a piece of flat metal or the like. The plate and the reference plane may be mounted on a common holding element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a carding machine with a device according to the invention;
FIG. 2 is a side view of a number of card flat bars with a fragment of a slideway and a flexible bend respectively;
FIG. 3 a is a side view of a back part and a carrier element of a card flat bar according to the invention;
FIG. 3 b is a side view in section through a clothing strip;
FIG. 3 c is a side view of a the card flat bar according to the invention in its assembled state;
FIG. 4 a is a section through another card flat bar with the card flat pins inserted;
FIG. 4 b is a section through the card flat bar of FIG. 4 a with the card flat pins fixed in position;
FIG. 5 is a front view of a card flat bar carrier showing the adjustment of the distance between the lower limit of the card flat pin and the lower limit of the card flat heel;
FIG. 6 is a front view of a card flat bar showing adjustment of the distance between the lower limit of the card flat pin and the free clothing tips,
FIG. 7 is a side view of a further embodiment with an additional compensating layer between card flat heel and clothing strip, and
FIG. 8 is a front view, partially in section, of a construction according to the invention with an arrangement for aligning the card flat bar (distance between card flat pin and clothing tips).
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to FIG. 1 , a carding machine, for example, a TC 03 card made by Trutzschler GmbH & Co. KG of Monchengladbach, Germany, has a feed roller 1 , feed table 2 , licker-ins 3 a , 3 b , 3 c , cylinder 4 , doffer 5 , stripping roller 6 , squeezing rollers 7 , 8 , web-guide element 9 , web funnel 10 , take-off rollers 11 , 12 , revolving card flat 13 with card flat guide rollers 13 a , 13 b and card flat bars 14 , can 15 and can coiler 16 . The directions of rotation of the rollers are shown by respective curved arrows. The letter M denotes the midpoint (axis) of the cylinder 4 . The reference numeral 4 a denotes the clothing and 4 b denotes the direction of rotation of the cylinder 4 . The letter C denotes the direction of rotation of the revolving card flat 13 in the carding setting and the letter D the return transport direction of the card flat bars 14 .
Referring to FIG. 2 , on each side of the carding machine, a flexible bend 17 having several adjusting screws is secured laterally to the machine frame. The flexible bend 17 has a convex outer surface 17 a and a lower surface 17 b . Above the flexible bend 17 , there is a first slideway 20 , for example, of anti-friction plastics material, which has a convex outer surface 20 a and a concave inner surface 20 b . The concave inner surface 20 b lies on the convex outer surface 17 a and is able to slide thereon in the direction of the arrows B, Q. Each card flat bar, which may be constructed in accordance with EP 0 567 747 A1, for example, consists of a back part 14 a and a carrier element 14 b . The carrier element 14 b has a heel face 14 c , two lateral faces 14 d , 14 e and two upper faces 14 f , 14 g (see FIG. 3 ). Each card flat bar 14 has at both ends a respective card flat head 14 ′, 14 ″ (see FIG. 8 ), each of which comprises two steel pins l 4 1 , 14 2 and 14 3 , 14 4 respectively, which with a portion thereof are secured axially (see length 1 in FIG. 8 ) in a compensating layer 24 . The parts of the steel pins 14 1 , 14 2 that project beyond the end faces of the carrier element 14 b slide on the convex outer surface 20 a of the slideway 20 in the direction of arrow Z. The clothing strip 18 is mounted on the lower surface of the carrier element 14 b . The reference number 21 denotes the tip circle of the card flat clothings 19 . On its circumference, the cylinder 4 has a cylinder clothing 4 a , for example, saw-tooth clothing. The reference numeral 22 denotes the tip circle of the cylinder clothing 4 a . The distance between the tip circle 21 and the tip circle 22 is denoted by the letter a, and is, for example, 3/1000′. The distance between the convex outer surface 20 a and the tip circle 22 is denoted by the letter b. The radius of the convex outer surface 20 a is denoted by r 1 and the radius of the tip circle 22 is denoted by r 2 . The radii r 1 and r 2 intersect at the mid-point M of the cylinder 4 .
FIG. 3 a shows a carding flat bar 14 , which is extruded from aluminium, consists of the back part 14 a and the carrier element 14 b . According to FIG. 3 b , a clothing strip 18 for the bar of FIG. 3 a consists of clothing tips 19 (wire hooks) and a backing element 23 of a textile material. The thickness of the backing element 23 is denoted by the letter f. The wire hooks 19 are secured in the backing element 23 , with one end passing through the surface 23 ′ thereof. The other ends of the wire hooks 19 , the clothing tips, are free. FIG. 3 c shows the card flat bar 14 corresponding to FIGS. 3 a and 3 b in the assembled state. There are openings in the carrier element 14 b (heel part) are in the form of slots, in which the card flat pins 14 1 , 14 2 are arranged. The card flat pins 14 1 , 14 2 are fixedly connected with the inner walls of the openings by means of a curable casting compound 29 1 , 29 2 respectively.
The curable casting compound 29 1 , 29 2 is able to compensate for different distances between the card flat bar 14 , namely the heel face 14 c , and the card flat clothing 19 , namely the envelope of the free tips. The fixing regions of the steel pins 14 1 , 14 2 that form the card flat head 14 ′ are arranged in respective openings 281 , 282 (see FIG. 4 a ). The sliding-contact region of the steel pins 14 1 , 14 2 extends beyond the end face (see FIGS. 5 to 7 ).
In the embodiment of FIGS. 4 a and 4 b , the openings 28 1 , 28 2 in the card flat bar are of hollow cylindrical construction. The outer diameter d 1 of the pins l 4 1 , 14 2 is smaller than the inner diameter d 2 of the fixing openings 28 1 , 28 2 . Between the fixing region i (see FIG. 5 ) of the card flat pins 14 1 , 14 2 and the openings 28 1 , 28 2 , there is a distance m (clearance), i.e. d 2 -d 1 =m. According to FIG. 4 a , the pins 14 1 , 14 2 are inserted in the openings 28 1 , 28 2 with their fastening region i (see FIGS. 5 to 7 ). According to FIG. 4 b , a curable casting compound (hardened) 29 1 , 29 2 is present in the bores 28 1 , 28 2 respectively. The pins 14 1 , 14 2 in FIG. 4 b are shown in end positions.
Referring to FIGS. 5 and 6 , the card flat pin 14 2 is arranged with its fixing region i in the opening 28 2 and the sliding-contact region k—the free end—is located outside the opening 28 2 .
As shown in FIG. 5 , a parallelepipedal bearing element 30 having parallel plane surfaces is arranged between the lower limit of the card flat pin 14 2 and a flat plate 25 . By means of this device, the preset distance h 1 between the lower limit of the sliding-contact region k of the card flat pin 142 and the lower limit 14 c of the card flat heel 14 b is set. First of all the card flat heel 14 b is placed on the plate 25 . The card flat pin 14 2 is then applied in such a way that the sliding-contact region k lies on the bearing element 30 and the fixing region i is arranged in the opening 28 2 . Finally, the curable casting compound 29 is introduced into the opening 28 2 and hardened. Once the clothing strip has been fastened to the surface 14 c , a preset uniform distance between the sliding-contact surface of the card flat pins and the clothing tips is realised.
FIG. 6 shows the adjustment of the distance h 2 between the lower limit of the sliding-contact region k of the card flat pin 14 2 and the free tips of the clothing 19 . The adjustment corresponds substantially to the adjustment shown in FIG. 5 , but first of all the clothing strip 23 is fixed to the heel face 14 c , the card flat bar 14 with the tips of the clothing 19 is placed on the plate 25 and then the card flat pin is applied and fixed in the manner specified with reference to FIG. 5 , using a bearing element 27 a instead of bearing element 30 .
In the card flat bar of FIG. 7 , an intermediate layer 24 , for example, of cured synthetic resin, is arranged between the carrier element 14 b and the backing element 23 . The upper surface 24 ′ lies in contact with the heel face 14 c ′ and the lower face 24 ″ lies in contact with the backing element. The upper face 24 ′ is also arranged at an angle α to the carrier element 14 b . The lower face 24 ″ on the other hand is aligned parallel to the connecting line between the sliding-contact points of the pins 14 1 , 14 2 and the tip circle 21 . In this way, the distance c between the sliding-contact points of the pins l 4 1 , 14 2 and the sliding-contact surface 20 a on the one hand and the tip circle 21 (envelope curve) of the card flat pins l 4 1 , 14 2 on the other hand is uniform. The different distances e 1 , e 2 between the faces 14 c ′ and 23 ′ are compensated for by the compensating layer 24 . In this manner—despite the undesirably sloping heel face 14 c ′ of the carrier element 14 b —the important and narrow carding distance a between the tip circle 21 of the card flat clothing 19 and the tips 22 of the cylinder clothing 4 a is constant on all sides. 14 3 denotes a connecting element that is fixed with a positive fit to the pins 14 1 , 14 2 .
The compensating layer 24 similarly compensates for local irregularities in the heel face 14 of the carrier element 14 b or in the face 23 ′ of the backing element 23 or any variation from parallel that exists between the distances of the tip circle 21 to the surface 23 ′ and/or to the face 23 ″.
As FIG. 8 shows, between the card flat pins 14 1 , 14 2 and a flat plate 25 there is fixedly arranged on the plate 25 a parallelepipedal bearing element 27 a with parallel and plane faces, and between the card flat pins 14 3 , 14 4 (hidden behind pin 14 3 ) and the plate 25 there is fixedly arranged on the plate 25 a further parallelepipedal bearing element 27 b of the same height h. With this device, and with (not shown) further lateral infill elements or the like (e.g. displaceable limiting faces for the compensating layer 24 and/or the backing element 23 ), the clothing tips 19 of the clothing strip 18 can be positioned on the plate 25 and pins l 4 1 , l 4 2 , 14 3 , 14 4 can be positioned on the bearing elements 27 a , 27 b . The compensating layer 24 is subsequently introduced between the carrier 14 b and the backing element 23 . This can be effected, for example, in that the compensating layer is cast, injected, spread, placed in position etc. The compensating layer 24 , for example of paste-like composition, then distributes itself in the space and fills this evenly.
Although the foregoing invention has been described in detail by way of illustration and example for purposes of understanding, it will be obvious that changes and modifications may be practised within the scope of the appended claims.
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A carding machine, includes a carrier element with a clothing support part (card flat heel). Two end head parts are associated with the carrier element. The carrier element and the end head parts form at least three assembled components, and the end head parts comprise at least one sliding-contact region, which is in contact with the slideway, and at least one fixing region, which is fixed to the carrier element and at the same time holds the sliding-contact region. Between the fixing region of the end head part and at least partial regions of the carrier element there is a distance (clearance), and the distance between the lower limit of the sliding contact region and the card flat heel and/or the free tips of the clothing is adjustable and fixable.
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This application is a continuation of application Ser. No. 08/389,296, filed Feb. 16, 1995, now abandoned.
FIELD OF THE INVENTION
This invention relates to methods for detecting the existence of harmful levels of bacterial growth in packaged foods.
BACKGROUND OF THE INVENTION
The presence of undesirable bacteria, for example, Botulism sp., among others, in food products intended for human consumption has recently caused increased concern among food product manufacturers. This is due to the potential that contaminated food has for serious illness or even death as a consequence of its ingestion by the consumer. While it would be desirable to monitor contamination in every sample of food, in most cases, it is simply not possible to detect the presence of contaminating bacteria by visual or other inspection. Consequently, chemical means must be used to facilitate such detection.
Although food is generally inspected prior to its being canned, it is presently not practical to inspect each can of food for contamination.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a method for detecting the presence of contaminating bacteria in a food sample, especially a food sample which has been stored in cans or other packages.
It is also an object of the present invention to provide new food storage cans which have been adapted to detect the presence of contaminating bacteria in food stored in cans.
It is also an object of the present invention to provide new polymeric compositions which can be incorporated onto the lining of a food can and used to detect contaminating bacteria in canned food.
These and other objects of the present invention may be readily gleaned from the description of the invention which follows.
SUMMARY OF THE INVENTION
The present invention relates to a method for determining the presence or absence of contaminating bacteria in a canned food sample comprising storing food in a can having as a lining a polymeric composition, said composition preferably being permeable to at least one gas selected from the group consisting of carbon dioxide, sulfur dioxide and ammonia gas and containing an indicator for detecting the presence or abscence of said gas; said indicator being polymerized or dispersed throughout said polymeric composition. Alternatively, the indicator may be coated onto the polymeric composition and used directly without further modification or coated in combination with or coated by a permeable polymer which helps the indicator to adhere to the first coating either in combination with the permeable polymer or underneath the permeable polymer.
The present invention also relates to novel food cans which have been lined with polymeric compositions containing an indicator which has been polymerized or dispersed throughout or coated onto the polymeric composition, the food cans being capable of storing food and detecting the presence of gas released by contaminating bacteria present in the food which is stored in the cans.
The present invention is useful for detecting bacterial contamination in food which has been stored after canning or packaging for extended periods of time. Although virtually any microorganism which produces a gas during growth and/or metabolism may be detected by the present invention, particularly important microorganisms which may be detected by the present invention include bacteria such as Salmonella sp, Streptococcus sp., Shigella sp., Botulism sp., Escherichia coli and Coliform bacteria. A number of types of E. coli may be detected by the instant invention including enterotoxigenic (ETEC), enteroinvasive (EIEC), enterohemorrhagic (EHEC), enteropathogenic (EPEC) and enteradherent (EAEC), among others.
Numerous polymeric compositions for lining the food storage package may be used, with preferred compositions including polymeric compositions which are sufficiently permeable to allow gas produced by contaminating bacteria to diffuse through the composition to a reactive site on an indicator dispersed or polymerized throughout the composition without allowing the food stored within the package to leak or come into contact with a package lining to be avoided, such as the steel lining of a food can.
Indicators include those which are well known in the art. The indicators which find use in the present invention are those which provide a calorimetric reaction upon exposure to the gases produced by contaminating microorganisms. Gases which are produced by contaminating microorganisms include, for example, carbon dioxide, sulfur dioxide and ammonia. Each of these gases in water produces an acid (carbonic, sulfuric) or a base (ammonia) which reacts with the chosen indicator to produce a calorimetric reaction, thus indicating the presence or absence (in the case where no reaction occurs) of contaminating bacteria.
DETAILED DESCRIPTION OF THE INVENTION
The following terms will be used throughout the specification to describe the present invention.
The term "polymeric composition" is used to describe the chemical lining of the food storage containers or plastic wrap according the present invention which contains indicator, whether polymerized or dispersed within the composition or coated onto the composition. Polymeric compositions for use in the present invention include those which are typically used to line cans or make food wrap, for example, polyvinyl acetate, polyvinylchloride copolymers of polyvinylacetate and polyvinylchloride and hydroxyl-modified vinyl chloride/vinyl acetate copolymers (for example, vinyl VAGH and VyHH copolymers available from Union Carbide). Additional, preferred polymers include those which are permeable to one or more of carbon dioxide, sulfur dioxide or ammonia gas produced by the contaminating bacteria. Additional exemplary polymeric compositions for use in the present invention include for example, polyethylene, polystyrene, polytertiarybutylstyrene, cellulose acetate butyrate, polytetrafluoroethylene, polytetrafluoroethylene/hexafluoropropene copolymers (Teflon FEP), butadiene/styrene copolymers, butadiene/methylstyrene copolymers, poly(meth)acrylates, butadiene/acrylonitrile copolymers, ethylene/propylene copolymers, polybutadiene, polyisoprene, polyester resins, poly(imino(1-oxohexamethylene) (Nylon 6), poly(imino(l-oxoundecamethylene) (Nylon 11), poly(oxy2,6-dimethyl-1,4-phenylene), poly(oxycarbonyloxy-1,4- 1,4phenyleneisopropylidene-1,4-phenylene) (Lexan), cellulose acetate, ethyl cellulose, polyethylene terephthalate and mixtures, thereof, among others.
The polymeric compositions may be hydrophilic or hydrophobic, but preferably, are hydrophobic in order to minimize the likelihood that the food or water in the food will come into contact with the metal lining of the storage can or the composition will absorb significant quantities of water from the food. In certain cases, for example, when carbon dioxide or sulfur dioxide is to be analyzed, it may be advantageous to have the polymeric composition accommodate or contain small amounts of water, in order to allow the formation of carbonic acid or sulfuric acid, which will be directly detected by the indicators included in the polymeric compositions.
The polymeric composition may line a food package, e.g., a steel can, in a manner to form a "tight coating", i.e., a coating which is designed to preclude any part of the stored food from coming into contact with the underlying can. The polymeric composition may be chosen so as to allow gases to pass through and come into contact with an indicator which has been polymerized or dispersed throughout the polymeric composition. Alternatively, the indicator may be coated onto the polymeric composition and used directly or coated onto the underlying polymeric composition in combination with or underneath a gas permeable polymer which holds the indicator in place for analysis.
One of ordinary skill in the art, simply relying on readily available information regarding the permeability data (for individual gases such as carbon dioxide, sulfur dioxide and ammonia) for the various polymeric compositions and the relative degree of hydrophobicity or hydrophilicity may easily determine the appropriate polymeric composition to use in a particular manner with a particular foodstuff. Thus, one of ordinary skill in the art may choose the appropriate polymeric composition to line the food container, or accommodate an effective amount of indicator based upon the food to be stored as well as a microorganism or bacteria to be detected. For example, in the case of detecting E. coli contamination in cans, one of ordinary skill in the art will recognize that it is appropriate to choose polymers containing an indicator which detects trace quantities of carbon dioxide produced by the bacteria. In the case of other bacteria and foodstuffs, the polymeric composition will be modified to accommodate the appropriate indicator and food.
The term "gas" is used to describe gaseous products of metabolism or growth of contaminating bacteria in food which is stored in the storage cans according to the present invention. Exemplary gases which are detected in the present invention include carbon dioxide, sulfur dioxide and ammonia, among others.
The term "permeable" is used to describe polymeric compositions according to the present invention which allow sufficient quantities of gases to flow through the composition and interact or react with the indicator.
The term "package" is used to describe any container, can, pail, bottle, drum, packing material or wrap in which food may be stored. In the present invention the food package is lined with a polymeric composition which contains or is coated by an indicator. The indicator, where it is coated onto a composition may be further coated with an additional polymeric composition, preferably permeable to the gas or gases to be detected.
The term "contaminating bacteria" is used to describe microorganisms such as bacteria which, if present in food, create a potential health hazard for the consumer. Life-threatening sickness, even death, may result from the consumption of food contaminated with any number of deleterious microorganisms such as bacteria. Although numerous contaminating microoraganisms including bacteria may be detected using the present invention, the most common bacteria which create health problems in food include Salmonella sp., Streptococcus sp., Shigella sp., Botulism sp., Escherichia coli and other Coliform bacteria. In the case of Escherichia coli, a number of types may be problematic, but are detected by the present invention including, for example, enterotoxigenic (ETEC), enteroinvasive (EIEC), enterohemorrhagic (EHEC), enteropathogenic (EPEC) and enteradherent (EAEC), among others. Numerous E. coli of O-serogroups may be problematic including for example, (EPEC) 026:K60, 055:K59, 0111:L58, 0127:K63, 086:K61, 0119:K69, 0124:K72, 0125:K70, 0126:K71, 0128:K67, 018:K77, 020:K61, 020:K84, 028:K73, 044:K74, 0112:K66; (ETEC) 06, 08, 011, 078; (EIEC) 028:K73, 0112:K66, 0124:K72, 0143:K b , 0144:K c ; and (EHEC) 0157:H7, among others. A particularly onerous serogroup of E. coli is (EHEC) 0157:H7.
The above-referenced bacteria, among others, as a consequence of growth and/or metabolism, produce significant quantities of gas including carbon dioxide, sulfur dioxide or ammonia gas, among others. The gases produced by these deleterious microorganisms may be readily detected using the present invention, thus alerting the consumer to the potential dangers of consuming contaminated food.
The bacteria generally remain dormant as spores in the food product until certain conditions exist. The most prevalent condition is a constant exposure to ambient temperatures of about 45.5° C.+2° C. outside the can, which promotes growth and germination of the bacterial spore. As the bacterial spore grows it releases an effervescent gas, which migrates toward the indicator and produces a chemical reaction.
The term "indicator" is used to describe chemical compounds which may be added to or coated onto polymeric compositions according to the present invention in amounts effective to detect gases which are produced by contaminating bacteria in food. Indicators are chemical compounds which undergo a chemical reaction in the presence of a gas or an acid or base conjugate of a gas and produce a calorimetric species in response to the acid or base produced. The chemical response of the indicator is generally concentration dependent. Indicators for use in the present invention may be solids or liquids. In the present invention, gases which are produced by contaminating bacteria including carbon dioxide, sulfur dioxide and ammonia gas, among others, react with the chosen indicator which has been polymerized or dispersed throughout the polymeric composition. The indicator produces a calorimetric reaction upon exposure to the gas or an acid or base conjugate of the gas, thus evidencing the presence of contaminating bacteria in the analyzed food sample. In certain preferred versions of the present invention, the indicator will produce an irreversible calorimetric reaction upon exposure to the gas produced by the contaminating bacteria, thus minimizing the possibility that leakage of the gas from the food storage container will result in a failure to detect contamination.
Exemplary indicators for the detection of carbon dioxide or sulfur dioxide include, for example, xylenol blue (p-Xylenolsulfonephthalein), bromocresol purple (5',55"-Dibromo-o-cresolsulfonephthalein), bromocresol green (Tetrabromo-m-cresolsulfonephthalein), cresol red (o-Cresolsulfonephthalein), phenolphthalein, bromothymol blue (3',3"-Dibromothymolsulfonephthalein), p-naphtholbenzein (4- alpha-(4-Hydroxy-1-naphthyl)benzylidene!-1(4H)-naphthalenone) and neutral red (3-Amino-7-dimethylamino-2-methylphenazine Chloride), among others. These indicators all provide calorimetric responses to the addition of quanities of acid, in the form of carbonic acid or sulfuric acid (from CO 2 or H 2 SO 4 production by contaminating bacteria). An exemplary indicator for the detection of ammonia produced by contaminating bacteria comprises a mixture of potassium iodide, mercuric (III) iodide, sodium borate, sodium hydroxide and water (in the ratio of 1.5:2.5:2.5:3.5:90 parts by weight).
Indicators which are advantageouusly employed in the present invention may be dispersed or polymerized throughout the polymeric composition or alternatively, simply coated onto the polymeric composition (lining of the food package). In the case of indicators which are polymerized throughout the polymeric composition, the indicators may be modified and placed in monomeric form in order to participate in the polymerization reaction and become part of a backbone or sidechain of the polymeric composition.
The present invention may be used in standard food cans or alternatively, may be used in other packing materials, such as plastic bags (especially in the case of sea food), saran wrap or cellophane or moisture barrier packing (in the case of storing meats, cheese, poultry, etc.).
In one aspect, the present invention is essentially a warning system for the presence of certain contaminants within containers of processed or non-processed comestibles. A positive analysis will alert a consumer to avoid eating contaminated food.
The uniqueness of this invention is manifest in the following exemplary manner:
1) The capability of ascertaining the presence or absence of contaminants within a container while the contents are in a closed and sealed atmosphere by way of an on-going, and continuous analysis procedure. 2) The container is prepared for the continuing analysis procedure during the manufacturing process where the polymeric composition containing indicator may be applied, directly onto the package or over a standard package (can) coating with a clear USDA or FDA approved indicator solution suspended or dispersed in the polymeric composition and applied by various methods to the package, e.g., sprayed, roller coated, printed, stamped, etc. The polymeric composition containing the indicator will dry, polymerize, convert or cross-link at the specification of the container fill line.
During the container manufacture procedure, the indicator solution, being clear when applied, may be printed or otherwise applied, over standard internal can coatings so as to convey a message to whomever opens the container. Exemplary messages may read:
WARNING| DO NOT EAT THE CONTENTS OF THIS CAN, or
WARNING| BEFORE EATING, THE CONTENTS OF THIS CAN MUST BE HEATED TO 150° F. FOR FIVE MINUTES, or
WARNING| DO NOT EAT, RETURN TO STORE FOR REFUND.
When applied, the indicator is still clear or a particular color which evidences that no reaction or contamination has occurred. When the food package is filled, closed and sealed, the continuing chemical analysis begins. If the food package contains contaminated toxic organic materials, these will begin to grow and multiply within the closed and sealed atmosphere, producing any one or more of carbon dioxide, sulfur dioxide or ammonia, among others during metabolic processes.
The microrganism growth particles may be spores or bacteria which produce gas as they grow and multiply. As the gas accumulates, it migrates in an upward direction to accumulate in a top end area. As the gas contacts the indicator, the indicator ink and gas react, thus causing the indicator to change from a clear or original color to a predetermined color, thus making the warning legible. If no gas is produced, there will be no reaction.
This invention may also be employed in additional applications. Employing the polymeric composition containing an indicator on the inside of a container, i.e., a can, jar lid, bottle cap, 5 gallon pail cover or 55 gallon drum lid, among other packages, the indicator or polymeric composition containing indicator may be deposited on either or both sides of "plastic wrap" sheets or rolls. With both sides of the plastic material printed, when used as a wrapper for table ready comestibles, the user applying the wrap to the food product will not be confused as to which side of the plastic wrap has been printed because the indicator is applied to both sides of the plastic wrap.
As in the instance of comestibles packaged in cans for sale to the general public or for temporary storage in large open containers in processing plants or retail markets, the organisms generate gases as they grow and multiply. The gases will migrate to the indicator and produce a calorimetric reaction, thus, preferably causing a warning to appear.
The following examples are provided to illustrate the present invention and should not be misunderstood to limit the scope of the present invention in any way.
EXAMPLE
The following is a description of the manufacturing process of a standard can that can be used in the packaging of vegetables such as corn, various kinds of beans, fruit, fruit sald, puddings, etc.
The raw material generally is a mild steel in large rolls delivered to the manufacturing site. A large roll is fed into the "slitter." The roll is then "slit" (cut), then rerolled in to various rolls, the width of which is equal to the exact height of the can in its finished state. A roll of the desired width is then painted with a vinyl paint (polyvinyl acetate or polyvinylchloride), the formula of which is compatible with the food product which is to be packaged in the finished can.
The roll is thereafter straightened and cut. The pieces are the exact size of the finsished can body. The pieces are stacked and portions of the stacks are introduced into a feeding device which is a gravity feeder inserting one body piece a time into a machine which forms the flat piece (blank) into a cylinder and passes the now cyclical "body" past an electrical resistance welder, joining the two edges together with an electrical resistance weld. The welded section is then coated with a "side seam enamel" which can tolerate the very high temperature of the welding process.
The welded cyclinder (body) moves along with the conveyer at the speed of of 400-600 can bodies per minute. The conveyor by design changes the direction of the "lie" of the can body. To this point, the can bodies have been in a horizontal position, following each other along the conveyor. They are now turned in a manner to create a side by side relationship, and then fed into a large platen with wide holes. The platen is turning in the same direction as the conveyor. As the platen turns, it takes the cans out of the conveyor line, the inside of the can is sprayed with a vinyl coating, and then the can is returned to the conveyor, the can body now moves along the conveyor a short distance. The solvent formula of the coating is adjusted to the speed of the conveyor and the distance traveled to the oven.
The body is then made. There are generally two and three piece can assemblies. Various formulas are used in the internal finish of the cans. Some have 100% solids and need no "flash off time." Other coatings may employ thermal conversion, chemical reactions or ultra violet light to ensure complete polymerization.
A two piece can involves a body made by deep draw. This method of manufacture would have a single piece deep drawn in the center of the flat stock resulting in a body with the bottom intact in a single impact referred to as a "deep draw." This can be accomplished singularly or by a multiple impact changing tools as the draw is deepened to a desired depth or height of the can. Three piece cans, the most widely-used design, involves a body, a bottom and a top.
The top and bottom of the can are both refrred to as lids, and are made from a single sheet of steel which is die cut to obtain a maximum number of lids per piece of sheet stock. Tops and bottoms are separated from the flash and they are printed with the indicator directly or along with the polymeric composition containing the indicator on the inside portion of the lids. The indicator applied will be specific for the product canned or may be formulated to be sensitive to several contaminating microorganisms.
The indicator used for a particular canning run must be compatible with the internal can coating and maintain acceptable adhesion whether the product is going to be frozen or cooked at a high temperature. Because the food product inside the can comes in contact with the food, the indicator is classified as a food additive and must meet all standards, as set forth by the FDA for food additives.
In the case of a three part can, there is a bottom, a body and a top. The bottom is attached in one of several methods to the body. The cans are filled with food product and the lid is fastened using an approved method. Some cans containing certain food products may be further processed (cooked) at this point. Other cans have fully processed food filled at the start. The filled can is now ready for labeling, packing and shipping.
During storage, if contaminant bacteria are present in the stored food, the gas produced by the bacteria will produce a reaction in the indicator in the lid (top or bottom) of the can. A color reaction will indicate the presence of deleterious quantities of bacteria, no reaction indicates the food product is safe for consumption.
Food Wrap
Generally, two types of vinyl compounds are used in food wrap, e.g., polyvinyl acetate and polyvinyl chloride. The treatment of either of these vinyl solutions is the same. The indicator, dispersed in a compatible carrier, is blended into the vinyl wrap mixture while the ingredients are in a liquid state. Both solutions together will be further processed until the liquid vinyl compound is processed into sheets, then into rolls.
When the wrap is used to cover food products and contaminant bacteria, if present, commence to grow and generate gases. When the gases reach the food wrap and contact the indicator bearing cover, the indicator will react by changing color. The absence of toxin is evidenced by no reaction.
It is to be understood that the embodiments described hereinabove are for the purposes of providing a description of the present invention by way of example and are not to be viewed as limiting the present invention in any way. Various modifications or changes that may be made to that described hereinabove by those of ordinary skill in the art are also contemplated by the present invention and are to be included within the spirit and purview of this application and the following claims.
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A method for determining the presence or absence of contaminating bacteria in a packaged food sample includes storing food in a package having as a lining a polymeric composition, said composition preferably being permeable to at least one gas selected from the group consisting of carbon dioxide and sulfur dioxide and containing an indicator for detecting the presence or abscence of the gas; the indicator being polymerized or dispersed throughout the polymeric composition or coated onto the polymeric composition.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to the telecommunications industry. More particularly, this invention pertains to a digital distribution apparatus for use in a telecommunications network.
2. Description of the Prior Art
The telecommunications industry requires cross-connecting and switching functions for a variety of equipment. Historically, the industry has utilized manually operated digital system cross-connect (DSX) apparatus for connecting two or more units of telecommunications equipment. The DSX equipment could provide cross-connect, monitoring, and other access functions to the telecommunication network.
In recent years, the telecommunications industry has considered the implementation of electronic digital signal cross-connect (EDSX) equipment to replace conventional manual DSX equipment. An example of a method for replacing DSX equipment with EDSX is shown in commonly assigned U.S. Pat. No. 4,941,165 entitled "Hot Cut Procedure For Telecommunication Network".
When utilizing EDSX equipment, it is desirable to retain opportunities for manual cross-connect as well as test access and monitoring functions independent of the EDSX equipment. It is an object of the present invention to provide such an apparatus. Also, it is an object of the present invention to provide line access equipment which may be used independent of an EDSX apparatus.
SUMMARY OF THE INVENTION
According to a preferred embodiment of the present invention an apparatus is disclosed for providing access to a plurality of telecommunication lines. The apparatus includes a frame which carries a plurality of normally closed contacts. The telecommunication lines are terminated on the normally closed contacts. A plurality of modules are provided to be releasably attached to the frame with electrical circuit elements on the modules engaging the normally closed contacts to open the contacts and create a new signal path through the module upon insertion of the module into the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front, top and right side perspective view of an apparatus according to the present invention;
FIG. 2 is a rear, top and right side perspective view of the apparatus of FIG. 1;
FIG. 3 is an exploded perspective view of the apparatus of FIG. 1;
FIG. 4 is a perspective view of a jack card for use in the apparatus of FIG. 1;
FIG. 4A is a schematic view of a jack card showing electrical circuit elements carried by the jack card;
FIG. 5 is a rear, top and right side perspective view of a connector assembly for use in the apparatus of FIG. 1;
FIG. 6 is a front elevation view of the connector assembly of FIG. 5;
FIG. 7 is a view taken along line 7--7 in FIG. 6;
FIG. 8 is a perspective view of a normally closed pair of spring contacts for use in the present invention;
FIG. 9 is a view showing the spring contacts of FIG. 8 in a position about to be opened by insertion of a card;
FIG. 10 is a perspective view of an alternative pair of spring contacts for use with the present invention;
FIG. 11 is a view of the spring contacts of FIG. 10 about to be opened by insertion of a card;
FIG. 12 is a schematic cross-sectional view of a frame for use with the present invention;
FIG. 13 is an alternative embodiment of the frame of FIG. 12;
FIG. 14 is a view showing in cross-section the frame of FIG. 12;
FIG. 15 is a schematic representation of a first use of the apparatus of the present invention in a telecommunications network;
FIG. 16 is a schematic representation of a second use of the apparatus of the present invention in a telecommunications network;
FIG. 17 is a schematic representation of a third use of the apparatus of the present invention in a telecommunications network;
FIG. 18 is a schematic representation, taken in cross-section, of the apparatus of the present invention with an embodiment of a reversible jack card shown in a first position;
FIG. 19 is the view of FIG. 18 with the jack card shown in a flipped position;
FIG. 20 is a schematic representation of the apparatus of FIG. 18 in a telecommunications network;
FIG. 21 is a schematic representation of the apparatus of FIG. 19 in a telecommunications network;
FIG. 22 shows, in schematic format, a telecommunications network with a manual DSX in places; and
FIG. 23 shows, in schematic format, a telecommunications network with an EDSX in use in conjunction with an apparatus of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the several drawing figures in which identical elements are numbered identically throughout, a description of the preferred embodiment of the present invention will now be provided.
With initial reference to FIGS. 1-3, the apparatus 10 is shown as including a frame 12 and a plurality of modules or jack cards 14 (only one of which is shown in FIGS. 1 and 3). As will be more fully described, the frame 12 includes a chassis 16 and a plurality of connector assemblies 18 (only two of which are shown in FIG. 2 and only one of which is shown in FIG. 3).
Chassis 16 is preferably formed of sheet metal and includes spaced apart side walls 20 connected by a rear wall 22, a forward top panel 24 and a forward bottom panel 26. Side flanges 28 are connected to side walls 20 to permit the chassis 16 to be mounted in stacked vertical array with a plurality of other chassis (not shown) in a mainframe or bay (not shown).
Rear wall 22 is provided with openings 30 therethrough sized to receive termination blocks 32. Blocks 32 are provided with wire wrap termination pins 34 extending therethrough. It will be appreciated that termination blocks having termination pins such as blocks 32 and pins 34 are well known in the art and form no part of this invention per se.
As shown in FIGS. 1-3, top panel 24 and bottom panel 26 are spaced apart to define a jack card receiving area 36 which extends between sidewalls 20 and from leading edges 24A,26A of panels 24,26, respectively, to be trailing edges 24B,26B.
The connector assembly 18 includes a block dielectric body 38 shown best in FIGS. 5 and 6. The forward face 40 of the block body 38 is provided with a plurality of vertical slots 41 each having a plurality of vertically aligned contact receiving chambers 42. The chambers 42 each receives a pair of spring contacts 44 which cooperate to define a normally closed switch 45 (illustrated best in FIG. 7).
The spring contacts 44 are provided with wire wrap termination pins 46 which extend through the rear face 48 of block 38 as best shown in FIG. 5.
As shown in FIG. 2, the block bodies 38 are disposed in side-by-side relation within the jack card receiving area 36. The bodies are sized to have a vertical dimension for the body 18 to extend between top and bottom panels 24,26. The bodies 18 are disposed adjacent the trailing edges 24B,26B with the pins 46 extending away from area 36.
Referring now to FIGS. 4 and 4A, the jack cards 14 include a dielectric body 50 which carries a printed circuit board card 52. The jack card 14 extends from a leading edge 54 of body 50 to a trailing edge 56 of card 52. An upper edge 58 of body 50 is provided with an axially extending rail 60. A lower edge 62 of body 50 is provided with a lower rail 64 (only a portion of which is shown in FIG. 4) similar in structure to that of rail 60.
The vertical dimension (i.e., the distance between upper edge 58 and lower edge 62) of jack card 14 is selected for the card to be received within area 36 with upper edge 58 opposing panel 24 and with lower edge 62 opposing panel 26. Bottom panel 26 is provided with a plurality of transverse slots 66 sized to slidably receive lower rail 64 (see FIGS. 1 and 3). The connector assembly 18 includes an upper slotted rail guide 68. Guide 68 is provided with clips 70 disposed to align with openings 72 formed in upper panel 24. Accordingly, the rail guide 68 is to be retained against an inner surface of upper panel 24. The rail guide 68 is provided with a plurality of transverse slots 74 (shown in FIG. 3 only) sized to slidably receive rail 60.
As shown in FIGS. 1-3, slots 66, rail guide 68 and back panel 18 are disposed for the elements of each to cooperate for jack card 14 to be slidably received between panels 24,26 and with the trailing edge 56 of card 52 receivable within a vertical slot 41 of body 38. Retaining clips 76 are provided on the jack in body 14. The clips 76 have ramps 78 which are releasably received within openings 80 formed in rail guide 68 to releasably secure jack card 14 in an inserted position in jack card receiving area 36 (as shown in FIG. 1).
Forward edge 54 of jack card 14 is provided with a plurality of holes or ports extending therethrough. The plurality of ports includes a monitor (or MON) port 82, an OUT port 84 and an IN port 86. As shown in FIG. 4A, the jack card carries an electrical circuit 88 which includes a plurality of spring contacts.
The plurality of spring contacts includes an IN tip normal spring 90 and an IN tip spring 91. The plurality also includes an IN ring normal spring 92 and an IN ring spring 93, an OUT tip normal spring 94 and an OUT tip spring 95. The plurality also includes an OUT ring normal spring 96 and an OUT ring spring 97, a monitor tip spring 98, a monitor ring spring 99, a first LED spring 100 and a second LED spring 101.
Springs 91 and 93 are disposed to be engaged by the tip and ring, respectively, of an electrical jack plug (not shown) inserted within the IN port 86. Springs 95,97 are selected to be engaged by the tip and ring of a plug, not shown, inserted within the OUT port 84. Similarly springs 98,99 are disposed to be engaged by the tip and ring of a plug, not shown, inserted within the MON port 82. Spring pairs 90-91, 92-93, 94-95, and 96-97 are in normal contact in the absence of a plug within either of ports 84,86 and will be opened by insertion of a plug. Springs 98,99 are connected across a resistance to springs 95,97. Spring 100 is engaged into electrical contact with spring 101 by means of spring 99 urging spring 100 via a dielectric pusher 102 against spring 101. Springs such as springs 90-101 are retained within dielectric body 50 in a manner similar to springs retained in a body such as that shown in commonly assigned U.S. Pat. No. 4,840,568.
The trailing edge 56 of card 52 is provided with a plurality of electrical contact pads 104-113 which are connected to springs 90-97 and 100-101, respectively, via circuit paths 114-123. As will become apparent, the use of LED springs 100,101 may be optional. In this event, contacts pads 112,113 could be eliminated. (To illustrate this option, the block 38 includes vertical columns of eight spaces 42 to accommodate only pads 104-111). In addition to permitting test access and monitoring (as will be described), the circuit boards 52 may be provided with additional electrical circuitry (such as repeaters or other circuit enhancement circuitry).
As previously mentioned, a plurality of spring contacts 44 are retained within the chambers 42 of assembly 18. Paired spring contacts 44 cooperate to define normally closed spring switches 45. Namely, the spring contacts pairs 44 are in electrical engagement on the absence of a card within slots 41.
The normally closed spring contacts 44 are best illustrated in FIGS. 7 and 8 where the contact ends 44a are shown in electrical engagement in the absence of a card 52 within the chambers 42. Preferably, the spring contacts 44 are also so-called make-before-break normally closed spring contacts which make electrical contact with a pad such as pads 104-111 before breaking or opening the electrical connection across the spring contacts 44. FIG. 9 shows a card 52 with pads 104", 105" in electrical contact with spring contacts 44 before forcing the spring contacts 44 apart upon full insertion of the card 52.
FIGS. 10 and 11 show an alternative arrangement for a make-before-break normally closed spring contact pairs with spring contacts 44' connected across a shunt bar 47. FIG. 11 shows electrical contact being made with the cards 44' before the spring contacts 44' are urged away from the shunt bar 47.
In FIGS. 4 and 4A, the contact pads 104-113 are shown on the same side of the card 52 for purposes of clarity of the illustrations. With this arrangement, the card 52 is used in conjunction with side-by-side paired contacts 44' as shown in FIGS. 10 and 11. If opposing paired contacts 44 (as shown in FIGS. 7-9) are used the pads 104-113 are disposed on opposite sides of the card 52 (as illustrated by pads 104", 105" in FIG. 9).
The wire wrap termination pins 46 of the connector assembly 18 are hard wired to the wire wrap termination pins 34 of the termination blocks 32 by wire conductors 112 as shown in FIG. 14 (and as schematically shown in FIGS. 12 and 13). FIGS. 12 and 13 shown in schematic format are alternative embodiments of the invention. FIG. 12 is shown for use with the jack card 14 of FIG. 4A which includes the MON port 82 with monitor springs 100,101. With that embodiment, the frame 12 is provided with an LED 114 connected via springs 100,101 to a voltage source 115 and a ground 117. The LED is illuminated upon insertion of a plug in the MON port 82. Alternatively, monitor springs can be omitted from the jack card 14 with monitor springs 100',101' carried by the frame 12 (as shown in FIG. 13).
With the apparatus thus described, tip and ring conductors of a telecommunications network may be terminated on the wire wrap termination pins 34 of blocks 32. The pins 34 are hard wired to the spring switches 45 which are normally closed. As a result, a signal flows through the apparatus 10 without modification or access in the absence of a jack card 14. The presence of a jack card 14 results in the signal now flowing through the circuitry 88 of the jack card 14. Insertion of a plug into ports 82,84,86 permits monitoring and test access to the telecommunications network in a manner similar to that provided by DSX equipment such as that shown in U.S. Pat. No. 4,840,568. The reader will note a significant difference between the structure of the present invention in the aforementioned U.S. Pat. No. 4,840,568 is that the spring contacts of the connector assembly of the aforementioned patent (items 300 in the aforementioned patent) do not include normally closed pairs of contacts. As a result, the prior DSX apparatus was not suitable for signal through in the absence of spring carrying jack cards.
The present apparatus is particularly suitable for use in conversion of prior art DSX networks to updated DCS networks. (Those skilled in the art will recognize DCS ("Digital Cross-Connect Systems") to include EDSX as well as DACS ("Digital Access Cross-Connect Systems"). As previously mentioned, commonly assigned U.S. Pat. No. 4,941,165, teaches a method for replacing manual DSX equipment with electronic DSX equipment (EDSX). Utilization of a so-called hot cut procedure as described in U.S. Pat. No. 4,941,165 permits replacement of the manual DSX with the DCS without service interruption. FIG. 22 shows a DSX equipment bay 120 connected through tip and ring lines 122 to network equipment 124. FIG. 23 shows the DSX replaced with an EDSX 126 and an apparatus 10 of the present invention. With the embodiment shown in FIG. 23, the apparatus 10 (in the absence of jack cards 14) provides signal flow through the apparatus 10 between the equipment 124 and the EDSX 126. Insertion of jack cards 14 within the apparatus 10 permits manual test access and monitoring as well as optional circuit enhancement without interference with the EDSX 126. The manual access capability is particularly desirable in the event of disfunction of EDSX equipment 126.
FIG. 15 illustrates use of the apparatus 10 for test access where the spring contacts 44 are shown normally closed and jack cards 14 are not inserted within the frame. In the embodiment of FIG. 15, the apparatus 10 provides a simple flow-through of a signal between network equipment 200 and a DCS 202. At the option of a user, the signal may be accessed by insertion of a jack card 14 into apparatus 10. FIG. 16 shows use of the apparatus 10 in an interconnect function. FIG. 17 shows use of the apparatus in a cross-connect function.
An alternative structure of the present invention is to provide for a jack card 14 which may be flipped in its orientation to reverse the test access capabilities of the jack card. Such an embodiment is shown in FIGS. 18 and 19.
In FIG. 18, a reversible jack card 214 is shown inserted within connector assembly 218 which is carried by chassis 216. The IN and OUT conductor pads (i.e. pads 104'-111' connected to springs 90'-97') are shown symmetrically arranged about a rotational axis X--X. The card 214 may be reversed about axis X--X and reinserted. With this embodiment, the card 214 may be inserted in its first or upright position as shown in FIG. 18. Upon insertion of a plug into the IN, OUT or monitor ports of jack card 214, the jack card will function similar to that of the embodiment of FIG. 4A. However, the present embodiment permits the jack card 214 to be rotated about axis X--X and be inserted in the inverted position as in FIG. 19. This permits alternative test access (indicated by the designations in FIGS. 18 and 19 of "NE OUT" and "NE IN" for network equipment IN and OUT and "DCS IN" and "DCS OUT" for Digital Cross-Connect System IN and OUT). Also, the monitor port is now connected to alternatively the OUT or the IN equipment lines depending upon the orientation of the card 214. In the embodiment shown in FIG. 19, the LED spring contacts are not in electrical contact upon flipping of the jack card assembly. However, an alternative embodiment to that design would be an inclusion of ground and tracer light leads disposed to electrically engage the pads when the jack card is in the flip position of FIG. 19.
FIGS. 20 and 21 show use of the apparatus of FIGS. 18 and 19 in a network indicating alternate directions for test access and monitoring dependent upon flipping of the jack card assembly 214.
Having described the present invention in a preferred embodiment it has been shown how the objects of the invention have been attained. However, modifications and equivalents of the disclosed concepts which will readily occur to one skilled in the art are intended to be included within the scope of the claims.
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An apparatus is disclosed for providing access to plurality of telecommunication lines. The apparatus includes a frame which carries a plurality of normally closed contacts. The telecommunication lines are terminated on the normally closed contacts. A plurality of modules are provided to be releasably attached to the frame with electrical circuit elements on the modules engaging the normally closed contacts to open the contacts and create a new signal path through the module upon insertion of the module into the frame.
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BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention relates to compositions and methods for isolating dental tissue for treatment thereupon. In particular, the present invention relates to polymerizable isolation barrier compositions and methods of using the same for isolating tooth surfaces. The polymerizable barrier compositions of the present invention may include constituents that enable the compositions to adhere to wet, dry, soft or hard oral tissues; to minimize injury risks due to heat from polymerization and/or light radiant energy from subsequent treatment(s); and that enable the barriers to be easily removed.
2. The Relevant Technology
Several dental procedures exist that use treatment compositions in the mouth that could be harmful and damaging to soft tissue. Harmful treatment compositions must be kept away from soft tissue such as the gums during such treatment procedures. There are other dental procedures that require a substantially dry tooth that must be maintained in a dry condition during a lengthy dental procedure to avoid damage.
In general, contact between a treatment composition and the cheeks and tongue of a patient can be minimized through the use of cotton rolls, absorbent isolators, rubber dams, rubber dam caulking or other conventional isolation techniques. The gums, adjacent dentin and surrounding sulcular tissues however are harder to protect from the treatment composition(s) due to their close proximity to the surfaces being treated and because the treatment composition is sometimes a freely flowable aqueous solution.
Although it is possible to incorporate some treatment compositions within a gel in order to inhibit the unwanted flow of the treatment composition from the desired treatment area, they generally must have a low enough viscosity to flow into the tiny crevices and other irregularities of the surface of the tooth being treated. Hence, it is generally impractical to have a treatment composition that is so viscous that it is not at least partially flowable.
In addition to adjusting the flow characteristics, the concentration of the treatment composition can be modified to reduce the damage caused by inadvertent contact with surrounding sulcus and gum tissues. However, significantly reducing the concentration of a treatment composition also reduces its ability to treat the tooth, thereby increasing the time in which the treatment composition must remain in contact with the surface being treated. In general, treatment compositions strong enough to adequately treat teeth may also damage and irritate surrounding soft gum tissues.
Rubber dam technology was developed as a means of isolating a tooth for treatment and also for protecting the vulnerable soft tissue. FIG. 1 illustrates the installation of a rubber dam 10 . It can be seen that rubber dam 10 has been placed over the teeth 14 and then rubber dam 10 is fitted with a dental instrument 16 by pushing rubber dam 10 up to the gum line 12 . This procedure must be carried out on each tooth. Rubber dams, however, have several disadvantages. One disadvantage is that rubber dams can be difficult to install. Rubber dams have a hole-punched perimeter shape that may or may not isolate soft tissue next to the tooth because the tooth perimeter shape might have concavities. For example, where a tooth forms an unusual groove or concavity, a hole-punched rubber dam may leave an exposed space through which treatment compositions could leak that could harm soft tissue. If the seal created by a rubber dam is faulty, soft tissue is exposed and likely to be damaged by the treatment composition.
Another disadvantage to rubber dams is that they are prone to tearing once placed over the tooth. If the rubber dam begins to tear in the middle of a dental procedure, the procedure must be aborted and a new rubber dam installed. This is time consuming and the new rubber dam may likewise tear at or near the same point of the treatment that the original rubber dam began to tear. Additionally, when the rubber dam tears during a procedure, it may be too late to prevent the treatment compositions from contacting the soft tissue and therefore too late to prevent soft tissue damage.
Another disadvantage to rubber dams is that they often cause patient discomfort. FIG. 2 illustrates installation of a rubber dam 10 with rubber dam clamps 22 and a frame 20 that covers the labia 24 and the tongue 26 . When, for example, a labial surface of a tooth is the only surface that needs to be isolated, rubber dam 10 may cover more than the teeth.
Additionally, where an intense dental curing or laser light is being used, heat buildup incidental to use of the light may cause patient discomfort due to heating of the rubber dam. Intense heating of the soft tissue will necessitate intermittent use of the dental light, a practice that slows the clinician in his procedure.
One attempt to overcome the problems associated with rubber dams provided a blue flowable resin that can be applied onto a dental substrate and then be polymerized. Due to the color of the resin, it absorbs light energy which resulting increases the risk of injury to soft tissue in contact with the resin. Additionally, the resin is hydrophobic which significantly hinders its ability to adhere well to dental tissues. Another significant problem with this resin is that it is too strong and consequently the polymerized resin is very difficult to remove. Difficulties related to excessive strength are only exacerbated by application of the resin onto dental surfaces such as wide open embrasures and undercuts. For example, open embrasures are typically filled from both sides which results in the embrasures being completely filled and solidly anchored. After polymerization, it is very difficult to remove the resin and may require prying instruments or even high speed drills. Similarly, undercuts present a problem when resin becomes lodged into the openings or crevices and it may then necessary be to remove the resin with dental tools which the require the use of some force such as prying instruments or excavating tools.
In light of the foregoing, it would be a significant advancement in the art to provide isolation barrier compositions and methods for protecting sulcular and gum tissues surrounding a tooth being treated from intense cumulative heat buildup in order to avoid patient discomfort and to expedite dental treatments that use a curing or laser light
It would also be a significant advancement in the art to provide isolation barrier compositions and methods for protecting sulcular and gum tissues surrounding a tooth being treated that can be easily removed following a dental procedure.
It would be a further advancement in the art to provide compositions and methods that result in a quickly and easily applied barrier to maintain a treatment composition within the area of the tooth that is desired to be treated.
Another advancement in the art would be to provide compositions for an isolation barrier material that, upon application to the dental substrate and polymerization, are sufficiently weakened to facilitate its removal in discrete, approximately tooth-sized segments or larger with a tweezers-like instrument from the dental substrate after use in a dental procedure.
Another advancement in the art would be to provide compositions for an isolation barrier material that, upon application to the dental substrate and polymerization, are resistant to deformation at the external surface of the barrier due to incidental touching but that remain adherent to the dental substrate at the internal surface of the barrier.
Another advancement in the art would be to provide a composition for an isolation barrier material that, upon application to the dental substrate and polymerization, is of a generally small size and conducive to a customized fit that avoids inducing patient discomfort.
Such polymerizable isolation barrier compositions and methods for using them are disclosed and claimed herein.
SUMMARY AND OBJECTS OF THE INVENTION
It is an object of the present invention to provide isolation barrier compositions and methods for protecting tissues surrounding a tooth and that can be easily removed following a dental procedure.
It is a further object of the present invention to provide compositions and methods that result in a quickly and easily applied barrier to maintain treatment composition within the area of the tooth that is desired to be treated.
Another object of the present invention is to provide compositions for an isolation barrier material that, upon application to the dental substrate and polymerization, are sufficiently weakened to facilitate their removal in discrete, approximately tooth-sized segments or larger with a tweezers-like instrument from the dental substrate after use in a dental procedure and even easily break lose from undercuts or when located between a large embrasure.
Another object of the present invention is to provide compositions for an isolation barrier material that, upon application to the dental substrate and polymerization, are resistant to deformation at the external surface of the barrier due to incidental touching but that remain adherent to the dental substrate at the internal surface of the barrier.
Another object of the present invention is to provide compositions for an isolation barrier material that, upon application to the dental substrate and polymerization, are configured to decrease the polymerization reaction rate and thereby reduce patient discomfort and thermal tissue damage due to substantial heat production during polymerization.
Various compounds were found to assist in formulation of a polymerizable isolation barrier for several types of dental procedures. These compounds are advantageously added together in whole or in partial combinations to achieve specific advantages over the prior art.
The isolation barrier of the present invention is made polymerizable by providing at least one monomer in the inventive composition. The monomer is preferably of substantially low toxicity to humans. The monomer can be a single monomer or a selection of monomers depending upon the specific application.
One advantage to using preferred monomers is that a cohesive isolation barrier may be fashioned in the mouth and the need for the traditional rubber dam is eliminated. As such, the clinician is not concerned with punching, fitting, repairing, and sealing a rubber dam, rather, with the inventive isolation barrier, the polymerizable isolation barrier is applied to seal soft tissue and isolate hard tissue for a desired procedure, and is removed in integral, tooth-sized segments or larger after completion of the dental procedure.
A curing agent is provided to induce the monomer to cross link upon exposure to adequate light radiant energy. The curing agent is preferably of substantially low toxicity to humans. Curing agents may also be selected to be complementary to other ingredients for a selected dental procedure. Optional additives are preferred in formulating curing agents depending upon the specific application of the polymerizable isolation barrier.
During polymerization, there are several variables to monitor. Heat is usually generated during polymerization. A significant increase in temperature during polymerization can cause discomfort to the patient or can be sufficient to also cause burning of oral tissue. To control heat production, an organic compound is preferred that will provide a compositional quality of preventing complete polymerization of the isolation barrier material, thus, the total exothermic heat potential for a given amount of monomer will be reduced during polymerization. In addition to preventing unwanted excess heat of reaction, it was found that certain organic compounds cause the isolation barrier material to become significantly weakened or brittle compared to a barrier material without such organic compounds. A weakened isolation barrier has the advantage of easy removal after completion of the dental procedure. The clinician can take hold of the polymerized isolation barrier with an instrument like tweezers and remove it in discrete segments that are about the size of a tooth or larger. The advantage is that, where a principally hydrophobic isolation barrier is required for a given dental procedure, removal after the procedure takes only one removal step or at most a few removal steps and if any smaller portions crumble, they are easily rinsed away after being dislodged.
During polymerization, it would be advantageous that the interior surface of the inventive isolation barrier will slightly adhere to wet or dry, hard or soft tissue (henceforth “tissue”). The term “slightly adhere,” refers to adherence of the isolation barrier to tissue that, upon removal, will not substantially remove epithelial tissue of the gums in a way that causes discomfort to the dental patient. As a feature of the present invention, it was found that when an adherence accentuator is added, the isolation barrier material will adhere better to tissue before, during, and after polymerization.
When the barrier is utilized in a dental procedure such as bleaching with a peroxide composition that would harm tissue, a preferred procedure is to apply the isolation barrier composition and begin to polymerize with a dental curing light. Later, as the dental curing light is also used to activate the peroxide bleaching composition, polymerization may continue. With preferred tissue adherence accentuators, the isolation barrier composition continues to adhere to wetted tissue even when the monomer becomes substantially polymerized. An advantage of this feature of the invention is that a substantially conformal isolation barrier can be laid up against the tooth to isolate it and the barrier will adhere adequately to tissue during a time period for standard isolation treatment procedures.
Another method of lowering harmful amounts of excess heat released during polymerization or during a subsequent dental procedure is to reflect some of the light radiant energy of the dental light away from the isolation barrier composition. Dental curing lights and laser treatment lights typically come with only intense light radiation settings. These intense light radiation settings are very desirable in some dental applications such as in peroxide teeth bleaching. It was found that the addition of reflective materials reflects some portion of the dental light thereby reducing heating of the isolation barrier during a dental procedure and minimizing harmful conductive or radiant heat transfer to gums or other soft tissues. Thus, the composition absorbs less light radiant energy, the isolation barrier is less energized than would be otherwise, and the underlying gum tissue is not subjected to undue heating during a dental procedure.
The inventive polymerizable isolation barrier material is preferably made in a paste or gel form that is Theologically rheologically able to be expressed from a dental syringe. The components of the isolation barrier material form either an emulsion or a solution depending upon selection of a preferred application.
The inventive polymerizable isolation barrier material is also preferably made in a roll or tape form of a curable putty. The roll or tape is unrolled, cut into a strip to a desired length, placed onto the gums, pressed substantially conformably into place, for example with finger pressure, carved to isolate hard tissue, and then cured with light radiant energy. The components of this isolation barrier material form either an emulsion, a dispersion, a suspension, a solution, etc. depending upon selection of a preferred application.
These and other objects and features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited and other advantages of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 is a prior art elevational front view of teeth and gums that are being isolated and protected, respectively in preparation for a dental procedure that requires isolating the teeth for the procedure while protecting tissue including gums from the treatment composition, and in which it can be seen that a rubber dam is the medium to protect the tissue by which it is being fitted to the tooth-gum juncture by a dental instrument.
FIG. 2 is a prior art elevational view of a patient with a rubber dam installed that includes a rubber dam frame and rubber dam clamps that are secured to a large molar.
FIG. 3 is an elevational front view of a patient during installation of the inventive isolation barrier, in which the isolation barrier is being expressed through a syringe substantially conformable to the tooth-gum interface in preparation for polymerization by light radiant energy.
FIG. 4 is an elevational front view of a patient during removal of the inventive isolation barrier after polymerization, in which the isolation barrier is being removed in a discrete segment with a tweezers-like instrument.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polymerizable isolation barriers are useful for many types of dental procedures. The polymerizable isolation barrier compositions comprise at least a monomer, a curing agent, and at least one other constituent. The other constituents include polymerization strength reducers, tissue adherence accentuators and reflective materials. The compositions can be utilized with any light radiant energy which includes the full electromagnetic spectrum.
The polymerization strength reducers prevent the polymerizable composition from becoming difficult to remove. The tissue adherence accentuators ensure adequate adhesion to any dental substrate. The reflective materials reflect light radiant energy. By reflecting light radiant energy, the heat produced by polymerization is maintained to a desirable level and harmful conductive or radiant heat transferred to gums or other soft tissues during a subsequent procedure is minimized. The combinations achieve specific advantages over the prior art.
A. Monomers
The isolation barrier of the present invention is made polymerizable by providing at least one monomer in the inventive composition. The monomer is preferably of substantially low toxicity to humans. The monomer can be a single monomer or a selection of monomers depending upon the specific application. For example, when performing a dental procedure involving acid etching, it is preferred to select a monomer or combination thereof that, when polymerized, is resistant to acid, thus, the isolation barrier will hold a seal against tissue to protect it from the acid.
One advantage to using the polymerizable isolation barrier is that a cohesive isolation barrier may be fashioned in situ in the mouth and the need for the traditional rubber dam is eliminated. As such, the clinician is not concerned with punching, fitting, repairing, and sealing a rubber dam, rather, with the inventive isolation barrier, the isolation barrier is applied to seal tissue and isolate hard tissue for a desired procedure, is polymerized, and is removed in integral tooth-sized segments or larger after completion of the dental procedure. The clinician can remove the barrier by any means. However, the composition enables a clinician to take hold of the polymerized isolation barrier by hand and easily remove it as an integral unit or in discrete segments, or a dental instrument like tweezers can be used for easy removal.
The size of the discrete segments is generally about one-half the area that the isolation barrier is isolating. For example, as illustrated in FIG. 3 , if the clinician were to stop applying the inventive isolation barrier at the point illustrated therein, the size of the discrete segments would generally be about one-half the length as applied. Another example is when the whole arch is being isolated, it is preferable that the discrete segments are at least about one-fourth the length of the arch, more preferably at least about one-half the length of the arch, and most preferably the isolation barrier will be removed as an integral unit.
Examples of suitable monomers include alkylmethacrylates, alklyhydroxymethacrylates, and alkylaminomethacrylates and derivatives thereof. The alkylmethacrylates include triethylene glycol dimethacrylate, polyethylene glycol (PEG) dimethacrylate (all molecular weights), butane di-ol dimethacrylate, and equivalents. The alkylhydroxymethacrylates include 2-hydroxy ethyl methacrylate, glycerol dimethacrylate, bis-GMA, and equivalents. The alkylaminomethacrylates include urethane dimethacrylate and equivalents. The monomers of the present invention are provided in a concentration range from about 50 to about 99 percent, preferably from about 60 to about 95 percent, and most preferably from about 70 to about 90 percent by weight of the composition. The preferred methacrylates include alkylmethacrylates. The more preferred methacrylate is triethylene glycol dimethacrylate. In addition to the above methacrylates, other monomers are within the contemplation of the present invention and can be found by routine experimentation by reading the disclosure and practicing the invention.
B. Curing Agents
Curing agents were found to be useful, and depending upon the specific dental procedure, were preferred with or without certain organic amine additives.
A curing agent is provided to induce the monomer to cross link upon exposure to adequate light radiant energy. The curing agent is preferably of substantially low toxicity to humans. Curing agents may also be selected to be complementary to other ingredients for a selected dental procedure. Curing agents include photoinitiators and amine additives as needed.
Examples of photoinitiators include camphorquinone; benzoin methyl ether; 2-hydroxy-2-methyl-1-phenyl-1-propanone; diphenyl 2,4,6-trimethylbenzoyl phosphine oxide; benzoin ethyl ether; benzophenone; 9,10-anthraquinone, and equivalents.
Optional additives such as amine additives are preferred in formulating curing agents to assist the curing agents depending upon the specific application of the polymerizable isolation barrier. Examples of amine additives include dimethyl amino ethyl methacrylate; tri ethyl amine; 2-dimethylamino ethanol; diethyl amino ethyl methacrylate; trihexyl amine; N,N-dimethyl-p-toluidine; N-methylethanolamine, and equivalents.
The curing agents of the present invention are provided in a concentration range from about 0.01 to about 2 percent, preferably from about 0.1 to about 1 percent, more preferably from about 0.2 to about 0.8 percent, and most preferably about 0.3 percent by weight of the composition. The preferred curing agent includes 2-hydroxy-2-methyl-1-phenyl-1-propanone and diphenyl 2,4,6-trimethylbenzoyl phosphine oxide. In addition to the above curing agents, other curing agents are within the contemplation of the present invention and can be found by routine experimentation by reading the disclosure and practicing the invention.
C. Polymerization Strength Reducers
During polymerization, there are several variables to consider. Heat is usually generated during polymerization due to the exothermic nature of polymerization. A significant increase in temperature during polymerization can cause discomfort to the patient or can be sufficient to also cause burning.
An organic compound is preferred that has the capability to substantially decrease or minimize the degree of polymerization of the isolation barrier material compared to a barrier material without such an organic compound. Thus, the total exothermic heat potential for a given amount of monomer will be reduced during polymerization.
In addition to preventing unwanted excess heat of reaction, it was found that certain organic compounds cause the isolation barrier material to become weakened. A weakened isolation barrier has the advantage of easy removal after completion of the dental procedure. The clinician can take hold of the polymerized isolation barrier by hand or with an instrument like tweezers and remove it in discrete segments or as integral unit. The size of the discrete segments is generally about one-half the area that the isolation barrier is isolating. For example, when the whole arch is being isolated, it is preferable that the discrete segments are at least about one-fourth the length of the arch, more preferable at least about one-half the length of the arch, and most preferably the isolation barrier will be removed as an integral unit. The advantage is that, where a hydrophobic isolation barrier is required for a given dental procedure, removal after the procedure takes only one or a few removal steps and any small portions that may crumble are easily rinsed away after being dislodged.
Examples of suitable polymerization strength reducers include oils such as mineral oils. Other suitable examples include alcohols such as cetyl alcohol, steryl alcohol, derivatives thereof, and equivalents. Yet other suitable examples include polyols such as polyethylene glycols, polypropylene glycols, propylene glycol, derivatives thereof, and equivalents. The polymerization strength reducers of the present invention are provided in a concentration range, when included, from about 1 to about 30 percent, preferably from about 5 to about 20 percent, more preferably from about 10 to about 15 percent, and most preferably about 12 percent by weight of the composition. Of the polymerization strength reducers, the preferred includes cetyl alcohol.
D. Tissue Adherence Accentuators
During polymerization of the isolation barrier and during treatment, it is desirable that the isolation barrier adhere between an interior surface of the inventive isolation barrier and wetted tissue. As a feature of the present invention, it was found that when an adherence accentuator is added, the isolation barrier material will adhere better to tissue before, during, and after polymerization. An inner surface of the isolation barrier is one that interfaces with the dental substrate.
When the isolation barrier is utilized as part of a dental procedure involving teeth bleaching with a peroxide composition that would harm tissue, it is preferable to apply the isolation barrier composition and begin to polymerize with a dental light. After the barrier is positioned and polymerized, the dental light is used to activate the peroxide bleaching composition which also may cause continued polymerization of the isolation barrier. With preferred tissue adherence accentuators, the isolation barrier composition continues to gently adhere to wetted tissue even when the monomer becomes substantially polymerized. An advantage of this feature of the invention is that a substantially conformal isolation barrier can be laid up against the tooth to isolate it and it will adhere adequately to tissues during a time period for standard isolation treatment procedures.
Examples of tissue adherence accentuators include gums such as xanthan gum, guar gum, tragacanth gum, their derivatives, and equivalents. Other examples include cellulose materials such as ethyl cellulose, hydroxypropyl methyl cellulose, their derivatives, and equivalents. Yet other examples include polymers such as carboxy poly methylene, polysiloxanes, water-soluble polyethylene oxide polymers, derivatives and equivalents. The water-soluble polyethylene oxides preferably have molecular weights of around 100,000 or more even up to several million. The preferred water-soluble polyethylene oxide polymer is sold as Polyox™ by Union Carbide. Additionally, high molecular weight polyols can function as tissue adherence accentuators such as polypropylene glycols and polyethylene glycols having a molecular weight of at least 600. The tissue adherence accentuators of the present invention, when used, are supplied to the inventive composition in a concentration range from about 0.01% to about 9%, preferably from about 0.03% to about 5%, more preferably from about 0.05% to about 3%, and most preferably about 0.1% by weight of the composition. The preferred tissue adherence accentuator is xanthan gum.
E. Reflective Materials
Another method of lowering harmful amounts of excess heat released during polymerization is to reflect some of the light radiant energy of the dental light away from the isolation barrier composition. Dental curing lights and laser treatment lights typically come with only intense light radiation settings, which is desirable in certain applications such as peroxide teeth bleaching. It was found that the addition of reflective materials causes a portion of the dental light to be reflected thereby reducing heating of the isolation barrier during polymerization, particularly when polymerized with a light at an intense light radiation setting, and during a subsequent dental procedure such as bleaching. Thus, the composition absorbs less light radiant energy, the isolation barrier is less energized than would be otherwise, the underlying gum tissue is not subjected to undue heating during a dental procedure that uses a curing or laser light and light is even reflected away from the underlying gums or other protected tissue.
Examples of reflective materials include metals such as gold flake, aluminum flake, titanium flake, and equivalents. Other examples include metal oxides such as aluminum oxide, titanium dioxide, precipitated silica, ceria, thoria and equivalents. Yet other examples include micas and equivalents. The reflective materials of the present invention, when included, are provided in a concentration range from about 1 to about 50 percent, preferably from about 2 to about 30 percent, more preferably from about 3 to about 20 percent, and most preferably about 15 percent. The preferred reflective material comprises micas.
F. General Properties
It is advantageous to combine various aspects of the present invention for preferred applications. For example, a peroxide gel may be the treatment composition and light radiant energy will be used both during polymerization of the compositions of the present invention and later during peroxide bleaching material. In such a case, the clinician may select a composition that includes polymerization strength reducers, tissue adherence accentuators, and reflecting materials. Thus, such a composition will achieve a weakened isolation barrier for easy removal and for resistance to incidental touching during the dental procedure, it will assure that the isolation barrier sufficiently remains in place to adequately seal off the soft tissue while the bleachant is on the tooth, and reflects intense light energy during a treatment procedure to protect the underlying gums from undue heating.
Alternatively, an application might be required where the tooth is to be isolated for dryness purposes. In such a case, the clinician may select a composition that includes polymerization strength reducers and tissue adherence accentuators. Thus, such a composition will achieve a weakened isolation barrier for easy removal yet adequate resistance to incidental touching during the dental procedure, and the composition will remain sufficiently in place against tissue during the procedure.
The method of making the polymerizable isolation barrier is carried out by providing at least one monomer; providing at least one curing agent for curing the at least one monomer; and by providing at least one of three preferred additives that include the organic polymerization strength reducer, the tissue adherence accentuator, or the reflective material. The ingredients are blended in a container until homogeneous, and the homogenous mixture is place in a container that is resistant to light energy. The inventive polymerizable isolation barrier material is preferably stored at or below room temperature. The inventive polymerizable isolation barrier material is stable enough to be stored under normal conditions at the operatory until activated by suitable light radiant energy.
G. Methods of Use
The inventive polymerizable isolation barrier material is made in a paste or gel form that is Theologically rheologically able to be expressed from a dental syringe. The components of the isolation barrier material form either an emulsion or a solution depending upon selection of a preferred application. The inventive polymerizable isolation barrier material is also preferably made in a roll or tape form of a curable putty that is rolled onto the gums, pressed into place, for example with finger pressure, carved to isolate hard tissue, and then cured with light radiant energy. The components of this isolation barrier material form either an emulsion, dispersion, suspension, solution, etc. depending upon selection of a preferred application.
The inventive polymerizable isolation barrier material is applied by any of several methods. FIG. 3 is an elevational oblique view of a patient during installation of the inventive isolation barrier 28 , in which isolation barrier 28 is being expressed through a syringe 30 substantially conformably to the tooth-gum interface 32 in preparation for polymerization by light radiant energy. A preferred method of use is to dry the tooth or teeth that are to be treated, retract the labia, and apply the isolation barrier material 28 with syringe 30 conformably at the base of the tooth upon the tissue such as the gums 34 . The width W of isolation barrier 28 as it extends across tissue may be selected by the clinician according to the application. For example, where a gel is being used and running of the gel is not likely, the clinician may apply a substantially conformal isolation barrier that touches the teeth and extends onto the gums 34 from about three to about 10 mm from the area to be treated. Larger or smaller isolation barriers may be applied depending upon the specific dental procedure.
Removal of isolation barrier 28 after the dental treatment is accomplished as illustrated in FIG. 4. A tweezers-like instrument 36 may be used to remove isolation barrier 28 by taking hold of isolation barrier 28 and removing it in discrete segments. It can be seen that isolation barrier 28 is lifting away from gums 34 at the area near where instrument 36 has fastened onto isolation barrier 28 . The clinician can take hold of polymerized isolation barrier 28 with instrument 36 and remove it in discrete segments. The size of the discrete segments is generally about one-half the area that isolation barrier 28 is isolating. For example, when the whole arch is being isolated, it is preferable that the discrete segments are about one-fourth the length of the arch, more preferably about one-half the length of the arch, and most preferably, as illustrated in FIG. 4 , isolation barrier 28 will be removed as an integral unit.
EXAMPLES OF THE PREFERRED EMBODIMENTS
Several examples of the present invention are presented as merely illustrative of some embodiments of the present invention. These examples are not to be construed as limiting the spirit and scope of the invention. The following nine hypothetical examples were produced in furtherance of reducing the present invention to practice. All amounts are given in weight percent.
Percent by Weight
Component
of the Mixture
mica
2.0
xanthan gum
0.1
curing agents
0.3
cetyl alcohol
12.5
precipitated silica
13.0
triethylene glycol dimethacrylate
72.1
The foregoing example produces an isolation barrier material composition that, upon application to the dental substrate and polymerization, is sufficiently weakened to facilitate its removal in discrete, tooth-sized segments or larger with a tweezers-like instrument from the dental substrate after use in a dental procedure. The barrier material also is resistant to deformation at the external surface of the barrier due to incidental touching but remains adherent to the dental substrate at the internal surface of the barrier. The barrier material also is configured to decrease the polymerization reaction rate and to reflect excessive light radiant energy to thereby resist thermal tissue damage due to substantial heat production during polymerization.
Percent by Weight
Component
of the Mixture
mica
3.0
xanthan gum
0.3
curing agents
0.5
PEO dimethacrylate (300)
96.2
The foregoing example produces an isolation barrier material composition that, upon application to the dental substrate and polymerization, is resistant to deformation at the external surface of the barrier due to incidental touching but remains adherent to the dental substrate at the internal surface of the barrier. The barrier material also reflects excessive light radiant energy in order to resist thermal tissue damage due to substantial heat production during polymerization.
Percent by Weight
Component
of the Mixture
titanium dioxide
1.0
guar gum
0.1
steryl alcohol
17.0
precipitated silica
12.0
2-hydroxy ethyl methacrylate
69.0
curing agents
0.9
The foregoing example produces an isolation barrier material composition that, upon application to the dental substrate and polymerization, is sufficiently weakened to facilitate its removal in discrete, tooth-sized segments or larger with a tweezers-like instrument from the dental substrate after use in a dental procedure. The barrier material also is resistant to deformation at the external surface of the barrier due to incidental touching but remains adherent to the dental substrate at the internal surface of the barrier. The barrier material also is configured to decrease the polymerization reaction rate and reflect excessive light radiant energy to thereby resist thermal tissue damage due to substantial heat production during polymerization.
Percent by Weight
Component
of the Mixture
xanthan gum
1.0
PEG dimethyacrylate (600)
98.5
curing agents
0.5
The foregoing example produces an isolation barrier material composition that, upon application to the dental substrate and polymerization, is resistant to deformation at the external surface of the barrier due to incidental touching but remains adherent to the dental substrate at the internal surface of the barrier.
Percent by Weight
Component
of the Mixture
cetyl alcohol
20.0
tri ethylene glycol dimethyacrylate
79.0
curing agents
1.0
The foregoing example produces an isolation barrier material composition that, upon application to the dental substrate and polymerization, is sufficiently weakened to facilitate its removal in discrete, tooth-sized segments or larger with a tweezers-like instrument from the dental substrate after use in a dental procedure.
Percent by Weight
Component
of the Mixture
titanium dioxide
1.0
mica
5.0
urethane dimethyacrylate
93.8
curing agents
0.2
The foregoing example produces an isolation barrier material composition that, upon application to the dental substrate and polymerization, reflects excessive light radiant energy in order to resist thermal tissue damage due to substantial heat production during polymerization.
Percent by Weight
Component
of the Mixture
xanthan gum
0.2
cetyl alcohol
12.0
curing agents
0.5
tri ethylene glycol dimethacrylate
87.3
The foregoing example produces an isolation barrier material composition that, upon application to the dental substrate and polymerization, is sufficiently weakened to facilitate its removal in discrete, tooth-sized segments or larger with a tweezers-like instrument from the dental substrate after use in a dental procedure. The barrier material also is resistant to deformation at the external surface of the barrier due to incidental touching but remains adherent to the dental substrate at the internal surface of the barrier. The barrier material is also configured to decrease the polymerization reaction rate and thereby resist thermal tissue damage due to substantial heat production during polymerization.
Percent by Weight
Component
of the Mixture
aluminum oxide
1.0
xanthan gum
2.0
curing agents
0.5
glycerol dimethyacrylate
96.5
The foregoing example produces an isolation barrier material composition that, upon application to the dental substrate and polymerization, remains adherent to the dental substrate at the internal surface of the barrier. The barrier material also is configured to decrease the polymerization reaction rate and thereby resist thermal tissue damage due to substantial heat production during polymerization.
Percent by Weight
Component
of the Mixture
cetyl alcohol
12.0
aluminum flake
3.0
butane di-ol dimethyacrylate
84.5
curing agents
0.5
The foregoing example produces an isolation barrier material composition that, upon application to the dental substrate and polymerization, is sufficiently weakened to facilitate its removal in discrete, tooth-sized segments or larger with a tweezers-like instrument from the dental substrate after use in a dental procedure. The barrier material also is configured to decrease the polymerization reaction rate and reflect excessive light radiant energy to thereby resist thermal tissue damage due to substantial heat production during polymerization.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrated and not restrictive. The scope of the invention is, therefore, indicated by the appended claims and their combination in whole or in part rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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The polymerizable dental isolation barrier has a monomer and an initiator. The barrier composition has at least one additive including a polymer strength reducer, a wet tissue adherence accentuator, and a reflective material. The polymer strength reducer is an organic compound that prevents complete polymerization. The tissue adherence accentuator enables the barrier to adhere to a dental substrate even after polymerization. The reflective material lowers the reaction rate and lowers the production of excess heat to reduce patient discomfort and to avoid tissue damage.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image processing method and apparatus, which can perform a color print operation of characters, figures, raster images, and the like on the basis of print data, commands, and the like supplied from a host computer.
2. Related Background Art
FIG. 1 shows an example of a coordinate system (to be referred to as a user coordinate system hereinafter) serving as a reference for coordinate points to be designated when figures, characters, and the like are drawn using a PDL (Page Description Language) or page description commands.
A hatched rectangular portion indicates an effective print area (a drawing enable area in a sheet). As shown in FIG. 1, the length of the effective print area will be referred to as an effective print area height hereinafter, and the width of the effective print area will be referred to as an effective print area width hereinafter.
The coordinate system shown in FIG. 1 is a two-dimensional x-y orthogonal coordinate system, and as an origin as the lower left corner of the effective print area, as shown in FIG. 1.
Any coordinate unit (e.g., 0.01 mm or 1/72 inch) can be arbitrarily set in this coordinate system.
Description elements of the PDL and page description commands for, e.g., figure drawing, which are set on the basis of the above-mentioned user coordinate system, are analyzed in an image processing apparatus in the reception order, and are converted into information to be developed onto a memory.
FIG. 2 shows an example of a coordinate system (to be referred to as a printer coordinate system hereinafter) serving as a reference when the above-mentioned memory development information is generated.
The coordinate unit of this coordinate system is determined by the resolution of an image processing apparatus (for example, when the resolution is 300 dpi, the coordinate unit is 1/300 inch).
A hatched rectangular portion is the same as the effective print area shown in FIG. 1.
This coordinate system is a two-dimensional x-y orthogonal coordinate system, and has an origin as the upper left corner of the effective print area.
FIG. 3 shows an example of a memory map of an internal RAM area in a conventional image processing apparatus for performing a color print operation on the basis of the PDL or page description commands.
The RAM area is constituted by a system work memory, a reserved area, and page development memories (each having a size corresponding to the effective print area shown in FIG. 2) for Y (yellow), M (magenta), C (cyan), and Bk (black) as coloring agents (toners or inks).
The system work memory is used as a storage area of information (e.g., variables) used in control in the image processing apparatus, and a permanent work area.
The reserved area is used as an area for storing memory development information, a character cache memory, and the like.
FIG. 4 shows an example of a line color designation command of drawing attribute designation commands.
This command is used for designating a color of a line or an outline of a figure.
A command No. varies depending on the drawing attribute designation commands, and is used for identifying each command function.
The content of a number-of-data parameter indicates the number of data input after the number-of-data parameter.
In this case, the content of the number-of-data parameter of the line color designation command is 4.
Y-, M-, C-, and Bk-values respectively indicate density data values of Y (yellow), M (magenta), C (cyan), and Bk (black) as primary colors of coloring agents.
FIG. 5 shows an example of a circle drawing command of drawing commands.
A command No. varies depending on the drawing attribute designation commands, and is used for identifying each command function.
The content of a number-of-data parameter indicates the number of data input after the number-of-data parameter.
In this case, the content of the number-of-data parameter of the circle drawing command is 3.
The x- and y-coordinates of the center are those on the user coordinate system.
An actual radius is calculated by multiplying a coordinate unit of the user coordinate system with a "radius" value.
FIG. 6 shows an example of memory development information generated by analyzing the line color designation command shown in FIG. 4.
A command table No. is used for identifying each memory development information. Other parameters are the same as those in FIG. 4.
FIG. 7 shows an example of memory development information generated by analyzing the circle drawing command shown in FIG. 5.
A command table No. is used for identifying each memory development information. Values xc and yc represent the coordinates of the center of a circle on the printer coordinate system.
A value r represents a radius value converted to have the resolution of the image processing apparatus as a unit.
FIG. 8 shows a case wherein on the user coordinate system shown in FIG. 1, the coordinate unit is set to be 1 mm, and drawing of a circle having coordinates (150, 150) of the center and a radius of 50 is set.
FIG. 9 shows an example of a command issued when the circle drawing operation shown in FIG. 8 is set.
FIG. 10 shows a case wherein the circle drawing operation on the user coordinate system shown in FIG. 8 is converted into a circle drawing operation on the printer coordinate system having a coordinate unit=1/300 inch (about 1/11.8 mm).
As shown in FIG. 10, the effective print area height is set to be 400 mm.
The x-coordinate of the center is 1,770 (150×11.8), the y-coordinate is 2,950 (250×11.8), and the radius is 590 (50×11.8).
FIG. 11 shows an example of memory development information of the circle drawing operation shown in FIG. 10, which information is generated by analyzing the circle drawing command shown in FIG. 9.
FIG. 12 shows an example of a line color designation command issued when the circle drawing operation shown in FIG. 8 is performed using yellow (a color corresponding to the coloring agent at a density of 100%).
Note that each of the Y-, M-, C-, and Bk-values falls within a range of 0 to 255. In this case, the Y-value is 255, and other values are 0.
As described above, in control of a conventional image processing apparatus for performing a color print operation on the basis of the PDL or page description commands, development memories each having a size corresponding to the effective print area of a sheet are used for Y (yellow), M (magenta), C (cyan), and Bk (black) as coloring agents of toners or inks.
However, the conventional apparatus suffers from the following drawbacks.
(1) When color print control is performed based on the PDL or page description commands in, e.g., an ink-jet printer which can interrupt recording at a halfway position of a sheet, and can restart recording, Y, M, C, and Bk memories each having a size corresponding to the effective print area of a sheet need not always be required, and the memory cannot be efficiently utilized.
(2) Since recording is started after all the page description elements or page description commands for recording one page are analyzed, and figures, characters, or the like are developed onto a memory, it takes much time for drawing.
(3) When color print control is performed based on the PDL or page description commands in, e.g., an ink-jet printer which can move a print head in the vertical and horizontal directions, control is not made to move the head within only a drawing range, or to print only the content of a memory which actually stores a drawing pattern of the Y, M, C, and Bk memories in the drawing range, resulting in the long drawing time.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an image processing method and apparatus, in which a horizontal range where data to be drawn is present is obtained and stored as a table in units of the height of a record head, and the moving range of the record head is controlled according to the table, so that the record head is moved within only a necessary range, thereby shortening a time required for drawing.
It is another object of the present invention to provide an image processing method and apparatus, which can specify an area for recording record information, and can eliminate unnecessary development onto a memory since information that falls outside the specified area is not developed to bit image data.
It is still another object of the present invention to provide an image processing method and apparatus, in which when paper jam occurs during recording, a table formed before the paper jam is held, paper jam recovery processing is performed, and the held table is utilized after the paper jam recovers, thereby shortening the processing time for re-forming the table.
It is still another object of the present invention to provide an image processing method and apparatus, which need not have attribute information in units of pages since attribute information of drawing information is reflected up to the next page, thereby effectively utilizing a memory.
It is still another object of the present invention to provide an image processing method and apparatus, which can perform efficient development in correspondence with a memory condition since the height of a development area is changed according to a memory capacity that can be used upon development of bit image data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing an example of a user coordinate system;
FIG. 2 is a view showing an example of a printer coordinate system;
FIG. 3 shows an example of a memory map of an internal RAM area of a color image processing apparatus which has Y, M, C, and Bk memories each having a size corresponding to an effective print area of a sheet;
FIG. 4 is a view showing an example of a line color designation command of drawing attribute commands;
FIG. 5 is a view showing an example of a circle drawing command of drawing commands;
FIG. 6 is a view showing an example of memory development information of a line-color-designation function of drawing attribute functions;
FIG. 7 is a view showing an example of memory development information of a circle drawing function of drawing functions;
FIG. 8 is a view showing an example of a circle drawing operation on the user coordinate system;
FIG. 9 is a view showing an example of a circle drawing command issued when the circle drawing operation shown in FIG. 8 is set;
FIG. 10 is a view showing an example of conversion of the circle drawing operation shown in FIG. 8 onto the printer coordinate system;
FIG. 11 is a view showing an example of memory development information of the circle drawing operation shown in FIGS. 8 and 10;
FIG. 12 is a view showing an example of a line color command designated when an outline of the circle shown in FIG. 8 is drawn using yellow (coloring agent Yellow at 100%);
FIG. 13 is a block diagram showing a circuit arrangement of an image processing apparatus according to an embodiment of the present invention;
FIG. 14 is a perspective view showing details of a portion around a head unit of an ink-jet image processing apparatus;
FIG. 15 is a view showing details of a heat unit 101 shown in FIG. 14;
FIG. 16 is a view showing an example of a band structure;
FIG. 17 is a view showing an example of a case wherein an effective print area of a sheet is divided into eight bands;
FIG. 18 shows an example of a memory map of a RAM area in which a development memory for one band is prepared for each coloring agent;
FIG. 19 shows an example of a memory map of a RAM area in which two development memories each for one band are prepared for each coloring agent;
FIG. 20 is a view showing an example of an attributes area for storing drawing attribute information used upon data development onto a memory;
FIG. 21 is a view showing an example of a path control table;
FIG. 22 is a flow chart executed when a color print operation is performed using only one-band memories corresponding to coloring agents;
FIG. 23 is a flow chart executed when the color print operation is performed using only one-band memories corresponding to coloring agents;
FIG. 24 is a flow chart executed when the color print operation is performed using only one-band memories corresponding to coloring agents;
FIG. 25 is a flow chart executed when the path control table is initialized in step S1 in FIG. 22;
FIG. 26 is a view showing the content of the path control table initialized by the flow chart of FIG. 25;
FIGS. 27A to 27C are views showing examples of color designation commands of drawing attribute designation commands;
FIGS. 28A to 28C are views showing examples of a line width designation command, a clip area designation command, and a paint definition designation command;
FIG. 29 is a view showing an example of a line or polygon drawing command;
FIGS. 30A and 30B are views showing examples of a circle drawing command and a character print command;
FIG. 31 is a view showing an example of a command analysis jump table;
FIG. 32 is a flow chart showing details of command data analysis processing;
FIG. 33 is a flow chart showing details of processing for executing a color-designation-command-analysis function;
FIG. 34 is a flow chart showing the details of the processing for executing the color-designation-command-analysis function;
FIG. 35 is a flow chart showing the details of the processing for executing the color-designation-command-analysis function;
FIG. 36 is a flow chart showing details of processing for executing a line-width-designation-command-analysis function;
FIG. 37 is a flow chart showing details of processing for executing a clip-area-designation-command-analysis function;
FIG. 38 is a flow chart showing details of processing for executing a paint-definition-designation-command analysis function;
FIG. 39 is a flow chart showing details of processing for setting a min band No. and a max band No. in a memory development information area;
FIG. 40 is a diagram showing color reproduction processing;
FIG. 41 shows color conversion processing;
FIG. 42 shows the color conversion processing;
FIG. 43 is a flow chart showing processing upon execution of a line-drawing-command-analysis function;
FIG. 44 is a flow chart showing the processing upon execution of the line-drawing-command-analysis function;
FIG. 45 is a flow chart showing the processing upon execution of the line-drawing-command-analysis function;
FIG. 46 is a flow chart showing processing upon execution of a polygon-drawing-command-analysis function;
FIG. 47 is a flow chart showing the processing upon execution of the polygon-drawing-command-analysis function;
FIG. 48 is a flow chart showing the processing upon execution of the polygon-drawing-command-analysis function;
FIG. 49 is a flow chart showing processing for setting data in a work area;
FIG. 50 is a flow chart showing the processing for setting data in the work area;
FIG. 51 is a flow chart showing the processing for setting data in the work area;
FIG. 52 is a flow chart showing processing upon execution of a circle-drawing-command-analysis function;
FIG. 53 is a flow chart showing the processing upon execution of the circle-drawing-command-analysis function;
FIG. 54 is a flow chart showing the processing upon execution of the circle-drawing-command-analysis function;
FIG. 55 is a flow chart showing the processing upon execution of the circle-drawing-command-analysis function;
FIG. 56 is a flow chart showing processing upon execution of a character-drawing-command-analysis function;
FIG. 57 is a flow chart showing the processing upon execution of the character-drawing-command-analysis function;
FIG. 58 is a flow chart showing the processing upon execution of the character-drawing-command-analysis function;
FIG. 59 is a flow chart showing the processing upon execution of the character-drawing-command-analysis function;
FIG. 60 is a flow chart showing processing for calculating a drawing range;
FIG. 61 is a view showing a drawing range of a polygon;
FIG. 62 is a flow chart showing processing for calculating a circle drawing range;
FIG. 63 is a view showing a circle drawing range;
FIG. 64 is a flow chart showing processing for calculating a character drawing range;
FIG. 65 is a view showing a character drawing range;
FIG. 66 is a flow chart showing clip check processing for a drawing range;
FIG. 67 is a flow chart showing the clip check processing for a drawing range;
FIG. 68 is view showing a case wherein a clip area is set in a drawing range;
FIG. 69 is a flow chart showing processing for setting color designation information (line);
FIG. 70 is a flow chart showing processing for setting color designation information (closed figure);
FIG. 71 is a flow chart showing processing in step S301 in FIG. 70;
FIG. 72 is a flow chart showing processing in step S302 in FIG. 70;
FIG. 73 is a flow chart showing processing for setting color designation information (character);
FIG. 74 is a flow chart showing processing for calculating a min band No. and a max band No.;
FIG. 75 is a flow chart showing processing for setting information in a path control table used in an output unit;
FIG. 76 is a flow chart showing the processing for setting information in the path control table used in the output unit;
FIG. 77 is a flow chart showing the processing for setting information in the path control table used in the output unit;
FIG. 78 is a flow chart showing the processing for setting information in the path control table used in the output unit;
FIG. 79 is a view showing a case wherein a polygon and a character are drawn on areas of paths 0, 1, and 2;
FIG. 80 is a view showing an example of the path control table;
FIG. 81 is a view showing an example of memory development information of a color designation command;
FIGS. 82A to 82C are views showing examples of memory development information;
FIGS. 83A and 83B are views showing examples of memory development information;
FIGS. 84A and 84B are views showing examples of memory development information;
FIG. 85 is a view showing a case wherein a drawing operation is performed using band memories in units of coloring agents, drawing attribute commands, and drawing commands;
FIGS. 86A to 86D are views showing examples of memory development information;
FIGS. 87A to 87E are views showing examples of memory development information;
FIG. 88 is a view showing a case wherein a drawing operation is performed while setting a clip area designation mode for a line drawing operation;
FIGS. 89A to 89D are views showing examples of memory development information;
FIG. 90 shows a command execution jump table 1;
FIG. 91 shows a command execution jump table 2;
FIG. 92 is a flow chart showing details of processing in step S12 of FIG. 23;
FIG. 93 is a flow chart showing details of processing in step S390 of FIG. 92;
FIG. 94 is a view showing an example of printer coordinates set when the band height is set to be 512 dots;
FIG. 95 is a view showing an example of a clip area setting operation;
FIG. 96 is a flow chart showing details of processing in step S391 of FIG. 92;
FIG. 97 is a view showing top or head addresses of virtual memories in units of coloring agents;
FIG. 98 is a flow chart showing processing upon execution of a line-width-designation function;
FIG. 99 is a flow chart showing processing upon execution of a line-color-designation function;
FIG. 100 is a flow chart showing processing upon execution of a paint-color-designation function;
FIG. 101 is a flow chart showing processing upon execution of a character-color-designation function;
FIG. 102 is a flow chart showing processing upon execution of a clip-area-designation function;
FIG. 103 is a flow chart showing processing upon execution of a paint-definition-designation function;
FIG. 104 is a flow chart showing processing upon execution of a line-drawing function;
FIG. 105 is a flow chart showing the processing upon execution of the line-drawing function;
FIG. 106 is a flow chart showing processing upon execution of a polygon-drawing function;
FIG. 107 is a flow chart showing the processing upon execution of the polygon-drawing function;
FIG. 108 is a flow chart showing the processing upon execution of the polygon-drawing function;
FIG. 109 is a flow chart showing processing upon execution of a circle-drawing function;
FIG. 110 is a flow chart showing the processing upon execution of the circle-drawing function;
FIG. 111 is a flow chart showing processing upon execution of a character-drawing function;
FIG. 112 is a flow chart showing processing upon execution of the character-drawing function;
FIG. 113 is a flow chart showing processing upon execution of a skip operation;
FIG. 114 is a flow chart showing the processing upon execution of a color print operation;
FIG. 115 is a flow chart showing the processing upon execution of the color print operation;
FIG. 116 is a view showing a band height information table storing band heights and memory capacities;
FIG. 117 is a flow chart showing processing for changing and setting development memories in units of coloring agents on the basis of RAM capacity information;
FIG. 118 is a flow chart showing another embodiment of FIG. 117;
FIG. 119 is a flow chart showing processing for initializing a band memory;
FIG. 120 is a flow chart showing the processing for initializing the band memory;
FIG. 121 is a flow chart showing the processing for initializing the band memory;
FIG. 122 is a flow chart showing processing which can be replaced with color print processing;
FIG. 123 is a flow chart showing processing which can be replaced with color print processing;
FIG. 124 is a flow chart showing processing which can be replaced with color print processing;
FIG. 125 is a flow chart showing processing which can be replaced with color print processing;
FIG. 126 is a flow chart showing processing for performing color print processing upon selection of a mode;
FIG. 127 is a view showing an example of an operator control panel 22 shown in FIG. 13;
FIG. 128 shows an example of a memory map using a set of band memories corresponding to coloring agents;
FIG. 129 is a flow chart showing processing for performing color print processing upon selection of a mode;
FIG. 130 is a view showing an example of a print control command shown in FIG. 129; and
FIG. 131 is a flow chart showing selection processing of a print control mode on the basis of a reserved capacity of a RAM area.
FIG. 132 is a flow chart showing jamming detection/recovery processing;
FIG. 133 is a flow chart showing details of jamming recovery processing in step S706; and
FIG. 134 is a flow chart showing details of jamming recovery processing in step S706.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will be described in detail hereinafter with reference to the accompanying drawings.
FIG. 13 is a block diagram showing a circuit arrangement of an image processing apparatus according to an embodiment of the present invention.
As shown in FIG. 13, an image processing apparatus according to this embodiment is constituted by a host computer 1 and an image processing apparatus main body 2.
The host computer 1 supplies print data or print commands to the image processing apparatus like in processing shown in the flow charts to be described later, and causes the image processing apparatus to execute print processing. The image processing apparatus has a microprocessor system including a CPU, a ROM, and a RAM. More specifically, the image processing apparatus main body comprises an interface 2 for exchanging data with the host computer 1, a command analyzer 3, which has a command analysis jump table 4 for storing jump addresses to analysis programs corresponding to command Nos. of commands sent from the host computer 1, and analyzes print data or commands sent from the host computer 1 to generate information for one page, which can be developed onto a development memory, a band storage 5, which has a band height table 6 for storing a band height and information (memory capacity) of the development memory for one coloring agent corresponding to the band height, and stores information such as the band height, a color storage 7 for storing information necessary for color reproduction processing, a color reproduction unit 8 for performing the color reproduction processing, a character storage 9 for storing information for drawing a character, a controller 10 for controlling the apparatus, a memory development storage 11 having an attributes area 12 for storing attribute information, and a memory development information area 13 for storing information for memory development, a memory development analyzer 14, which has a command execution jump table 1 (15) and a command execution jump table 2 (16), and analyzes memory development information, a pattern development unit 17 for developing the analyzed memory development information onto a development memory 18, an output unit 19, which has a path control table 20 for controlling, e.g., movement of a print head, and an output buffer 21, and outputs developed data onto a sheet as a permanently visualized image, an operator control panel 22 at which print environmental parameters can be changed and set, and a data bus 23.
FIG. 14 is a perspective view showing details of a portion around a head unit of an ink-jet image processing apparatus.
A head unit 101 is constituted by arranging a large number of ink-jet heads in the sub-scanning direction in correspondence with one coloring agent. In this embodiment, Y, M, C, and Bk head units are prepared.
Ink tanks 102 and signal lines 103 are connected to these head units. A carriage drive motor 104 moves a carriage, which mounts the head units thereon, along a rail in cooperation with a conveyor belt.
FIG. 14 also illustrates print paper 107, a platen 108, print paper convey rollers 109 and 110, a print paper roll 111, and a guide roller 112.
Each head unit 101 is constituted by a plurality of ink-jet heads utilizing heat generation elements shown in FIG. 15. For example, ink-jet heads utilizing electro-mechanical conversion means such as piezo elements may also be used.
FIG. 15 shows details of the head units 101 shown in FIG. 14.
In FIG. 15, each head unit has the number of Y, M, C, or Bk nozzles corresponding to the head height.
More specifically, the head units 101 have yellow, magenta, cyan, and black ink ejection nozzles.
FIG. 16 shows an example of a band structure.
As shown in FIG. 16, a rectangular area having a width corresponding to the effective print area width of a sheet, and a length corresponding to the head height is defined as a segment.
One band is defined by vertically arranging the segments, as shown in FIG. 16, and has a size corresponding to an integer multiple of the segment.
Therefore, the band height corresponds to an integer multiple of the head height.
In FIG. 16, one band is constituted by four segments.
FIG. 17 shows a case wherein the effective print area of a sheet is divided into eight bands each having a band height corresponding to 512 scan lines.
As shown in FIG. 17, the eight bands respectively have band Nos. 0 to 7.
When the number of bands is n, the band Nos. are assigned from 0 to (n-1).
A point (e.g., (0, 512)) on the printer coordinates shown in FIG. 17 indicates a point at the upper left corner of each band area, and is calculated by (0, (n-1)×512).
The effective print area height is not always equal to the integer multiple of the band height. The height of a final band (a band 7 in FIG. 17) is sometimes equal to or smaller than the band height.
FIG. 18 shows an example of a memory map of an internal RAM area of the color image processing apparatus.
The RAM area is constituted by a system work memory, a reserved area, and memories (i.e., memories each having a size corresponding to one band area in FIG. 17) each having a size corresponding to one band for Y (yellow), M (magenta), C (cyan), and Bk (black) as coloring agents (toners or inks).
The system work memory is used as a storage area of information (e.g., variables) used in control in the image processing apparatus, and a permanent work area.
The reserved area is used as an area for storing memory development information, a character cache memory, and the like.
A dotted portion represents the size of the RAM area shown in FIG. 3.
In this manner, since the development memories need only have a size 1/8 that shown in FIG. 3, a color print operation can be performed using a smaller RAM area than a conventional apparatus.
FIG. 19 shows an example of a memory map when Y (yellow), M (magenta), C (cyan), and Bk (black) one-band memories are added to the RAM area shown in FIG. 18.
In this case, since the sizes of the development memories can be 1/4 that shown in FIG. 4, a color print operation can be performed using a smaller RAM area than a conventional apparatus.
FIG. 20 shows the attributes area (RAM) 12 shown in FIG. 13.
The attributes area is constituted by areas for temporarily retreating drawing attribute information used upon data development onto a memory, and variable areas in which the drawing attribute information is set.
As shown in FIG. 20, a retreat area is determined for each drawing attribute, and m pieces of information can be retreated.
lwidth, lymck, and the like represent variables in which each drawing attribute information is set.
FIG. 21 shows an example of the path control table 20 shown in FIG. 13.
In this case, a "path" means an area which has a width corresponding to the effective print area width, and a height corresponding to the head height, in which a print head is actually moved in the horizontal direction.
In FIG. 21, n of a path n corresponds to a value obtained by subtracting 1 from the number of paths in the effective print area of a sheet.
The path control table stores information for controlling horizontal movement of the print head, and information for confirming the presence/absence of the contents of the development memories to be printed.
In FIG. 21, minimum and maximum values are those of a drawing range of each path, and are values in a +x direction on the printer coordinates.
The minimum value corresponds to a horizontal idle moving amount (its unit is determined by the resolution of the image processing apparatus) of the print head without printing the contents of the development memories.
The maximum value indicates a maximum value when the print head is moved from the minimum value while recording the contents of the development memories.
In FIG. 21, a drawing memory flag indicates whether or not patterns are developed on Y, M, C, and Bk development memories corresponding to each path. The drawing memory flag consists of 4 bits, i.e., 1 bit for each of Y, M, C, and Bk.
If a bit is ON, this indicates that a pattern is developed on the corresponding development memory; otherwise, this indicates that no pattern is developed.
FIGS. 22, 23, and 24 are flow charts when a color print operation is performed using only Y (yellow), n (magenta), C (cyan), and Bk (black) one-band memories in the color image processing apparatus for receiving page description command data in units of pages, and performing print control in units of pages.
In step S1, the path control table shown in FIG. 21 is initialized (set with initial values), and the flow advances to step S2.
In step S2, the attributes area shown in FIG. 20 is assured on the RAM, and the flow advances to step S3.
In step S3, a set of command data (e.g., one drawing command, drawing attribute command, or the like) is read, and the flow advances to step S4.
In step S4, the read command data is analyzed by the command analyzer 3, and the flow advances to step S5.
If it is determined in step S5 that another command data for a corresponding page remains, the flow returns to step S3; otherwise, the flow advances to step S6.
In step S6, drawing attribute information necessary for data development onto the memories at that time is temporarily retreated in the retreat areas of the attributes area 12 assured in step S2, and the flow advances to step S10.
In step S10, 0 is set in a constant i, and the flow advances to step S11.
In step S11, a pointer is set the head of the first memory development information (one set) stored in the memory development information area 13, and the flow then advances to step S12.
In step S12, the memory development information read in step S11 is analyzed by the memory development analyzer 14, and is developed onto the development memories (Y, M, C, and Bk band memories) corresponding to band portions i. Thereafter, the flow advances to step S13.
If it is determined in step S13 that another memory development information remains, the flow advances to step S14. In step S14, a pointer is set at the head of the next memory development information (one set), and the flow returns to step S12.
If it is determined in step S13 that no information remains, the flow advances to step S15.
In step S15, the contents of the memories developed in step S12 are color-printed by the output unit 19, and the flow advances to step S16.
In step S16, i is incremented by one, and the flow advances to step S17.
In step S17, the Y, M, C, and Bk band memories are cleared, and the flow advances to step S18.
In step S18, the number of bands is compared with i, and if a coincidence is found therebetween, the processing is ended.
If a non-coincidence is found, the flow advances to step S19. In step S19, the drawing attributes temporarily retreated in the retreat areas of the attributes area 12 in step S6 are loaded, and are set in the variable areas of attributes area 12. The flow then returns to step S11.
With the above-mentioned processing, page description command data in units of pages are received, and a color print operation can be performed using only the Y (yellow), M (magenta), C (cyan), and Bk (black) one-band memories.
FIG. 25 is a flow chart showing processing upon initialization of the path control table in step S1 of FIG. 22.
In step S20, a pointer is set at the head of the path control table shown in FIG. 21, and the flow advances to step S21.
In step S21, 0 is set in a constant m, and the flow advances to step S22.
In step S22, a value larger than the effective print area width (its unit is equal to that of the printer coordinates) is set in a constant k, and the flow advances to step S23.
In step S23, the value k is set in the minimum value of the path indicated by the pointer, and the flow advances to step S24.
In step S24, 0 is set in the maximum value of the path indicated by the pointer, and the flow advances to step S25.
In step S25, the drawing memory flag indicated by the pointer is cleared to 0, and the flow advances to step S26.
In step S26, the values m and n are compared with each other. If m is equal to or larger than n, the processing is ended.
Otherwise, the flow advances to step S27, and the pointer is advanced by one. The flow then advances to step S28, and m is incremented by one. The flow then returns to step S23.
With the above-mentioned processing, the path control table can be initialized.
FIG. 26 shows the content of the path control table initialized by the flow chart of FIG. 25.
FIGS. 27A, 27B, and 27C show examples of color designation commands (line color designation, paint color designation, and character color designation commands) of drawing attribute designation commands.
The line color designation command is used for designating a color of a line or an outline of a figure.
The paint color designation command is used for designating a color for painting a portion inside a closed figure.
The character color designation command is used for designating a character color.
A command No. varies depending on color designation commands, and is used for identifying a command.
The content of a number-of-data parameter indicates the number of data input after the number-of-data parameter.
The content of a kind flag parameter indicates a kind of color designation data.
FIG. 27A shows a case wherein the kind flag value is 0, and represents that color designation data are R (red), G (green), and B (blue) luminance data values as three primary colors of light.
FIG. 27B shows a case wherein the kind flag value is 1, and represents that color designation data are L*, a*, and b* data values of a uniform perceptual space defined by the CIE (Commission Internationale de l'Eelairage) in 1976.
FIG. 27C shows a case wherein the kind flag value is 2, and represents that color designation data are Y (yellow), M (magenta), C (cyan), and Bk (black) density data values as primary colors of coloring agents (toners or inks).
FIGS. 28A, 28B, and 28C show examples of a line width designation command, a clip area designation command, and a paint definition designation command of the drawing attribute designation commands.
A command No. varies depending on drawing attribute designation commands, and is used for identifying a command.
The content of a number-of-data parameter indicates the number of data input after the number-of-data parameter.
The line width designation command shown in FIG. 28A is used for designating a line width of a line or an outline of a figure.
The unit of a line width value corresponds to the coordinate unit of the user coordinate system.
The clip area designation command shown in FIG. 28B is used for designating a drawing enable area of figures, characters, or the like.
In FIG. 28B, the unit of x and y minimum and maximum values corresponds to the coordinate unit of the user coordinate system.
The paint definition designation command shown in FIG. 28C is used for designating a paint pattern inside an outline of a closed figure, and the presence/absence of the outline.
In FIG. 28C, a paint pattern No. is used for identifying a paint pattern. When the pattern No. is 0, this indicates the absence of a paint pattern (blank), and when the pattern No. is other than 0, this indicates a paint pattern such as a hatched pattern.
An outline flag indicates the absence of an outline when it is 0; it indicates the presence of an outline when it is 1.
FIG. 29 shows an example of a line or polygon drawing command of drawing commands.
A command No. varies depending on drawing functions, and is used for identifying a command.
The content of a number-of-data parameter indicates the number of data input after the number-of-data parameter.
The line drawing command is used for drawing a line.
The polygon drawing command is used for drawing a polygon.
Note that x- and y-coordinate values of coordinates 1 to n are those on the user coordinate system.
FIGS. 30A and 30B show examples of a circle drawing command and a character drawing command of the drawing commands.
A command No. varies depending on drawing functions, and is used for identifying a command.
The content of a number-of-data parameter indicates the number of data input after the number-of-data parameter.
The circle drawing command shown in FIG. 30A is used for drawing a circle.
The x- and y-coordinates of the center are those on the user coordinate system.
An actual radius is calculated by multiplying a coordinate unit of the user coordinate system with a "radius" value.
The character drawing command shown in FIG. 30B is used for drawing a character.
The x- and y-coordinates of the drawing position are those on the user coordinate system indicating a start reference position of a character drawing operation.
Character data represents a character string (e.g., ABC) to be printed.
FIG. 31 shows the command analysis jump table (ROM) 4 (FIG. 13) for storing jump addresses to functions for analyzing the drawing commands and drawing attribute commands.
The jump addresses to the respective command analysis functions are stored in correspondence with command Nos. (0 to n).
FIG. 32 is a flow chart showing details of command data analysis processing in step S4 shown in FIG. 22.
In step S30, a command No. is obtained from command data (one set), and the flow advances to step S31.
In step S31, a pointer is set at the head of the command analysis jump table shown in FIG. 31, and the flow advances to step S32.
In step S32, the pointer is advanced by an amount corresponding to the command No., and the flow advances to step S33.
In step S33, a content (jump address) indicated by the pointer is obtained, and the flow advances to step S34.
In step S34, a function indicated by the jump address is executed, and the processing is ended.
FIGS. 33 to 35 are flow charts showing details of processing upon execution of a color-designation-command-analysis function in step S34 in FIG. 32.
In step S40, a min band No. and a max band No. are set in the memory development information area 13, and the flow advances to step S41.
In step S41, a command No. is read from a command, and is set in the memory development information area 13 to advance the pointer. Thereafter, the flow advances to step S42.
In step S42, a number-of-data parameter is read out from the command, and (the number of data-1) is set in a constant n. Thereafter, the flow advances to step S43.
In step S43, "4" is set as the number of data in the memory development information area 13 to advance the pointer. The flow then advances to step S44.
In step S44, a kind parameter is read from the command, and is set in a kind flag Csmflg. The flow then advances to step S45.
In step S45, color designation data corresponding in number to the constant n are read, and the flow advances to step S46.
In step S46, the value of the kind flag Csmflg is compared with 0.
If it is determined in step S46 that the value of the kind flag Csmflg is equal to 0, it is determined that the color designation data read in step S45 are R, G, and B luminance data, and the flow advances to step S49. In step S49, the R, G, and B luminance data are converted into Y, M, C, and Bk density data, and the flow then advances to step S53.
If it is determined in step S46 that the value of the kind flag Csmflg is not equal to 0, the flow advances to step S47.
In step S47, the value of the kind flag Csmflg is compared with 1.
If it is determined in step S46 that the value of the kind flag Csmflg is equal to 0, it is determined that the color designation data read in step S45 are L*, a*, and b* data of the uniform perceptual space defined by the CIE (Commission Internationale de l'Eelairage) in 1976. The flow then advances to step S50, and the CIE L*, a*, and b* data are converted into CIE X, Y, and Z data (of an XYZ calorimetric system defined by the CIE in 1931). Thereafter, the flow advances to step S51.
In step S51, the CIE X, Y, and Z data are converted into R, G, and B luminance data, and the flow advances to step S52.
In step S52, the R, G, and B luminance data are converted into Y, M, C, and Bk density data, and the flow then advances to step S53.
If it is determined in step S47 that the value of the kind flag Csmflg is not equal to 1, the flow advances to step S48.
In step S48, the value of the kind flag Csmflg is compared with 2.
If it is determined in step S48 that the value of the kind flag Csmflg is equal to 2, it is determined that the color designation data read in step S45 are Y, M, C, and Bk density data, and the flow advances to step S53. In step S53, the Y, M, C, and Bk density data are set in internal variables (Lymck, Fymck, and Tymck), and the flow advances to step S54. In step S54, the Y, M, C, and Bk density data are set in the memory development information area 13 to advance the pointer. Thus, the processing is ended.
If it is determined in step S48 that the value of the kind flag Csmflg is not equal to 2, the processing is ended.
In this manner, the color designation command is analyzed, and memory development information of the color designation command is generated.
FIG. 36 is a flow chart showing details of processing upon execution of a line-width-designation-command-analysis function in step S34 in FIG. 32.
In step S60, a min band No. and a max band No. are set in the memory development information area 13, and the flow advances to step S61.
In step S61, a command No. is read from a command, and is set in the memory development information area 13 to advance a pointer. The flow then advances to step S62.
In step S62, a number-of-data parameter is read out from the command, and is set as the number of data in the memory development information area 13 to advance the pointer. The flow then advances to step S63.
In step S63, a line-width value parameter is read from the command, and the flow advances to step S64.
In step S64, the read line-width value is converted into a pixel (dot) value with reference to the resolution of the image processing apparatus, and the flow advances to step S65.
In step S65, the converted line-width value is set in an internal variable Lwidth, and the flow advances to step S66.
In step S66, the converted line-width value is set in the memory development information area 13 to advance the pointer. The processing is then ended.
In this manner, the line width designation command is analyzed, and memory development information of the line width designation command is generated.
FIG. 37 is a flow chart showing details of processing upon execution of a clip-area-designation-command-analysis function in step S34 in FIG. 32.
In step S70, a min band No. and a max band No. are set in the memory development information area 13, and the flow advances to step S71.
In step S71, a command No. is read from a command, and is set in the memory development information area 13 to advance a pointer. The flow then advances to step S72.
In step S72, a number-of-data parameter is read from the command, and is set as the number of data in the memory development information area 13 to advance the pointer. The flow then advances to step S73.
In step S73, x and y minimum and maximum value parameters of a clip area are read from the command, and the flow advances to step S74.
In step S74, the read x and y minimum and maximum values are converted into values xmin, ymin, xmax, and ymax on the printer coordinate system on the basis of the resolution of the image processing apparatus, and the flow advances to step S75.
In step S75, the values xmin, ymin, xmax, and ymax are respectively set in cxmin, cymin, cxmax, and cymax, and the flow advances to step S76.
In step S76, the values xmin, ymin, xmax, and ymax are set in the memory development information area 13 to advance the pointer. Thereafter, the processing is ended.
In this manner, the clip area designation command is analyzed, and memory development information of the clip area designation command is generated.
FIG. 38 is a flow chart showing details of processing upon execution of a paint-definition-designation-command-analysis function in step S34 in FIG. 32.
In step S80, a min band No. and a max band No. are set in the memory development information area 13, and the flow advances to step S81.
In step S81, a command No. is read from a command, and is set in the memory development information area 13 to advance a pointer. The flow then advances to step S82.
In step S82, a number-of-data parameter is read from the command, and is set as the number of data in the memory development information area 13 to advance the pointer. The flow then advances to step S83.
In step S83, a paint pattern No. is read from the command, and is set in the memory development information area 13 to advance the pointer. The flow then advances to step S84.
In step S84, an outline flag is read from the command, and is set in the memory development information area 13 to advance the pointer. Thereafter, the flow advances to step S85.
In step S85, the paint pattern No. in an internal variable Fpat, and the flow advances to step S86.
In step S86, the content of the outline flag is set in an internal variable Fpermt, and the processing is ended.
In this manner, the paint definition designation command is analyzed, and designation memory development information of the paint definition designation command is generated.
FIG. 39 is a flow chart showing details of processing for setting the min band No. and the max band No. in the memory development information area in steps S40, S60, S70, and S80 in FIGS. 33, 36, 37, and 38.
In step S90, 0 is set in the min band No., and the flow advances to step S91.
In step S91, the min band No. is set in the memory development information area 13 to advance a pointer, and the flow advances to step S92.
In step S92, information indicating the current number of bands is obtained from the band storage 5, and the flow advances to step S93.
In step S93, a value (the number of bands-1) is set in the max band No., and the flow advances to step S94.
In step S94, the max band No. is set in the memory development information area 13 to advance the pointer, and the processing is ended.
In this manner, in the memory development information of each drawing attribute, 0 is set in the min band No., and the value (the number of bands-1) is set in the max band No. so that the memory development information is analyzed in each band processing.
FIG. 40 shows an example of color reproduction processing shown in steps S49 and S52 in FIG. 34.
In process 1, density conversion processing for LOG-converting R, G, and B values as luminance information into C, M, and Y as density information is executed.
In process 2, undercolor or color removal processing for extracting a Bk value from the C, M, and Y value is executed.
In process 3, masking processing is executed to correct unnecessary absorption characteristics of C, M, and Y toners or inks, so as to attain appropriate color reproduction.
In process 4, γ-conversion processing is executed to adjust a contrast and brightness according to an image.
The above-mentioned processing operations are performed by the color reproduction unit 8 using information in the color storage 7.
The above-mentioned R, G, and B data are assumed to have a predetermined conversion method with the CIE X, Y, and Z data.
FIG. 41 shows an example of color conversion processing in step S50 in FIG. 34.
The CIE L*, a*, and b* data can be converted into the CIE X, Y, and Z data by equations (a) to (d).
Note that Xn, Yn, and Zn are values determined according to one of CIE standard light sources to be used.
FIG. 42 shows an example of color conversion processing in step S51 in FIG. 34.
The CIE X, Y, and Z data can be converted into R, G, and B luminance data by a matrix conversion equation shown in FIG. 42.
The parameter values of the matrix are determined according to one of CIE standard light sources to be used, and this embodiment exemplifies values when the CIE standard light source D65 is used.
FIGS. 43 to 45 show processing upon execution of a line-drawing-command-analysis function in step S34 in FIG. 32.
In step S600, data are set in a work area, and xmin, ymin, xmax, and ymax are set. Thereafter, the flow advances to step S601.
In step S601, a drawing range (a line and a polygon) is calculated, and the flow advances to step S602.
In step S602, clip check processing for the drawing range is performed, and the flow advances to step S603.
In step S603, a drawing range flag set in the clip check processing of the drawing range is checked.
If it is determined in step S603 that the drawing range flag=ERROR, the processing is ended.
However, if it is determined in step S603 that the drawing range flag≠ERROR, the flow advances to step S604 to set color designation information (line). Thereafter, the flow advances to step S605.
In step S605, information for the path control table 20 used in the output unit 19 is set, and the flow advances to step S606.
In step S606, the min band No. and the max band No. are calculated, and the flow advances to step S607.
In step S607, a pointer 1 is set in the memory development information area 13, and the flow advances to step S608.
In step S608, the min band No. and the max band No. are set in the memory development information area 13 to advance the pointer 1, and the flow then advances to step S609.
In step S609, a pointer 2 is set at the head of the work area, and the flow advances to step S610.
In step S610, a command No. is obtained from the work area, and is set in the memory development information area 13. Thereafter, the flow advances to step S611.
In step S611, the pointers 1 and 2 are advanced, and the flow advances to step S612.
In step S612, the number of data is obtained from the work area, and is set in the memory development information area 13. The flow then advances to step S613.
In step S613, 1 is set in m, and the flow advances to step S614.
In step S614, xm and ym are obtained from the work area, and are set in the memory development information area 13. Thereafter, the flow advances to step S615.
In step S615, m and n (the numbers of coordinates) are compared with each other.
If m is equal to or larger than n, the processing is ended.
However, if n is larger than m, the flow advances to step S616 to increment m by 1, and the flow advances to step S617.
In step S617, the pointers 1 and 2 are advanced, and the flow returns to step S614.
In this manner, the line drawing command is analyzed, and memory development information of the line drawing command is generated.
FIGS. 46 to 48 show processing upon execution of a polygon-drawing-command-analysis function in step S34 in FIG. 32.
In step S120, data are set in a work area, and xmin, ymin, xmax, and ymax are set. Thereafter, the flow advances to step S121.
In step S121, a drawing range (a line and a polygon) is calculated, and the flow advances to step S122.
In step S122, clip check processing for the drawing range is performed, and the flow advances to step S123.
In step S123, a drawing range flag set in the clip check processing of the drawing range is checked.
If it is determined in step S123 that the drawing range flag=ERROR, the processing is ended.
However, if it is determined in step S123 that the drawing range flag≠ERROR, the flow advances to step S124 to set color designation information (closed figure). Thereafter, the flow advances to step S125.
In step S125, information for the path control table 20 used in the output unit 19 is set, and the flow advances to step S126.
In step S126, the min band No. and the max band No. are calculated, and the flow advances to step S127.
In step S127, a pointer 1 is set in the memory development information area 13, and the flow advances to step S128.
In step S128, the min band No. and the max band No. are set in the memory development information area 13 to advance the pointer 1, and the flow then advances to step S129.
In step S129, a pointer 2 is set at the head of the work area, and the flow advances to step S130.
In step S130, a command No. is obtained from the work area, and is set in the memory development information area 13. Thereafter, the flow advances to step S131.
In step S131, the pointers 1 and 2 are advanced, and the flow advances to step S132.
In step S132, the number of data is obtained from the work area, and is set in the memory development information area 13. The flow then advances to step S133.
In step S133, 1 is set in m, and the flow advances to step S134.
In step S134, xm and ym are obtained from the work area, and are set in the memory development information area 13. Thereafter, the flow advances to step S135.
In step S135, m and n (the numbers of coordinates) are compared with each other.
If n is larger than m, the flow advances to step S136 to increment m by 1, and the flow advances to step S137.
In step S137, the pointers 1 and 2 are advanced, and the flow returns to step S134.
If it is determined in step S135 that m is equal to or larger than n, the flow advances to step S138.
In step S138, the pointer 2 is set at the head of the work area, and the flow advances to step S139.
In step S139, the pointer 2 is advanced by 2, and is set in x1. The flow then advances to step S140.
In step S140, x1 and y1 are obtained from the work area, and are set in the memory development information area 13, thus ending the processing.
In this manner, the polygon drawing command is analyzed, and memory development information of the polygon drawing command is generated.
FIGS. 49 to 50 show details of processing for setting data in the work area, and setting xmin, ymin, xmax, and ymax in step S600 in FIG. 43 and S120 in FIG. 46.
In step S150, a pointer is set at the head of the work area, and the flow advances to step S151.
In step S151, a command No. is read, and is set in the work area to advance the pointer, and thereafter, the flow advances to step S152.
In step S152, the number of data is read, and is set in the work area to advance the pointer. Thereafter, the flow advances to step S153.
In step S153, a value 1/2 the number of data (the number of coordinate points of a line) is set in a constant n, and the flow advances to step S154.
In step S154, x- and y-coordinates of coordinates 1 are read, and the flow advances to step S155.
In step S155, the x- and y-coordinates of the coordinates 1 are converted into printer coordinates, and are set in x1 and y1. The flow then advances to step S156.
In step S156, x1 is set in xmin and xmax, and y1 is set in ymin and ymax. The flow then advances to step S157.
In step S157, x1 and y1 are set in the work area to advance the pointer. Thereafter, the flow advances to step S158.
In step S158, 1 is set in m, and the flow advances to step S159.
In step S159, m and n (the numbers of coordinates) are compared with each other.
If m is equal to or larger than n, the processing is ended.
However, if n is larger than m, the flow advances to step S160 to increment m by 1, and the flow advances to step S161.
In step S161, x- and y-coordinates of coordinates m are read, and the flow advances to step S162.
In step S162, the x- and y-coordinates of the coordinates m are converted into printer coordinates, and are set in xm and ym. Thereafter, the flow advances to step S163.
In step S163, values xm and xmin are compared with each other.
If xm is equal to or larger than xmin, the flow advances to step S165.
If xmin is larger than xm, the flow advances to step S164 to set the value xm in xmin, and the flow advances to step S165.
In step S165, values xm and xmax are compared with each other.
If xmax is equal to or larger than xm, the flow advances to step S167.
If xm is larger than xmax, the flow advances to step S166 to set the value xm in xmax, and the flow advances to step S167.
In step S167, values ym and ymin are compared with each other.
If ym is equal to or larger than ymin, the flow advances to step S169.
If ymin is larger than ym, the flow advances to step S168 to set the value ym in ymin, and the flow advances to step S169.
In step S169, values ym and ymax are compared with each other.
If ymax is equal to or larger than ym, the flow advances to step S171.
If ym is larger than ymax, the flow advances to step S170 to set the value ym in ymax, and the flow advances to step S171.
In step S171, xm and ym are set in the work area to advance the pointer. Thereafter, the flow returns to step S159.
In this manner, data can be set in the work area, and xmin, ymin, xmax, and ymax can be set.
FIGS. 52 to 55 show processing upon execution of a circle-drawing-command-analysis function in step S34 in FIG. 32.
In step S175, a pointer is set at the head of the work area, and the flow advances to step S176.
In step S176, a command No. is read, and is set in the work area to advance the pointer. Thereafter, the flow advances to step S177.
In step S177, the number of data is read, and is set in the work area to advance the pointer, and the flow then advances to step S178.
In step S178, x- and y-coordinates of the center are read, and the flow advances to step S179.
In step S179, the x- and y-coordinates of the center are converted into printer coordinates, and are set in xc and yc. Thereafter, the flow advances to step S180.
In step S180, xc and yc are set in the work area to advance the pointer, and the flow then advances to step S181.
In step S181, a radius value is read from the command, and the flow advances to step S182.
In step S182, the radius value is converted into a pixel (dot) value on the basis of the resolution of the image processing apparatus, and is set in r. Thereafter, the flow advances to step S183.
In step S183, r is set in the work area, and the flow advances to step S184.
In step S184, the drawing range of a circle is calculated, and the flow advances to step S185.
In step S185, clip check processing of the drawing range is executed, and the flow then advances to step S186.
In step S186, a drawing range flag set in the clip check processing of the drawing range is checked.
If it is determined in step S186 that the drawing range flag=ERROR, the processing is ended.
However, if it is determined in step S186 that the drawing range flag≠ERROR, the flow advances to step S187 to set color designation information (closed figure), and the flow then advances to step S188.
In step S188, information for the path control table 20 used in the output unit 19 is set, and the flow advances to step S189.
In step S189, the min band No. and the max band No. are calculated, and the flow advances to step S190.
In step S190, a pointer 1 is set in the memory development information area 13, and the flow advances to step S191.
In step S191, the min band No. and the max band No. are set in the memory development information area 13 to advance the pointer 1, and the flow then advances to step S192.
In step S192, a pointer 2 is set at the head of the work area, and the flow then advances to step S193.
In step S193, the command No. is obtained from the work area, and is set in the memory development information area 13. Thereafter, the flow advances to step S194.
In step S194, the pointers 1 and 2 are advanced, and the flow advances to step S195.
In step S195, the number of data is obtained from the work area, and is set in the memory development information area 13. The flow then advances to step S196.
In step S196, the pointers 1 and 2 are advanced, and the flow advances to step S197.
In step S197, xc and yc are obtained from the work area, and are set in the memory development information area 13. Thereafter, the flow advances to step Sl98.
In step S198, the pointers 1 and 2 are advanced, and the flow advances to step S199.
In step S199, r is obtained from the work area, and is set in the memory development information area 13, thus ending the processing.
In this manner, the circle drawing command is analyzed, and memory development information of the circle drawing command is generated.
FIGS. 56 to 59 show processing upon execution of a character-drawing-command-analysis function in step S34 in FIG. 32.
In step S210, a pointer is set at the head of the work area, and the flow advances to step S211.
In step S211, a command No. is read, and is set in the work area to advance the pointer. The flow then advances to step S212.
In step S212, the number of data is read, and the flow advances to step S213.
In step S213, x- and y-coordinates of a drawing position are read, and the flow advances to step S214.
In step S214, the x- and y-coordinates of the drawing position are converted into printer coordinates, and are set in xr and yr. Thereafter, the flow advances to step S215.
In step S215, character data is read from the command, and is converted into an internal code. The flow then advances to step S216.
In step S216, (the number of data in the internal code)+2 is set as the number of data in the work area to advance the pointer, and the flow advances to step S217.
In step S217, xr and yr are set in the work area to advance the pointer, and the flow advances to step S218.
In step S218, the internal code is set in the work area, and the flow advances to step S219.
In step S219, the drawing range of a character is calculated, and the flow advances to step S220.
In step S220, clip check processing of the drawing range is executed, and the flow then advances to step S221.
In step S221, a drawing range flag set in the clip check processing of the drawing range is checked.
If it is determined in step S221 that the drawing range flag=ERROR, the processing is ended.
However, if it is determined in step S221 that the drawing range flag≠ERROR, the flow advances to step S222 to set color designation information (character), and the flow then advances to step S223.
In step S223, information for the path control table 20 used in the output unit 19 is set, and the flow advances to step S224.
In step S224, the min band No. and the max band No. are calculated, and the flow advances to step S225.
In step S225, a pointer 1 is set in the memory development information area 13, and the flow advances to step S226.
In step S226, the min band No. and the max band No. are set in the memory development information area 13 to advance the pointer 1, and the flow then advances to step S227.
In step S227, a pointer 2 is set at the head of the work area, and the flow then advances to step S228.
In step S228, the command No. is obtained from the work area, and is set in the memory development information area 13. Thereafter, the flow advances to step S229.
In step S229, the pointers 1 and 2 are advanced, and the flow advances to step S230.
In step S230, the number of data is obtained from the work area, and is set in the memory development information area 13. The flow then advances to step S231.
In step S231, the pointers I and 2 are advanced, and the flow advances to step S232.
In step S232, xr and yr are obtained from the work area, and are set in the memory development information area 13. The flow then advances to step S233.
In step S233, the pointers 1 and 2 are advanced, and the flow advances to step S234.
In step S234, the internal code is obtained from the work area, and is set in the memory development information area 13, thus ending the processing.
In this manner, the character drawing command is analyzed, and memory development information of the character drawing command is generated.
FIG. 60 shows details of the processing for calculating the drawing range in step S601 in FIG. 43 and in step S121 in FIG. 46.
In step S240, xmin and xmax are respectively set in pxmin and pxmax, and the flow advances to step S241.
In step S241, ymin and ymax are respectively set in pymin and pymax, and the flow advances to step S242.
In step S242, α (a constant equal to or larger than 0) is added to Lwidth/2, and the sum is set in β. The flow then advances to step S243.
In step S243, pxmin-β is set in pxmin, and pxmax +β is set in pxmax. The flow then advances to step S244.
In step S244, pymin-β is set in pymin, and pymax +β is set in pymax, thus ending the processing.
In this manner, the drawing range for a line and a polygon can be calculated.
FIG. 61 shows a drawing range for a polygon designated by four points (x1, y1) to (x4, y4).
This range is a rectangular area surrounded by (pxmin, pymin) and (pxmax, pymax), and corresponds to a calculation result when the value α is set to be 0 in the processing shown in FIG. 60.
FIG. 62 shows details of the processing for calculating the drawing range for a circle in step S184 in FIG. 53.
In step S250, xc-r is set in pxmin, and xc+r is set in pxmax. The flow advances to step S251.
In step S251, yc-r is set in pymin, and yc+r is set in pymax. The flow advances to step S252.
In step S252, α (a constant equal to or larger than 0) is added to Lwidth/2, and the sum is set in β. The flow then advances to step S253.
In step S253, pxmin-β is set in pxmin, and pxmax +β is set in pxmax. The flow then advances to step S254.
In step S254, pymin-β is set in pymin, and pymax +β is set in pymax, thus ending the processing.
In this manner, the drawing range for a circle can be calculated.
FIG. 63 shows the drawing range for a circle.
This range is a rectangular area surrounded by (pxmin, pymin) and (pxmax, pymax), and corresponds to a calculation result when the value α is set to be 0 in the processing shown in FIG. 62.
FIG. 64 shows details of the processing for calculating the drawing range for a character in step S219 in FIG. 57.
In step S260, left and top offset values are obtained from the character storage 9 (FIG. 13), and the flow advances to step S261.
In step S261, the left and top offset values are respectively set in α1 and α2, and the flow advances to step S262.
In step S262, xr+α1 is set in pxmin, and yr-α2 is set in pymin. The flow then advances to step S263.
In step S263, a pattern width and pattern height are obtained from the character storage 9, and the flow advances to step S264.
In step S264, the pattern width is set in β1, and the pattern height is set in β2. The flow then advances to step S265.
In step S265, pxmin+β1 is set in pxmax, and pymin+β2 is set in pymax. Thus, the processing is ended.
In this manner, the drawing range for a character can be calculated.
FIG. 65 shows the drawing range for a character.
This range is a rectangular area surrounded by (pxmin, pymin) and (pxmax, pymax).
FIGS. 66 and 67 show details of the clip check processing for the drawing range in step S602 in FIG. 43, step S122 in FIG. 46, step S185 in FIG. 53, and step S220 in FIG. 57.
In step S270, values pxmax and cxmin are compared with each other.
If cxmin is larger than the value pxmax, the flow advances to step S274, and the drawing range flag is set to be ERROR, thus ending processing.
Otherwise, the flow advances to step S271.
In step S271, values pxmin and cxmax are compared with each other.
If pxmin is larger than the value cxmax, the flow advances to step S274, and the drawing range flag is set to be ERROR, thus ending processing.
Otherwise, the flow advances to step S272.
In step S272, values pymax and cymin are compared with each other.
If cymin is larger than the value pymax, the flow advances to step S274, and the drawing range flag is set to be ERROR, thus ending processing.
Otherwise, the flow advances to step S273.
In step S273, values pymin and cymax are compared with each other.
If pymin is larger than the value cymax, the flow advances to step S274, and the drawing range flag is set to be ERROR, thus ending processing.
Otherwise, the flow advances to step S275.
In step S275, values pxmin and cxmin are compared with each other.
If cxmin is larger than the value pxmin, the flow advances to step S276, and the value cxmin is set in pxmin. The flow then advances to step S277.
Otherwise, the flow advances to step S277.
In step S277, values pymin and cymin are compared with each other.
If cymin is larger than the value pymin, the flow advances to step S278, and the value cymin is set in pymin. Thereafter, the flow advances to step S279.
If pymin≧cymin in step S277, the flow advances to step S279.
In step S279, values pxmax and cymax are compared with each other.
If pxmax is larger than the value cxmax, the flow advances to step S280, and the value cxmax is set in pxmax. The flow then advances to step S281.
If pxmax≦cxmax in step S279, the flow advances to step S281.
In step S281, values pymax and cymax are compared with each other.
If pymax is larger than the value cymax, the flow advances to step S282, and the value cymax is set in pymax. The flow then advances to step S283.
If pymax≦cymax in step S281, the flow advances to step S283.
In step S283, the drawing range flag is set to be OK, and the processing is ended.
In this manner, a common range between the drawing range and the clip area can be obtained.
FIG. 68 shows a case wherein a clip area defined by a rectangular area surrounded by (cxmin, cymin) and (cxmax, cymax) is set for the drawing range defined by a rectangular area surrounded by (pxmin, pymin) and (pxmax, pymax).
With the processing shown in FIGS. 66 and 67, the drawing range shown in FIG. 68 is defined by a rectangular area surrounded by (cxmin, cymin) and (cxmax, cymax).
FIG. 69 shows details of the processing for setting color designation information (line) in step S604 in FIG. 43.
In step S290, a Y-value of Lymck is set in P -- Y, and the flow advances to step S291.
In step S291, an M-value of Lymck is set in P -- M, and the flow advances to step S292.
In step S292, a C-value of Lymck is set in P -- C, and the flow advances to step S293.
In step S293, a Bk-value of Lymck is set in P -- Bk, and the processing is ended.
In this manner, color designation information of a line can be set in P -- Y, P -- M, P -- C, and P -- Bk.
FIG. 70 shows details of processing for setting color designation information (closed figure) in step S124 in FIG. 46 and step S187 in FIG. 53.
In step S300, a product of values Fpat and Fpermt is compared with 0.
If the product is equal to 0, the flow advances to step S301, and color designation information is set (subprocessing 1), thus ending the processing.
If the product is not equal to 0, the flow advances to step S302, and color designation information is set (subprocessing 2), thus ending the processing.
FIG. 71 shows details of the processing in step S301 in FIG. 70.
In step S310, the value Fpat is compared with 0.
If the value Fpat is not equal to 0, the flow advances to step S311, and a Y-value of Fymck is set in P -- Y. The flow then advances to step S312.
In step S312, an M-value of Fymck is set in P -- M, and the flow advances to step S313.
In step S313, a C-value of Fymck is set in P -- C, and the flow advances to step S314.
In step S314, a Bk-value of Fymck is set in P -- Bk, and the processing is ended.
If it is determined in step S310 that the value Fpat is equal to 0, the flow advances to step S315, and the value Fpermt is compared with 0.
If the value Fpermt is equal to 0, the processing is ended.
If the value FpernMt is not equal to 0, a Y-value of Lyrck is set in P -- Y, and the flow advances to step S317.
In step S317, an M-value of Lymck is set in P -- M, and the flow advances to step S318.
In step S318, a C-value of Lyrnck is set in P -- C, and the flow advances to step S319.
In step S319, a Bk-value of Lyt ck is set in P -- Bk, and the processing is ended.
In this manner, color designation information for a closed figure can be set in P -- Y, P -- M, P -- C, and P -- Bk.
FIG. 72 shows details of the processing in step S302 in FIG. 70.
In step S320, a Y-value of Fymck is compared with a Y-value of Lymck.
If the Y-value of Fyrck is larger than the Y-value of Lymck, the flow advances to step S321, and the Y-value of Fymck is set in P -- Y. The flow then advances to step S323.
Otherwise, the flow advances to step S322, the Y-value of Lymck is set in P -- Y, and the flow advances to step S323.
In step S323, an M-value of Fymck is compared with an M-value of Lymck.
If the M-value of Fymck is larger than the M-value of Lymck, the flow advances to step S324, and the M-value of Fyick is set in P -- M. The flow then advances to step S326.
Otherwise, the flow advances to step S325, the M-value of Lymck is set in P -- M, and the flow advances to step S326.
In step S326, a C-value of Fymck is compared with a C-value of Lymck.
If the C-value of Fymck is larger than the C-value of Lymck, the flow advances to step S327, and the C-value of Fymck is set in P -- C. The flow then advances to step S329.
Otherwise, the flow advances to step S328, the C-value of Lymck is set in P -- C, and the flow advances to step S329.
In step S329, a Bk-value of Fymck is compared with a Bk-value of Lymck.
If the Bk-value of Fymck is larger than the Bk-value of Lymck, the flow advances to step S330, and the Bk-value of Fymck is set in P -- Bk, thus ending the processing.
Otherwise, the flow advances to step S331, the Bk-value of Lymck is set in P -- Bk, thus ending the processing.
In this manner, color designation information for a closed figure can be set in P -- Y, P -- M, P -- C, and P -- Bk.
FIG. 73 shows details of the processing for setting color designation information (character) in step S222 in FIG. 57.
In step S340, a Y-value of Tymck is set in P -- Y, and the flow advances to step S341.
In step S341, an M-value of Tymck is set in P -- M, and the flow advances to step S342.
In step S342, a C-value of Tymck is set in P -- C, and the flow advances to step S343.
In step S343, a Bk-value of Tymck is set in P -- Bk, thus ending the processing.
In this manner, color designation information for a character can be set in P -- Y, P -- M, P -- C, and P -- Bk.
FIG. 74 shows details of the processing for calculating the min band No. and the max band No. in step S606 in FIG. 44, step S126 in FIG. 47, step S189 in FIG. 54, and step S224 in FIG. 58.
In step S350, information indicating a band height (the height of one band) is obtained from the band storage 5, and the flow advances to step S351.
In step S351, the band height is set in h, and the flow advances to step S352.
In step S352, pymin and pymax of the drawing range information are obtained, and the flow advances to step S353.
In step S353, a quotient of (pymin/h) is set in the min band No., and the flow then advances to step S354.
In step S354, a quotient of (pymax/h) is set in the max band No., thus ending the processing.
In this manner, the min band No. and max band No. can be calculated from the drawing range information.
FIGS. 75 to 78 show details of the processing for setting information for the path control table used in the output unit in step S605 in FIG. 43, step S125 in FIG. 46, step S188 in FIG. 53, and step S223 in FIG. 57.
In step S360, information indicating a head height (the height of the print head) is obtained from the band storage 5, and the flow advances to step S361.
In step S361, the head height is set in h, and the flow advances to step S362.
In step S362, pxmin, pxmax, pymin, and pymax of the drawing range information are obtained, and the flow advances to step S363.
In step S363, a quotient of (pymin/h) is set in a min path No., and the flow advances to step S364.
In step S364, a quotient of (pymax/h) is set in a max path No., and the flow advances to step S365.
In step S365, P -- Y, P -- M, P -- C, and P -- Bk as the pieces of color designation information are obtained, and the flow advances to step S366.
In step S366, a pointer is set at the head of the path control table, and the flow advances to step S367.
In step S367, the pointer is advanced by the min path No., and the flow advances to step S368.
In step S368, the value of the min path No. is set in α, and the flow advances to step S369.
In step S369, a value pxmin is compared with a minimum value indicated by the pointer.
If the minimum value is larger than the value pxmin, the flow advances to step S370, and the value pxmin is set in the minimum value. Thereafter, the flow advances to step S371.
If pxmin≧minimum value, the flow advances to step S371.
In step S371, a value pxmax is compared with a maximum value indicated by the pointer.
If the value pxmax is larger than the maximum value, the flow advances to step S372, and the value pxmax is set in the maximum value. Thereafter, the flow advances to step S373.
If pxmax≦maximum value, the flow advances to step S373.
In step S373, the value P -- Y is compared with 0.
If the value P -- Y is not equal to 0, the flow advances to step S374, and a Y bit of a drawing information flag is set ON. Thereafter, the flow advances to step S375.
If the value P -- Y is equal to 0, the flow advances to step S375.
In step S375, a value P -- M is compared with 0.
If the value P -- M is not equal to 0, the flow advances to step S376, and an M bit of the drawing information flag is set ON. Thereafter, the flow advances to step S377.
If the value P -- M is equal to 0, the flow advances to step S377.
In step S377, a value P -- C is compared with 0.
If the value P -- C is not equal to 0, the flow advances to step S378, and a C bit of the drawing information flag is set ON. Thereafter, the flow advances to step S379.
If the value P -- C is equal to 0, the flow advances to step S379.
In step S379, a value P -- Bk is compared with 0.
If the value P -- Bk is not equal to 0, the flow advances to step S380, and a Bk bit of the drawing information flag is set ON. Thereafter, the flow advances to step S381.
If the value P -- Bk is equal to 0, the flow advances to step S381.
In step S381, the value of the max path No. is compared with the value α.
If the value of the max path No. is larger than α, the flow advances to step S382 to increment α by 1, and the flow advances to step S383.
In step S383, the pointer is advanced by one, and the flow returns to step S369.
If it is determined in step S381 that the max path No. is equal to or smaller than α, the processing is ended.
In this manner, information for the path control table used in the output unit can be set.
FIG. 79 shows a case wherein a polygon and a character are drawn on areas of paths 0, 1, and 2.
x1 and x2 respectively indicate the minimum and maximum values of x-coordinates of a polygon drawing area.
x3 and x4 respectively indicate the minimum and maximum values of x-coordinates of a character drawing area.
FIG. 80 shows the path control table when information for the path control table used in the processing shown in FIGS. 75 to 78 by the output unit is set for the drawing example shown in FIG. 79.
In FIG. 80, a value k is set in the initialization of the path control table shown in FIG. 25.
FIG. 81 shows an example of memory development information of color designation commands (line, paint, character) generated by analyzing the color designation command shown in FIG. 27 on the basis of the flow charts shown in FIGS. 33 to 35.
In FIG. 81, a command table No. varies depending on memory development information of color designation commands, and is used for identifying a command.
In this case, the content of the number-of-data parameter is 4.
Y-, M-, C-, and Bk-values are density data values of Y (yellow), M (magenta), C (cyan), and Bk (black) as primary colors of coloring agents (toners or inks), and represent that color designation data values are converted into Y, M, C, and Bk data values upon generation of memory development information after analysis even when a color designation command includes another kind of color designation data values.
FIGS. 82A, 82B, and 82C respectively show examples of memory development information generated by analyzing the line width designation command (FIG. 28A), the clip area designation command (FIG. 28B), and the paint definition designation command (FIG. 28C) according to the flow charts shown in FIGS. 36, 37, and 38.
In FIGS. 82A to 82C, a command table No. varies depending on memory development information, and is used for identifying a command.
The content of a number-of-data parameter indicates the number of data input after the number-of-data parameter.
FIGS. 83A and 83B respectively show examples of memory development information generated by analyzing the line and polygon drawing commands shown in FIG. 29 on the basis of the flow charts shown in FIGS. 43 to 45, and in FIGS. 46 to 48.
In FIGS. 83A and 83B, a command table No. varies depending on memory development information, and is used for identifying a command.
The content of a number-of-data parameter indicates the number of data input after the number-of-data parameter.
The final parameters of the memory development information of the polygon drawing command are x1 and y1, as shown in FIG. 83B, since they correspond to the start point (i.e., the polygon is closed at the start point).
FIGS. 84A and 84B respectively show examples of memory development information generated by analyzing the circle drawing command (FIG. 30A) and the character drawing command (FIG. 30B) on the basis of the flow charts shown in FIGS. 52 to 55 and in FIGS. 56 to 59.
In FIGS. 84A and 84B, a command table No. varies depending on memory development information, and is used for identifying a command.
The content of a number-of-data parameter indicates the number of data input after the number-of-data parameter.
FIG. 85 shows a case wherein one page is divided into four bands, and a drawing operation is performed using Y, M, C, and Bk band memories each having this band size, and some of the drawing attribute commands and drawing commands shown in FIGS. 27A to 30B.
A drawing order is an order of a circle, polygon, and character.
The circle is designated to have an internal paint mode=OFF, an outline mode=ON, and an outline color of cyan.
The polygon is designated to have an internal paint mode=ON, an outline mode=OFF, and a paint color of magenta.
The character has an internal paint color of yellow.
FIGS. 86A to 86D and FIGS. 87A to 87E show memory development information used in the drawing operation shown in FIG. 85.
In FIGS. 86A to 86D and FIGS. 87A to 87E, pieces of information are aligned in the analysis order, i.e., in the reception order of commands.
As shown in FIGS. 86A to 86D and FIGS. 87A to 87E, in all the pieces of memory development information of the drawing attribute commands, the min band No. is set to be 0, and the max band No. is set to be 3, so that the corresponding commands are analyzed in all the bands.
If the pieces of memory development information of the drawing attribute commands are not set as described above, since drawing attribute information must be added to memory development information of a corresponding drawing command, the data amount of the memory development information is undesirably increased.
As for memory development information of each drawing command, a minimum band No. where a drawing range is present is set in the min band No., and a maximum band No. where the drawing range is present is set in the max band No.
For example, in the memory development information of the circle drawing command, the min band No. is 1, and the max band No. is 2.
FIG. 88 shows a case wherein one page is divided into four bands, Y, M, C, and Bk band memories each having this band size are used, a clip area designation mode is set in the line drawing command, and a drawing operation is performed.
The color of a line is assumed to be red (M100%, Y100%).
FIGS. 89A to 89D show memory development information used in the drawing operation shown in FIG. 88.
In FIGS. 89A to 89D, pieces of information are aligned in the analysis order, i.e., in the reception order of commands.
The drawing range of a line extends from a band "0" to a band "3" by the processing shown in FIG. 60 regardless of a clip area.
In consideration of the clip area, the drawing range of the line extends from a band "1" to a band "2" by the processing shown in FIGS. 66 and 67.
Therefore, as for the memory development information of the line drawing command, the min band No. is set to be 1, and the max band No. is set to be 2.
FIG. 90 shows the command execution jump table 1 (ROM), which stores jump addresses to functions for developing patterns to be drawn onto a memory in practice, and jump addresses to functions for designating drawing attributes (setting attributes in internal variables, and the like).
The jump addresses are stored in correspondence with command Nos. (0 to n).
FIG. 91 shows the command execution jump table 2 (ROM) in which all the jump addresses to the functions for developing patterns to be drawn onto the memory in FIG. 90 are replaced with jump addresses to skip functions.
Like in FIG. 90, the jump addresses are stored in correspondence with command Nos. (0 to n).
FIG. 92 is a flow chart showing details of the processing in step S12 in FIG. 23.
In step S390, a possible drawing range is set in consideration of a clip range (a rectangular area for setting a possible drawing range of a figure, character, and the like), and the flow advances to step S391.
In step S391, the head addresses of Y, M, C, and Bk virtual page memories are calculated and set, and the flow advances to step S392.
In step S392, min and max band No. values of memory development information are read, and a pointer is advanced to indicate the next data. The flow then advances to step S393.
In step S393, a command No. is read, and the flow advances to step S394.
In step S394, it is checked if a relation of min band No.≦i (current band No.)≦max band No. is established.
If YES in step S394, the flow advances to step S395, and a pointer is set at the head of the command execution jump table 1 shown in FIG. 90. The flow then advances to step S397.
If NO in step S394, the flow advances to step S396, and a pointer is set at the head of the command execution jump table 2 shown in FIG. 91. The flow then advances to step S397.
In step S397, the table pointer is advanced by an address corresponding to the command No., and the flow advances to step S398.
In step S398, a content (jump address) indicated by the pointer is obtained, and the flow advances to step S399.
In step S399, a function indicated by the jump address is executed, and the processing is ended.
FIG. 93 is a flow chart showing details of the processing in step S390 in FIG. 92.
In the following description, y-coordinate values of the drawing range, and clip area values are assumed to be those on the printer coordinate system.
In step S400, band height information the height of one band (the number of dots or the number of scan lines)! is obtained from the band storage 5, and the flow advances to step S401.
In step S401, a value given by (the above-mentioned band height)×i (current band No.) is set in a minimum value many of the y-coordinate of the possible drawing range, and the flow advances to step S402.
In step S402, a value (i+1) is compared with the number of bands.
If the number of bands is larger than the value (i+1), the flow advances to step S403, a value given by (the above-mentioned band height)×(i+1)-1 is set in a maximum value maxy of the y-coordinate of the possible drawing range. Thereafter, the flow advances to step S405.
Otherwise, the flow advances to step S404, a maximum value of the y-coordinate of the effective print area of a sheet is set in the maximum value maxy of the y-coordinate of the possible drawing range. Thereafter, the flow advances to step S405.
In step S405, a minimum value dspymi and a maximum value dspymx of the y-coordinate of information of the clip area (a rectangular area for setting a possible drawing range of a figure, character, and the like) are obtained, and the flow advances to step S406.
In step S406, miny and dspymi are compared with each other.
If miny is larger than dspymi, the flow advances to step S407, and the value miny is set in dspymi. Thereafter, the flow advances to step S408.
If miny≦dspymi, the flow directly advances to step S408.
In step S408, maxy and dspymx are compared with each other.
If dspymx is larger than maxy, the flow advances to step S409, and the value maxy is set in dspymx, thus ending the processing.
If maxy≦dspymx, the processing is directly ended.
An actual possible drawing range for a figure, character, and the like, used in band memory development uses dspymi and dspymx set in this flow.
FIG. 94 shows the printer coordinates set when a band height=512 dots.
In this case, as shown in FIG. 94, the value miny of a band "0" is 0, and the value maxy is 511. The value miny of a band "1" is 512, and the value maxy is 1023.
FIG. 95 shows a case wherein a clip area satisfying dspymi<miny and maxy<dspymx is set for a possible drawing range for a figure, character, and the like when a band No.=i.
In this case, an actual possible drawing range for a figure, character, and the like used in band memory development having a band No. corresponding to i is a hatched portion in FIG. 95 according to the processing described above.
Note that dspxmi and dspxmx are minimum and maximum values of the x-coordinate of the clip area.
FIG. 96 is a flow chart showing details of processing in step S391 in FIG. 92.
In step S410, information X -- bandptr (X=y, m, c, k) of the head address of each of Y, M, C, and Bk band memories is obtained from the band storage 5, and the flow advances to step S411.
In step S411, information indicating the capacity (byte) of each band memory is obtained from the band storage 5, and the flow advances to step S412.
In step S412, the head addresses of Y, M, C, and Bk virtual page memories are calculated by X -- topadr (X=y, m, c, k)×i (current band No.), thus ending processing.
FIG. 97 shows the head addresses of the Y, M, C, and Bk virtual page memories when a pattern is to be developed on a fifth band (band No. 4) shown in FIG. 17.
The addresses shown in FIG. 97 are obtained by the processing shown in FIG. 96.
FIG. 98 shows processing upon execution of a line-width-designation function in step S399 in FIG. 92.
In step S420, a line width value is read from memory development information of the line width designation command, and the flow advances to step S421.
In step S421, the line width value is set in a variable lwidth as line width information used when a drawing pattern is developed onto a memory upon execution of a drawing function, thus ending the processing.
FIG. 99 shows processing upon execution of a line-color-designation function in step S399 in FIG. 92.
In step S430, Y-, M-, C-, and Bk-values of a line color are read from memory development information of a line color designation command, and the flow advances to step S431.
In step S431, the Y-, M-, C-, and Bk-values are set in a variable lymck as line color information used when a drawing pattern is developed onto a memory upon execution of a drawing function, thus ending the processing.
FIG. 100 shows processing upon execution of a paint-color-designation function in step S399 in FIG. 92.
In step S430, Y-, M-, C-, and Bk-values of a paint color are read from memory development information of a paint color designation command, and the flow advances to step S431.
In step S431, the Y-, M-, C-, and Bk-values are set in a variable fymck as paint color information used when a drawing pattern is developed onto a memory upon execution of a drawing function, thus ending the processing.
FIG. 101 shows processing upon execution of a character-color-designation function in step S399 in FIG. 92.
In step S440, Y-, M-, C-, and Bk-values of a character color are read from memory development information of a character color designation command, and the flow advances to step S441.
In step S441, the Y-, M-, C-, and Bk-values are set in a variable tymck as character color information used when a drawing pattern is developed onto a memory upon execution of a drawing function, thus ending the processing.
FIG. 102 shows processing upon execution of a clip-area-designation function in step S399 in FIG. 92.
In step S450, values xmin, ymin, xmax, and ymax of a clip area are read from memory development information of a clip area designation command, and the flow advances to step S451.
In step S451, the values xmin, ymin, xmax, and ymax are respectively set in variables dspxmi, dspymi, dspxmx, and dspymx as clip area information used when a drawing pattern is developed onto a memory upon execution of a drawing function. The flow then advances to step S452.
In step S452, values miny and maxy (on the printer coordinates) of a drawing range of a band corresponding to a band No. i are obtained from the band storage 5, and the flow advances to step S453.
In step S453, miny and dspymi are compared with each other.
If miny is larger than dspymi, the flow advances to step S454 to set the value miny in dspymi. The flow then advances to step S455.
If miny≦dspymi, the flow advances to step S455.
In step S455, maxy and dspymx are compared with each other.
If dspymx is larger than maxy, the flow advances to step S456 to set the value maxy in dspymx, thus ending the processing.
If dspymx≦maxy, the processing is directly ended.
FIG. 103 shows processing upon execution of a paint-definition-designation function in step S399 in FIG. 92.
In step S460, a paint pattern No. is read from memory development information of a paint definition designation command, and the flow advances to step S461.
In step S461, the paint pattern No. is set in a variable fpat as paint pattern information used when a drawing pattern is developed onto a memory upon execution of a drawing function. The flow then advances to step S462.
In step S462, an outline flag value is read from the memory development information of the paint definition designation command, and the flow advances to step S463.
In step S463, the outline flag value is set in a variable fpermt as information indicating the presence/absence of an outline used when a drawing pattern is developed onto a memory upon execution of a drawing function, thus ending processing.
FIGS. 104 and 105 show processing upon execution of a line-drawing function in step S399 in FIG. 92.
In step S470, the number of data is read from memory development information of a line drawing command, and the flow advances to step S471.
In step S471, a value (the number of coordinate points of a line) 1/2 the number of data is set in a constant n, and the flow advances to step S472.
In step S472, values of line color information lymck are obtained, and the flow advances to step S473.
In step S473, clip area information values dspxmi, dspxmx, dspymi, and dspymx are obtained, and the flow advances to step S474.
In step S474, the head addresses of the Y, M, C, and Bk virtual page memories are obtained, and the flow advances to step S475.
In step S475, 1 is set in a constant m, and the flow advances to step S476.
In step S476, a point (xm, ym) on the printer coordinates is read from the memory development information of the line drawing command, and the flow advances to step S477.
In step S477, another point (xm+1, ym+1) on the printer coordinates is read from the memory development information of the line drawing command, and the flow advances to step S478.
In step S478, a line pattern between the two points (xm, ym) and (xm+1, ym+1) on the printer coordinates is developed onto the Y, M, C, and Bk band memories together with the line color information lymck, clip area information, and the head addresses of the Y, M, C, and Bk virtual page memories. Thereafter, the flow advances to step S479.
In step S479, values n and (m+1) are compared with each other.
If n is larger than (m+1), the flow advances to step S480 to increment m by one. The flow then returns to step S477.
Otherwise, the processing is ended.
In this manner, a line drawing pattern can be developed onto the band memories using the memory development information of the line drawing, line color designation, and line width designation commands.
FIGS. 106 to 108 show processing upon execution of a polygon-drawing function in step S399 in FIG. 92.
In step S481, the number of data is read from memory development information of a polygon drawing command, and the flow advances to step S482.
In step S482, a value (the number of coordinate points of a polygon) 1/2 the number of data is set in a constant n, and the flow advances to step S483.
In step S483, 1 is set in a constant m, and the flow advances to step S484.
In step S484, a point (xm, ym) on the printer coordinates is read from the memory development information of the polygon drawing command, and the flow advances to step S485.
In step S485, the values xm and ym are set in a storage area in the system work memory, and the flow advances to step S486.
In step S486, the values n and m are compared with each other.
If n is larger than m, the flow advances to step S487 to increment m by one, and the flow returns to step S484.
If n≦m, the flow advances to step S488.
In step S488, values dspxmi, dspxmx, dspymi, and dspymx of clip area information are obtained, and the flow advances to step S489.
In step S489, the head addresses of the Y, M, C, and Bk virtual page memories are obtained, and the flow advances to step S490.
In step S490, the value of paint pattern information fpat is compared with 0.
If the value of the information fpat is equal to 0, flow advances to step S493.
If the value of the information fpat is not equal to 0, the flow advances to step S491 to obtain values of paint color information fymck, and the flow advances to step S492.
In step S492, an internal paint pattern of a polygon is developed onto an area surrounded by outline points (x1, y1), . . . , (xm, ym) of the polygon set in the storage area of the system work memory in step S485 on the Y, M, C, and Bk band memories on the basis of the paint pattern information fpat, the paint color information fymck, the clip area information, and the head addresses of the Y, M, C, and Bk virtual page memories. Thereafter, the flow advances to step S493.
In step S493, a value of outline information fpermt is compared with 0.
If the value of the information fpermt is equal to 0, the processing is ended.
If the value of the information fpermt is not equal to 0, the flow advances to step S494, and 1 is set in the constant m. The flow then advances to step S495.
In step S495, values of line color information lymck are obtained, and the flow advances to step S496.
In step S496, coordinates xm and ym of an outline point of a polygon are obtained from the storage area in the system work memory, and the flow advances to step S497.
In step S497, coordinates xm+1 and ym+1 of another outline point of the polygon are obtained from the storage area in the system work memory, and the flow advances to step S498.
In step S498, a line pattern between the two points (xm, ym) and (xm+1, ym+1) on the printer coordinates is developed onto the Y, M, C, and Bk band memories on the basis of the line color information lymck, the clip area information, and the head addresses of the Y, M, C, and Bk virtual page memories. Thereafter, the flow advances to step S499.
In step S499, values n and (m+1) are compared with each other.
If n is larger than (m+1), the flow advances to step S500 to increment m by one, and the flow then returns to step S497.
Otherwise, the processing is ended.
In this manner, a polygon drawing pattern can be developed onto the band memories on the basis of the memory development information of the polygon drawing, paint definition designation, line color designation, and paint color designation commands.
FIGS. 109 and 110 show processing upon execution of a circle-drawing function in step S399 in FIG. 92.
In step S501, the number of data is read from memory development information of a circle drawing command, and the flow advances to step S502.
In step S502, xc and yc as the x- and y-coordinates of the center are read from the memory development information of the circle drawing command, and the flow advances to step S503.
In step S503, a radius r is read from the memory development information of the circle drawing command, and the flow advances to step S504.
In step S504, values dspxmi, dspxmx, dspymi, and dspymx of clip area information are obtained, and the flow advances to step S505.
In step S505, the head addresses of the Y, M, C, and Bk virtual page memories are obtained, and the flow advances to step S506.
In step S506, a value of paint pattern information fpat is compared with 0.
If the value of the information fpat is equal to 0, the flow advances to step S509.
If the value of the information fpat is not equal to 0 the flow advances to step S507 to obtain values of paint color information fymck. The flow then advances to step S508.
In step S508, an internal paint pattern of a circle is developed onto the Y, M, C, and Bk band memories on the basis of xc and yc, the radius r, the paint pattern information fpat, the paint color information fymck, the clip area information, and the head addresses of the Y, M, C, and Bk virtual page memories. The flow then advances to step S509.
In step S509, a value of outline information fpermt is compared with 0.
If the value of the information fpermt is equal to 0, the processing is ended.
If the value of the information fpermt is not equal to 0, the flow advances to step S510 to obtain values of color information lymck, and the flow then advances to step S511.
In step S511, an outline pattern of a circle is developed onto the Y, M, C, and Bk band memories on the basis of xc and yc, the radius r, the paint color information lymck, the clip area information, and the head addresses of the Y, M, C, and Bk virtual page memories. Thereafter, the processing is ended.
In this manner, a circle drawing pattern can be developed onto the band memories on the basis of the memory development information of the circle drawing, paint definition designation, line color designation, and paint color designation commands.
FIGS. 111 and 112 show processing upon execution of a character-drawing function in step S399 in FIG. 92.
In step S520, the number of data is read from memory development information of a character drawing command, and the flow advances to step S521.
In step S521, the x- and y-coordinates xr and yr of the drawing position are read from the memory development information of the character drawing command, and the flow advances to step S522.
In step S522, the internal code of a character is read from the memory development information of the character drawing command, and the flow advances to step S523.
In step S523, values dspxmi, dspxmx, dspymi, and dspymx of clip area information are obtained, and the flow advances to step S524.
In step S524, the head addresses of the Y, M, C, and Bk virtual page memories are obtained, and the flow advances to step S525.
In step S525, values of character color information tymck are obtained, and the flow advances to step S526.
In step S526, a character pattern is developed onto the Y, M, C, and Bk band memories on the basis of xr and yr, the internal code, the character color information tymck, the clip area information, and the head addresses of the Y, M, C, and Bk virtual page memories, thus ending the processing.
In this manner, a character pattern can be developed onto the band memories on the basis of the memory development information of the character drawing and character color designation commands.
FIG. 112 shows processing upon execution of a skip function in step S399 in FIG. 92.
In step S530, the number of data is read from memory development information, and the flow advances to step S531.
In step S531, the number of data is set in a constant n, and the flow advances to step S532.
In step S532, 0 is set in a constant j, and the flow advances to step S533.
In step S533, a pointer is set at data next to the number-of-data parameter, and the flow advances to step S534.
In step S534, data indicated by the pointer is read, and the flow advances to step S535.
In step S535, the constant j is incremented by one, and the flow advances to step S536.
In step S536, the pointer is advanced to indicate the next data, and the flow advances to step S537.
In step S537, the constant j and the number n of data are compared with each other. If these values are not equal to each other, the flow returns to step S534.
If these values are equal to each other, the processing is ended.
In this manner, the control can skip memory development information of a drawing command.
FIGS. 113 to 115 show processing upon execution of a color print operation in step S15 in FIG. 23.
In step S540, the number of segments (the number of paths) per band is obtained from the band storage 5, and the flow advances to step S541.
In step S541, the number of segments per band is set in a constant α, and the flow advances to step S542.
In step S542, a pointer is set at the head of the path control table, and the flow advances to step S543.
In step S543, 1 is set in a constant β, and the flow advances to step S544.
In step S544, a value of a drawing memory flag indicated by the pointer is compared with 0.
If the value of the flag is equal to 0, the flow advances to step S556.
If the value of the flag is not equal to 0, the flow advances to step S545.
In step S545, it is checked if the Bk-bit of the drawing memory flag is ON.
If the Bk-bit is not ON, the flow advances to step S547.
If a Bk-bit is ON, the flow advances to step S546, and the memory content of the current segment from the minimum value to the maximum value indicated by the pointer of the Bk band memory is stored in an output buffer. Thereafter, the flow advances to step S547.
In step S547, it is checked if a C-bit of the drawing memory flag is ON.
If the C-bit is not ON, the flow advances to step S549.
If the C-bit is ON, the flow advances to step S548, and the memory content of the current segment from the minimum value to the maximum value indicated by the pointer of the C band memory is stored in the output buffer. Thereafter, the flow advances to step S549.
In step S549, it is checked if an M-bit of the drawing memory flag is ON.
If the M-bit is not ON, the flow advances to step S551.
If the M-bit is ON, the flow advances to step S550, and the memory content of the current segment from the minimum value to the maximum value indicated by the pointer of the M band memory is stored in the output buffer. Thereafter, the flow advances to step S551.
In step S551, it is checked if a Y-bit of the drawing memory flag is ON.
If the Y-bit is not ON, the flow advances to step S553.
If the Y-bit is ON, the flow advances to step S552, and the memory content of the current segment from the minimum value to the maximum value indicated by the pointer of the Y band memory is stored in the output buffer. Thereafter, the flow advances to step S553.
In step S553, the print head is horizontally moved to the position of the minimum value indicated by the pointer, and the flow advances to step S554.
In step S554, the content of the output buffer is recorded on a sheet in correspondence with the horizontal movement of the print head to the position of the maximum value indicated by the pointer. Thereafter, the flow advances to step S555.
In step S555, the print head is horizontally moved to the left edge, and the flow advances to step S556.
In step S556, the print head is vertically moved by the height of one segment (path), and the flow advances to step S557.
In step S557, the values α and β are compared with each other.
If the two values are equal to each other, the processing is ended.
If the two values are not equal to each other, the flow advances to step S558 to advance the pointer by one, and the flow then advances to step S559.
In step S559, the value β is incremented by one, and the processing is ended.
FIG. 116 shows a band height information table storing band heights and corresponding development memory information (memory capacity) for one coloring agent.
FIG. 117 is a flow chart showing an operation for changing band height information on the basis of capacity information of an additional RAM, and changing and setting the Y, M, C, and Bk development memories.
In step S101, information of the memory capacity of an additional RAM is obtained, and is set in a constant a. The flow then advances to step S102.
In step S102, a reference value (a memory capacity serving as a reference for changing a band height) of the memory capacity is set in b, and the flow advances to step S103.
In step S103, the value a is divided (rounded) by the value b, and the quotient is set in a constant i. The flow then advances to step S104.
In step S104, a pointer is set at the head of the band height information table shown in FIG. 116, and the flow advances to step S105.
In step S105, the pointer is advanced by the value i, and the flow advances to step S106.
In step S106, band height information is obtained from the content indicated by the pointer, and the flow advances to step S107.
In step S107, the obtained band height information is set in the current band height information, and the flow advances to step S108.
In step S108, development memory information is obtained from the content indicated by the pointer, and the flow advances to step S109.
In step S109, the four, i.e., Y, M, C, and Bk development memories are assured and set on the RAM on the basis of the obtained development memory information, thus ending the processing.
As described above, the height of one band can be changed according to the capacity of an additional memory, and the development memory for one band can be changed.
The processing shown in FIG. 117 can also be realized by processing shown in FIG. 118.
In step S201, information of the memory capacity of an additional RAM is obtained, and is set in a constant a. The flow then advances to step S202.
In step S202, a constant b as a reference value (a memory capacity serving as a reference for changing a band height) of a predetermined memory capacity is compared with the constant a.
If b is larger than a, the processing is ended.
Therefore, neither the band height nor the development memory are changed.
If a is equal to or larger than b, the flow advances to step S203.
In step S203, a constant c as a reference value (a memory capacity serving as a reference for changing a band height; c>b) of a predetermined memory capacity is compared with the constant a.
If c is larger than a, the flow advances to step S204. In step S204, a constant d (a predetermined band height information value for the reference value b of the memory capacity) is set in the current band height information, and the flow advances to step S205.
In step S205, the four, i.e., Y, M, C, and Bk development memories corresponding to the band height information d are assured and set on the RAM, thus ending the processing.
If it is determined in step S203 that a is equal to or larger than c, the flow advances to step S206.
In step S206, a constant e (a predetermined band height information value for the reference value c of the memory capacity) is set in the current band height information, and the flow advances to step S207.
In step S207, the four, i.e., Y, M, C, and Bk development memories corresponding to the band height information e are assured and set on the RAM, thus ending the processing.
As described above, the height of one band can be changed according to the capacity of an additional memory, and the development memory for one band can be changed.
FIGS. 119 to 121 show band memory initialization processing that can be replaced with the processing in step S17 shown in FIG. 23.
In step S560, the number of segments (the number of paths) per band is obtained from the band storage 5, and the flow advances to step S561.
In step S561, the number of segments per band is set in a constant α, and the flow advances to step S562.
In step S562, a pointer is set at the head of the path control table, and the flow advances to step S563.
In step S563, 1 is set in a constant β, and the flow advances to step S564.
In step S564, 0 is set in flg (4 bits), and the flow advances to step S565.
In step S565, a drawing memory flag indicated by the pointer and the content of flg are logically ORed, and the ORed result is set in flg. The flow then advances to step S566.
In step S566, the values α and β are compared with each other.
If the two values are not equal to each other, the flow advances to step S567 to advance the pointer by one. Thereafter, the flow advances to step S568.
In step S568, the value β is incremented by one, and the flow returns to step S565.
If it is determined in step S566 that the two values are equal to each other, the flow advances to step S569.
In step S569, it is checked if a Bk-bit (0th bit) of flg is equal to 0.
If the two values are equal to each other, the flow advances to step S571.
If the two values are not equal to each other, the flow advances to step S570, and the content of the Bk band memory is cleared. Thereafter, the flow advances to step S571.
In step S571, it is checked if a C-bit (1st bit) of flg is equal to 0.
If the two values are equal to each other, the flow advances to step S573.
If the two values are not equal to each other, the flow advances to step S572, and the content of the C band memory is cleared. Thereafter, the flow advances to step S573.
In step S573, it is checked if an M-bit (2nd bit) of fig is equal to 0.
If the two values are equal to each other, the flow advances to step S575.
If the two values are not equal to each other, the flow advances to step S574, and the content of the M band memory is cleared. Thereafter, the flow advances to step S575.
In step S575, it is checked if a Y-bit (3rd bit) of fig is equal to 0.
If the two values are equal to each other, the processing is ended.
If the two values are not equal to each other, the flow advances to step S576, and the content of the Y band memory is cleared. Thereafter, the processing is ended.
FIGS. 122 to 125 show processing that can be replaced with the color print processing shown in FIGS. 113 to 115.
In step S620, the number of segments (the number of paths) per band is obtained from the band storage 5, and the flow advances to step S621.
In step S621, the number of segments per band is set in a constant α, and the flow advances to step S622.
In step S622, a pointer is set at the head of the path control table, and the flow advances to step S623.
In step S623, 1 is set in a constant β, and the flow advances to step S624.
In step S624, the value of a drawing memory flag indicated by the pointer is compared with 0.
If the value of the flag is equal to 0, the flow advances to step S641.
If the value of the flag is not equal to 0, the flow advances to step S625.
In step S625, it is checked if a Bk-bit of the drawing memory flag is ON.
If the Bk-bit is not ON, the flow advances to step S627.
If the Bk-bit is ON, the flow advances to step S626, and the memory content of the current segment from the minimum value to the maximum value indicated by the pointer of the Bk band memory is stored in the output buffer. Thereafter, the flow advances to step S627.
In step S627, it is checked if a C-bit of the drawing memory flag is ON.
If the C-bit is not ON, the flow advances to step S629.
If the C-bit is ON, the flow advances to step S628, and the memory content of the current segment from the minimum value to the maximum value indicated by the pointer of the C band memory is stored in the output buffer. Thereafter, the flow advances to step S629.
In step S629, it is checked if an M-bit of the drawing memory flag is ON.
If the M-bit is not ON, the flow advances to step S631.
If the M-bit is ON, the flow advances to step S630, and the memory content of the current segment from the minimum value to the maximum value indicated by the pointer of the M band memory is stored in the output buffer. Thereafter, the flow advances to step S631.
In step S631, it is checked if a Y-bit of the drawing memory flag is ON.
If the Y-bit is not ON, the flow advances to step S633.
If the Y-bit is ON, the flow advances to step S632, and the memory content of the current segment from the minimum value to the maximum value indicated by the pointer of the Y band memory is stored in the output buffer. Thereafter, the flow advances to step S633.
In step S633, the minimum and maximum values indicated by the pointer are respectively set in xmin and xmax, and the flow then advances to step S634.
In step S634, the pointer is advanced to indicate a segment immediately below the current segment, and the flow advances to step S635.
In step S635, the minimum value indicated by the pointer is compared with the value xmax.
If the minimum value is larger than xmax, the flow advances to step S636 to horizontally move the print head to the position of xmin. Thereafter, the flow advances to step S637.
In step S637, the content of the output buffer is recorded on a sheet in correspondence with the horizontal movement of the print head to the position of xmax. Thereafter, the flow advances to step S641.
If it is determined in step S635 that the minimum value is equal to or smaller than the value xmax, the flow advances to step S638 to horizontally move the print head to the position of xmin. Thereafter, the flow advances to step S639.
In step S639, the content of the output buffer is recorded on a sheet in correspondence with the horizontal movement of the print head to the position of xmax. Thereafter, the flow advances to step S640 to horizontally move the print head to the left edge, and the flow then advances to step S641.
In step S641, the print head is vertically moved by the height of one segment (path), and the flow advances to step S642.
In step S642, the values α and β are compared with each other.
If the two values are equal to each other, the processing is ended.
If the two values are not equal to each other, the flow advances to step S643 to increment the value β by one. Thereafter, the flow returns to step S624.
The image processing apparatus of this embodiment can select one of a mode for performing a color print operation using a set of Y, M, C, and Bk band memories, and a mode for performing a color print operation using two sets of Y, M, C, and Bk band memories according to an instruction from the host computer 1 (FIG. 13) or the operator control panel 22 (FIG. 13), and can perform color print processing in the selected mode.
FIG. 126 is a flow chart showing processing for selecting one of the above-mentioned mode according to an instruction from the operator control panel 22 (FIG. 13), and performing color print processing.
In step S650, a record control mode of the operator control panel 22 (FIG. 13) is selected, and the flow advances to step S651.
In step S651, the selected record control mode is checked.
If the control mode using two sets of Y, M, C, and Bk band memories is selected, the flow advances to step S652 to select a record control mode (2-set mode) using two sets of Y, M, C, and Bk band memories. The flow advances to step S653 to perform color print processing using the two sets of Y, M, C, and Bk band memories, thus ending the processing.
If the control mode using one set of Y, M, C, and Bk band memories is selected, the flow advances to step S654 to select a record control mode (1-set mode) using one set of Y, M, C, and Bk band memories. The flow then advances to step S655 to perform color print processing using one set of Y, M, C, and Bk band memories, thus ending the processing.
As described above, one of the color print mode using one set of Y, M, C, and Bk band memories, and the color print mode using two sets of Y, M, C, and Bk band memories can be selected on the operator control panel, and the color print processing can be performed in the selected mode.
FIG. 127 shows the operator control panel 22 shown in FIG. 13.
As shown in FIG. 127, the operator control panel is constituted by an LCD display and switches. A switch at the right end in FIG. 127 is used for selecting the above-mentioned record control mode.
FIG. 128 shows an example of the memory map of a RAM area used upon execution of record control using one set of Y, M, C, and Bk band memories.
As can be understood from comparison with FIG. 19 showing the example of the memory map of the RAM area used execution of record control using two sets of Y, M, C, and Bk band memories, a reserved area that can be used for a character cache memory, and the like is large.
FIG. 129 is a flow chart showing processing for selecting a record control mode upon analysis of a record control command, and performing color print processing.
In step S660, a record control command is read, and the flow advances to step S661.
In step S661, the read control command is analyzed by the command analyzer 3, and the flow advances to step S662.
In step S662, the selected record control mode is checked.
If the control mode using two sets of Y, M, C, and Bk band memories is selected, the flow advances to step S663 to select a record control mode (2-set mode) using the two sets of Y, M, C, and Bk band memories. Thereafter, the flow advances to step S664 to perform color print processing using the two sets of Y, M, C, and Bk band memories, thus ending the processing.
If the control mode using one set of Y, M, C, and Bk band memories is selected, the flow advances to step S665 to select a record control mode (1-set mode) using one set of Y, M, C, and Bk band memories. Thereafter, the flow advances to step S666 to perform color print processing using one set of Y, M, C, and Bk band memories, thus ending the processing.
As described above, one of the color print mode using one set of Y, M, C, and Bk band memories, and the color print mode using two sets of Y, M, C, and Bk band memories can be selected by analyzing the record control command, and the color print processing can be performed in the selected mode.
FIG. 130 shows an example of the record control command shown in FIG. 129.
As shown in FIG. 130, the record control command consists of a command No. for identifying a command, and a record control mode selection parameter.
When the value of the record control mode selection parameter is 0, it indicates the mode for performing color print control using one set of Y, M, C, and Bk band memories; when it is 1, it indicates the mode for performing color print control using two sets of Y, M, C, and Bk band memories.
FIG. 131 is a flow chart showing processing for selecting the record control mode on the basis of a vacant capacity of the RAM area, and performing color print processing.
In step S670, the vacant capacity of the RAM area is compared with a constant M1 (a given capacity).
If the vacant capacity of the RAM area is equal to or larger than the constant M1, the flow advances to step S671 to select a record control mode (2-set mode) using the two sets of Y, M, C, and Bk band memories. Thereafter, the flow advances to step S672 to perform color print processing using the two sets of Y, M, C, and Bk band memories, thus ending the processing.
If the vacant capacity of the RAM area is smaller than the constant M1, the flow advances to step S673 to select a record control mode (1-set mode) using one set of Y, M, C, and Bk band memories. Thereafter, the flow advances to step S674 to perform color print processing using one set of Y, M, C, and Bk band memories, thus ending the processing.
As described above, one of the color print mode using one set of Y, M, C, and Bk band memories, and the color print mode using two sets of Y, M, C, and Bk band memories can be selected according to the vacant capacity of the RAM area, and the color print processing can be performed in the selected mode.
FIG. 132 is a flow chart showing jamming detection/recovery processing executed in step S6 and subsequent steps in FIG. 22, i.e., after page description commands in units of pages are analyzed, and setting for the path control table and formation of memory development information are completed.
In step S700, a jamming signal is detected, and the flow advances to step S701 to check if jamming occurs.
If NO in step S701, the flow advances to step S702, and the control waits for a time α (msec) α is a constant!. If YES in step S701, recovery from jamming is detected in step S703. The flow then advances to step S704 if recovery from jamming is completed.
If NO in step S704, the flow advances to step S705, and the control waits for a time β (msec) β is a constant!. Thereafter, the flow returns to step S703.
If YES in step S704, the flow advances to step S706, and jamming recovery processing is performed, thus ending processing.
FIGS. 133 and 134 are flow charts showing the jamming recovery processing in step S706 in FIG. 132.
In step S710, 0 is set in a constant i, and the flow advances to step S711.
In step S711, a pointer is set at the head of first memory development information (one set) stored in the memory development information area 13, and the flow advances to step S712.
In step S712, the memory development information read in step S711 is analyzed by the memory development analyzer 14 to develop the information onto the development memories (Y, M, C, and Bk band memories) corresponding to band i portions. Thereafter, the flow advances to step S713.
If it is determined in step S713 that another memory development information remains, the flow advances to step S714, and the pointer is set at the head of the next memory development information (one set). Thereafter, the flow returns to step S712.
If no information remains, the flow advances to step S715.
In step S715, the contents of the memories developed in step S712 are color-printed by the output unit 19, and the flow advances to step S176.
In step S176, i is incremented by one, and the flow advances to step S717.
In step S717, the Y, M, C, and Bk band memories are cleared, and the flow advances to step S718.
In step S718, the number of bands is compared with i. If a coincidence is found between them, the processing is ended.
If no coincidence is found between them, the flow advances to step S719, drawing attributes temporarily retreated in the retreat areas of the attributes area 12 in step S6 in FIG. 22 are loaded, and are set in the variable areas of attributes area 12. The flow then returns to step S711.
The processing in step S712 is the same as that in step S12 in FIG. 23, and the processing in step S715 is the same as that in step S15 in FIG. 23.
With the above-mentioned processing, jamming recovery processing can be performed using the content of the path control table set at the time of step S6 in FIG. 22.
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An image processing system for receiving a coded record information in units of pages for use with a recording head includes a method and apparatus for (1) analyzing the received coded record information to derive a minimum band number and a maximum band number of a band in which an object image represented by the coded record information exists, the band having a height which is an integer multiple of a height of the record head, (2) storing the derived minimum band number and the maximum band number for each object image, (3) comparing the stored minimum band number and the maximum band number with a current band number to obtain a comparison result, and (4) determining, in response to the obtained comparison result, whether the object image is to be developed into dot data in the band.
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BACKGROUND OF THE INVENTION
[0001] An example of a liquid conductor-based switch device is disclosed by Jonathon Simon et al. in A Liquid - Filled Microrelay with a Moving Mercury Drop, 6 IEEE J. OF MICROELECTROMECHANICAL SYSTEMS, 208-216. The disclosed switch device has a pair of cavities that are adjacent each other and connected by a communicating portion. Non-conductive liquid material is trapped inside the cavities. A drop of mercury is located in the communicating portion. A pair of terminals, which are disposed opposite each other, is also provided at the communicating portion. The mercury drop forms an electrical path in conjunction with the terminals.
[0002] A heater is provided in each of the pair of cavities. The heater can be turned on to heat the inside of one of the cavities and vaporize the non-conductive liquid material. The vapor forms a bubble inside the cavity. The heating raises the pressure inside the cavity, causing the non-conductive liquid material to push the mercury drop toward the other cavity. As a result of the movement of the mercury drop, an electrical path that is normally in a connected or “on” state is put in a disconnected or “off” state. Conversely, movement of the mercury drop can put an electrical path that is normally in a disconnected state into a connected state.
[0003] In this switch design, the non-conductive liquid material cannot be kept in a stable state that is suitable for operation. For example, operation can become unstable when a bubble is unexpectedly generated, such as by a non-uniform change in temperature, and the vapor that makes up the bubble moves undesirably between the cavities. Also, the disclosed switch device does not switch smoothly between the connected and disconnected states.
SUMMARY OF THE INVENTION
[0004] In one aspect of the invention, a switch device comprises first and second cavities, a passage extending between the first and second cavities, a conductive liquid located in the passage and movable in the passage, an actuating liquid enclosed in each of the first and second cavities and covering inner surfaces of the first and second cavities, the actuating liquid being either an insulator or having low conductivity, and an actuating gas enclosed in each of the first and second cavities and existing as a bubble in each of the first and second cavities, the actuating gas being either an insulator or having low conductivity. In response to heating of the first cavity, part of the actuating liquid in the first cavity vaporizes and the actuating gas bubble in the first cavity expands, which causes part of the actuating liquid to be expelled out of the first cavity and the conductive liquid to move in the passage such that an electrical path that includes the conductive liquid changes from one of a connected and a disconnected state to the other of a connected state and a disconnected state. The first cavity includes a constriction element shaped to constrain the expansion of the actuating gas bubble in the first cavity.
[0005] In another aspect of the invention, a method for switching an electrical path in a switch device having first and second cavities, the first cavity including a constriction element, a passage extending between the first and second cavities, a conductive liquid located in the passage and movable in the passage, an actuating liquid enclosed in each of the first and second cavities and covering inner surfaces of the first and second cavities, the actuating liquid being either an insulator or having low conductivity, an actuating gas enclosed in each of the first and second cavities and existing as a bubble in each of the first and second cavities, the actuating gas being either an insulator or having low conductivity. The method includes vaporizing part of the actuating liquid in the first cavity and expanding the actuating gas bubble in the first cavity in response to heating of the first cavity. The expansion of the gas bubble in the first cavity is constrained by the shape of the constriction element. Part of the actuating liquid is expelled from the first cavity in response to the expansion of the actuating gas bubble in the first cavity. The conductive liquid moves in response to the expulsion of part of the actuating liquid from the first cavity, which puts an electrical path that includes the conductive liquid from one of a connected and a disconnected state to the other of a connected state and a disconnected state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a perspective view of a simplified structure of a switch device consistent with the invention;
[0007] [0007]FIG. 2 is a simplified plan view of the structure of the passage extending between the pair of cavities shown in FIG. 1;
[0008] [0008]FIG. 3 is a cross-sectional view of one of the cavities shown in FIG. 1, in which the boundary between the liquid phase portion and vapor phase portion is indicated with a solid line for a normal state, and with a broken line for a state of elevated pressure in the vapor phase portion;
[0009] [0009]FIG. 4 is a perspective view of a heater for application to the cavity of FIG. 1;
[0010] [0010]FIGS. 5A and 5B are plan views of the top and bottom, respectively, of a glass substrate or sheet used in another switch device consistent with the invention;
[0011] [0011]FIGS. 6A and 6B are plan views of the top and bottom, respectively, of a glass substrate or sheet used in another switch device consistent the invention;
[0012] [0012]FIGS. 7A and 7B are plan views of another switch device consistent with the invention;
[0013] [0013]FIG. 7C is a cross section along the line 7 C- 7 C in FIG. 7B; and
[0014] [0014]FIGS. 8A and 8B are perspective views of a simplified structure of another switch device consistent with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Switch devices in accordance with various aspects of the present invention will now be described through reference to the appended figures.
[0016] In FIGS. 1 and 2, a switch device 10 in a first aspect of the invention has a pair of cavities 11 and 12 and an elongate passage 13 , which extends between the cavities 11 and 12 to enable the cavities to communicate with each other. An actuating gas 21 and an actuating liquid 22 are enclosed in each of the cavities 11 and 12 . The actuating gas 21 and actuating liquid 22 are preferably maintained in a state of equilibrium within the cavities 11 and 12 .
[0017] The actuating liquid 22 is preferably a material capable of wetting glass and having a surface tension Γ of less than 7.5×10 −2 N/m. The actuating liquid 22 may be selected from among liquids that can be easily vaporized by a heater or other form of heat stimulation. For example, the actuating liquid 22 may comprise Freon (a trademark and product E. I. Du Pont de Nemours and Company Corporation), methanol, ethanol, ethyl bromide, acetone, cyclohexane, or other material with similar qualities.
[0018] The actuating gas 21 may either comprise the same material as the actuating liquid 22 in its vapor phase, or comprise a mixture of the actuating liquid 22 with another gas. As shown in FIG. 3, the actuating gas 21 occupies the majority of the volume of the cavities 11 and 12 , while the actuating liquid 22 covers the inner surfaces 19 of the cavities 11 and 12 . The cavities 11 and 12 are preferably small enough to enable the actuating liquid 22 to cover the inner surfaces 19 of the cavities 11 and 12 by its own surface tension without being affected by gravity. As a result, the actuating gas 21 exists as a bubble in each of the cavities 11 and 12 . The bubble improves the reliability of the operation of the switch device 10 , as will be discussed in detail below.
[0019] Referring specifically to FIG. 1, the passage 13 has a narrower width than the cavities 11 and 12 . A drop 23 of an electrically-conductive liquid is located in the passage 13 . As shown by the direction of arrow A in FIG. 2, the drop 23 of conductive liquid can move in the lengthwise direction of the passage 13 . The lengthwise direction of the passage 13 will be called the communicating direction. As shown in FIG. 2, terminals 15 and 16 are located on opposite sides of the passage 13 part-way along the length of the passage 13 . The drop 23 of conductive liquid may be positioned along the length of the passage 13 at a location where it electrically connects the terminals 15 and 16 . It is preferable for the conductive liquid constituting drop 23 to be a liquid metal, such as gallium, mercury, or an alloy that includes gallium, such as GaInSn, GaInSnAg, GaInSnBi, or GaInSnAgBi.
[0020] As shown in FIG. 4, a heater 17 is located inside the cavity 11 . The heater 17 is shown located at the bottom of the cavity 11 , but may be located on another of the sides of the cavity instead. Another heater with the same construction may also be provided inside the cavity 12 . The heater 17 serves to heat and vaporize the actuating liquid 22 inside the cavities 11 and 12 . The current that flows to the heater 17 for heating may be pulsed. The internal pressure of the cavity 11 is increased by energizing the heater 17 inside the cavity 11 and vaporizing part of the actuating liquid 22 . The elevated internal pressure of the cavity 11 causes the drop 23 of conductive liquid to move along the length of the passage 13 toward the cavity 12 . As a result of its movement, the drop 23 moves out of contact with either or both of the terminals 15 and 16 . The movement of drop 23 opens the electrical circuit formed in a normal state of the switch device 10 by the drop 23 contacting the terminals 15 and 16 and puts the circuit in a disconnected state. Conversely, by turning off the heater 17 in the cavity 11 or by energizing a heater (not shown) in the cavity 12 , the drop 23 of conductive liquid can be moved in the opposite direction into contact with the terminals 15 and 16 to restore the normally-connected state of the electrical circuit.
[0021] As shown in FIG. 4, the heater 17 may be composed of two heating elements that extend parallel to each other. Grooves 18 that extend parallel to the heater 17 and store additional actuating liquid 22 may also be formed. The actuating liquid 22 fills the grooves 18 through capillary action. As a result, even though the actuating gas 21 fills the majority of the volume of the cavity 11 , the actuating liquid 22 can be effectively heated by the heater 17 , and the efficiency of vaporization can be improved. The amount of actuating liquid 22 stored in the grooves 18 can be regulated by suitably selecting the depth and width of the grooves 18 . By regulating the amount of actuating liquid 22 stored in the grooves 18 , the amount of actuating liquid 22 vaporized in a specific time will not exceed a specified maximum even if power to the heater 17 is accidentally left on. As a result, there is no danger of damage to the device in such a situation. The grooves 18 can also be formed in the step of forming grooves 138 and 247 illustrated in FIGS. 5B and 6B, respectively.
[0022] As described above, the actuating liquid 22 collects along the edges and in the corners of the cavities 11 and 12 , and the actuating gas 21 is located on the inside of the cavities 11 and 12 . The cavities 11 and 12 preferably have a substantially rectangular cross section. As shown in FIG. 3, the boundary 24 between the actuating gas 21 and the actuating liquid 22 is aspherical. A boundary portion 24 a of the boundary, which extends parallel to the inner surfaces 19 of the cavities 11 and 12 , is a portion in which deformation of the boundary in response to an increase in pressure of the actuating gas 21 is restricted by the inner surfaces 19 . However, a boundary portion 24 b , which corresponds to the comers of the rectangular inner surfaces 19 , is not significantly restricted by the inner surfaces 19 .
[0023] When heat is generated by the heater 17 with the boundary 24 in the state shown by the solid line in FIG. 3, part of the actuating liquid 22 vaporizes, and the pressure of the actuating gas 21 increases. The increased pressure primarily deforms the boundary portion 24 b outwards, as indicated by the broken line 25 in FIG. 3. The increased pressure expels part of the actuating liquid 22 out of the cavity 11 to move the drop 23 of conductive liquid along the passage 13 , as described above. Although not shown in the figures, the volume of the actuating gas 21 inside the actuating liquid 22 is reduced when no heat is applied to the cavity. By providing a bubble of sufficient volume in the one of the cavities 11 and 12 that is not heated, excessive accumulation of the actuating liquid 22 is prevented, and the movement of the drop 23 is smoother.
[0024] As heat increases the pressure inside the cavity 11 or 12 , the bubble of actuating gas 21 expands and the boundary portion 24 b is deformed so that its radius of curvature decreases. The surface tension force on the surface of the actuating gas bubble increases approximately proportionally to the decrease in the radius of curvature of the boundary portion 24 b . The increased surface tension force resists further expansion of the actuating gas bubble, and limits the expulsion of the actuating liquid 22 into the passage 13 .
[0025] Even when the heater 17 is not energized, heat from the environment may heat the actuating gas 21 . When such environmental heating occurs, the resulting increase in the pressure of the actuating gas 21 will deform the boundary portion 24 b more than the boundary portion 24 a . Deforming the boundary portion 24 b will increase the surface tension force on the surface of the actuating gas bubble.
[0026] The increasing surface tension force on the surface of the actuating gas bubble constrains further expansion of the gas bubble in one of the cavities 11 and 12 subject to heating, and limits the expulsion of the actuating liquid 22 from the cavity subject to heating into the passage 13 . As a result, the switch device 10 according to the invention is highly stable and resists accidental changes in the connection state.
[0027] [0027]FIGS. 5A and 5B show the glass substrates that form part of a switch device of a second aspect of the invention. FIGS. 5A and 5B show a top and a bottom glass substrate, respectively. In this aspect of the invention, as well as other aspects discussed below, specific structures are disclosed that facilitate manufacturing of the switch device. Since the switch device in these other aspects of the invention operates in the same manner as the switch device of the first aspect of the invention, the operation of the switch device in these other aspects of the invention will not be discussed.
[0028] The switch device of the second aspect of the present invention may be manufactured by using the two glass substrates 110 and 120 shown in FIGS. 5A and 5B, respectively, and laying one of them on top of the other. An actuating liquid, an actuating gas, and a conductive liquid (each not shown), which act in the same way as in the first aspect of the present invention, are trapped in channels formed in the glass substrates 110 and 120 . These materials and the steps of manufacturing the switch device will be discussed in detail below.
[0029] In a first manufacturing step, the glass substrate 110 , shown in FIG. 5A, is etched, such as by sandblasting, to form depressions approximately 150 μm deep. The depressions constitute cavities 131 and 132 and a passage 133 , corresponding to cavities 11 and 12 and passage 13 of the switch device 10 described above with reference to FIG. 1. The total length of the cavities 131 and 132 and the passage 133 is approximately 1.05 mm, and the total width of the cavities 131 and 132 is approximately 0.30 mm. Two rectangular chambers 141 and 142 formed in the passage 133 hold the conductive liquid in one of two stable location states and ensure the proper switching connection between the conductive liquid and the electrical traces 134 . Specifically, in the completed switch device, the conductive liquid can be latched in either of the chambers 141 and 142 . The conductive liquid connects a different electrical circuit path when located in each of the chambers 141 and 142 .
[0030] In a second step, electrical traces 134 and 135 , heaters 136 , and grooves 137 and 138 are formed in and on the glass substrate 120 . The electrical traces 134 serve to form an electrical path in conjunction with the conductive liquid, and the electrical traces 135 serve to connect the heaters 136 to power sources. The electrical traces 134 and 135 and the heater 136 may be formed by known conductive film formation and patterning methods. The electrical traces 134 and 135 may be formed by patterning a tungsten film, while the heaters 136 may be formed by patterning a tantalum nitride film, for example.
[0031] The groove 137 disposed parallel to the long edges of the substrate 120 and located to communicate with the passage 133 when the switch device is assembled enables the actuating liquid to move through the passage 133 when the conductive liquid is disposed in the passage 133 in the completed switch device. The grooves 138 provide a space adjacent to the heater 136 into which the actuating liquid enters to raise the efficiency of thermal transfer from the heater 136 to the actuating liquid. The groove 137 is not necessarily needed to move the actuating liquid through the passage 133 as long as the conductive liquid can be moved smoothly. This is because there are gaps between the inner surface of the passage 133 and the surface of the conductive drop that produce a similar effect. The grooves 137 and 138 may be formed simultaneously by reactive ion etching, for example. Rather than being formed in the glass substrate 120 , the groove 138 may be formed by patterning the tantalum nitride film having a thickness of approximately 10 μm that also constitutes the heater 136 .
[0032] In a third step, the two glass substrates 110 and 120 are assembled with the conductive liquid, the actuating liquid, and the actuating gas trapped between them. More specifically, the glass substrate 110 is first arranged with the cavities 131 and 132 and the passage 133 facing up. Then, 6.5×10 6 μm 3 of the actuating liquid and actuating gas, such as Freon, is divided roughly in half and a dispenser is used put the portions of actuating liquid into the cavities 131 and 132 . By using a material such as Freon, which has good wettability with respect to the glass substrate 110 , as the actuating liquid, a suitable quantity of the material is retained in the cavities 131 and 132 . Additionally, 2×10 6 μm 3 of the conductive liquid, such as gallium, is placed in drops along the portion of the glass substrate 120 corresponding to the passage 133 in the glass substrate 110 . Because the glass substrate 120 is not wetted by the gallium, the surface tension of the gallium causes the form of the drops to be nearly spherical. It is also possible to use mercury instead of gallium.
[0033] Next, the glass substrate 110 is turned over and positioned relative to the glass substrate 120 . The two substrates are then pressed together. As the glass substrate 110 is turned over, it faces downward, but since the Freon has good wettability, the Freon is retained in the cavities 131 and 132 . The gallium drops are held in the passage 133 of the substrate 110 by pressure. Epoxy resin is then applied around the edges of the glass substrate 110 , and the glass substrate 110 is fixed to the glass substrate 120 to complete the switch device.
[0034] Assembly is preferably performed in a way that excludes gas other than Freon vapor from the cavities 11 and 12 . The glass substrate 120 is preferably selected by taking into account its wettability by Freon. If the Freon does not spreadably wet the surface of the tungsten nitride heaters, then the required wettability can be obtained by forming a thin film of silicon oxide over the tantalum nitride.
[0035] [0035]FIGS. 6A and 6B are diagrams of the glass substrates used in a switch device of a third aspect of the invention. FIG. 6A and FIG. 6B show the top and bottom glass substrate, respectively. This aspect of the invention is a variation of the second aspect of the invention.
[0036] In this aspect of the invention, a switch device is also completed by putting the two glass substrates 210 and 220 together and trapping the actuating liquid, actuating gas, and conductive liquid between them. In particular, the cavities 231 and 232 are shaped to maintain a stable bubble state in an extremely low surface tension liquid even with liquid materials that will not spreadably wet surfaces of the cavities 231 and 232 . As a result, it is unnecessary for the actuating liquid to exhibit spreadable wetting, which makes the selection of the actuating liquid easier. The groove 246 , which eases the flow of the actuating liquid, extends all the way to the heaters 245 and includes at either end a number of branch grooves 247 interleaved with the heater 245 . Electrical traces 243 and the heaters 245 may be formed from nickel films with a thickness of 1 μm, and are formed to be interleaved with the branch grooves 247 . This structure for the branch grooves 247 and the heater 245 provides effective thermal conduction from the heater 245 to the actuating liquid
[0037] When the switch device is assembled, the actuating liquid 251 that can be vaporized so as to pool as a contiguous mass in the approximate center of the passage 233 , as indicated by the broken lines FIG. 6A, and a substantially equal amount of actuating gas 252 is placed in the two cavities 231 and 232 . Although not depicted in FIGS. 6A and 6B, a conductive liquid, such as mercury, gallium, or an alloy that includes gallium, is disposed in the passage 233 . The conductive material is able to move in the same manner as described above, and can be latched in either of first and second chambers 234 and 235 provided along the passage 233 , just as in the second aspect of the present invention.
[0038] The gas material that forms bubbles in the cavities 231 and 232 in the initial state may be nitrogen gas at approximately 0.2 atm. As discussed above, the liquid material 251 is placed as a contiguous mass in the center of the passage 233 . However, since the groove 247 , which is part of the groove 246 , extends up to the proximity of the heater 245 , the actuating liquid 251 flows to the proximity of the heater 245 through capillary action. This effectively brings about the vaporization of the actuating liquid. The groove 246 does not necessarily have to continue to the center if the movement of the mercury, gallium, or other conductive liquid is sufficiently smooth.
[0039] [0039]FIGS. 7A, 7B and 7 C show a switch device 300 in a fourth aspect of the invention. FIGS. 7A and 7B are plan views of the completed switch device, and FIG. 7C is a cross section along the line 7 C- 7 C in FIG. 7B. As shown in FIG. 7C, the switch device 300 is also manufactured by assembling two glass substrates 371 and 372 . The switch device 300 includes a pair of cavities 321 and 322 , and an elongate passage 330 that extends between these cavities. The passage 330 includes first, second, and third chambers 331 , 332 , and 333 .
[0040] In the initial state, a conductive liquid 350 , which may be mercury, gallium or an alloy that includes gallium, is placed as a contiguous mass in the passage 330 to form an approximately T-shape extending into the first and second chambers 331 and 332 from the center of the passage 330 . As shown in FIG. 7A, electrical traces 343 are located in each of the first and second chambers 331 and 332 . The conductive liquid 350 acts to electrically connect the electrical traces 343 located in the chambers 331 and 332 . The cavities 321 and 322 are similar to the cavities 11 and 12 described above.
[0041] If heat is applied to the cavity 321 , part of the actuating liquid vaporizes and raises the internal pressure of the cavity 321 . This rise in the internal pressure of the cavity 321 causes the actuating liquid to move part of the conductive liquid 350 toward the cavity 322 , enter the third chamber 333 , and be latched therein. As a result, the conductive liquid 350 is separated into two portions, with the conductive liquid 350 located in the passage 330 being separated from the conductive liquid 350 located in the first and second chambers 331 and 332 . This separation of the conductive liquid 350 puts the electrical trace 343 in a disconnected state. The state shown in FIG. 7B can be restored by applying heat to the cavity 322 . The actuating liquid and actuating gas in the cavities 321 and 322 are maintained in a normal stable state, as described above.
[0042] Band-shaped nickel films 361 a and 361 b are located opposite one another on the surface of the substrates 371 and 372 at some point along the passage 330 . After being put together, the two glass substrates 371 and 372 are bonded with epoxy resin 390 . A slight gap may be left between the nickel films 361 a and 361 b , or a tight fit with no gap may be produced. The tight fit with no gap is preferable for the more effective action of the pressure. Effective operation of the switch device 300 is ensured when the conductive liquid has sufficiently good wettability with respect to nickel.
[0043] Switch devices described above in the various aspects of the present invention are merely examples, and do not limit the present invention, which can be variously modified by a person skilled in the art. For example, it is also possible to manufacture more than one switch device on a single glass substrate, and a plurality of glass substrates can be laminated to create a switch device with a multilayer structure. In the former case in particular, a plurality of cavities can be radially linked to a single cavity, as shown in FIG. 8A, or a plurality of cavities can be concatenated.
[0044] As shown in FIG. 8A, a switch device 400 includes a cavity 411 linked to a cavity 412 by a passage 433 and a cavity 413 linked to the cavity 412 by a passage 434 . If the cavity 412 is heated, the state of the electrical paths, which include traces 443 and 444 disposed along the passages 433 and 434 , respectively, are switched from being connected to disconnected, or vise versa.
[0045] Furthermore, a plurality of cavities 411 - 413 may be linked to one another by a communicating portion located between them, as shown in FIG. 8B. In this case, the communicating portion can have a substantially radial structure or a branched structure, as shown by the passages 433 and 434 in the switch device 400 of FIG. 8B. A conductive liquid, such as a liquid metal, can be placed at an intersecting location so as to close off all of the passages or to close off the middle of all of the passages in this structure. In FIG. 8B, the electrical paths, which include traces 443 and 444 disposed along the passages 433 and 434 , respectively, are switched between connected and disconnected states by heating the cavity 412 .
[0046] Other materials can also be used in place of a glass substrate. Furthermore, in addition to Freon, the vaporizable actuating liquid may be other halogen-based materials, or alcohols, acetone, and other such materials.
[0047] The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light in the above teachings or may be acquired from practice of the invention. The embodiment was chosen and described in order to explain the principles of the invention and as practical application to enable one skilled in the art to use the invention in various embodiments and with various modifications suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claim appended hereto and their equivalents.
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The switch device includes first and second cavities, a passage extending between the cavities, a conductive liquid located in the passage and movable therein, a conductive path that includes the conductive liquid, an actuating liquid enclosed in each of the first and second cavities and covering the inner surfaces thereof and an actuating gas enclosed in each of the first and second cavities and existing as a bubble therein. At least one of the cavities includes a constriction element shaped to constrain the expansion of the actuating gas bubble in the cavity. This limits expulsion of the actuating liquid into the passage and movement of the conductive liquid along the passage.
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This application is the U.S. national phase of International Application No. PCT/IB2012/057463 filed 19 Dec. 2012 which designated the U.S. and claims priority to International Application No. PCT/IB2011/055812 filed 20 Dec. 2011, the entire contents of each of which are hereby incorporated by reference.
TECHNICAL FIELD
The present invention relates to optical fiber sensors and a sensing method comprising the use of such fiber sensors.
BACKGROUND ART
Sensing fibers may be used in different applications, for instance to control the functionality of fiber optic networks or to be installed like a sensing nerve system in a structure. These sensing fibers are primarily used for testing and can perform a similar function to a “strain gauge”.
The sensor fiber represents the physical condition of the main optical fiber line and by testing the operational condition of the sensing fiber, the environment of the main line can be determined.
Glass fibers are sensitive to temperature or pressure and tensile forces, which locally change the characteristics of light transmission and reflections in the fiber. Such sensing properties of the glass fibers make it possible to also incorporate sensor fibers in a long distance tubing, such as a pipeline, in order to detect and localize a deformation or a change in temperature.
The standard method for measuring reflections from a pulsed probe signal is Optical Time Domain Reflectometry (OTDR) and uses a combination of optoelectronic testing instruments, such as a laser source and a pulse generator, to inject a series of optical pulses into the sensing fiber end.
The optical pulses travel through the optic fiber and are continuously reflected back to the same fiber end where the pulses were initially injected. Other optoelectronic testing instruments (detector combined with an oscillator) receive and interpret the return signal from the same fiber end by measuring the back-scattered light. The back scattered light contains a large quantity of different information based on reflections from reference points along the fiber. The strength of the return pulses is measured and interpreted as a function of time, and can be plotted as a function of fiber length.
Since the first demonstration of distributed fiber sensing using OTDR, based on Rayleigh scattering, a variety of distributed fiber sensing systems has been extensively developed over last two decades, using different physical phenomena such as Raman and Brillouin scattering. Most distributed sensing techniques rely on spontaneous light back-scattering while the light propagates through a sensing fiber installed along a structure under monitoring. However, the efficiency of spontaneous light scattering in any OTDR system based on Rayleigh, Raman and Brillouin scattering is insufficient to achieve a high spatial resolution over a long measurement range.
The process of light scattering can be significantly enhanced based on optical parametric interactions between two optical waves such as stimulated Brillouin scattering, designated as Brillouin optical time-domain analysis (BOTDA). This type of sensing system has shown its potentiality to interrogate distributed temperature and/or deformation of structures over 50 km with 2 m spatial resolution. In principle, the spatial resolution is determined by duration of the Brillouin pump pulse. So, a higher spatial resolution (shorter than 2 m) can be achieved simply by reducing the pump pulse duration. However, the sensing system will suffer from significant spectral broadening of the Brillouin resonance, which is inversely proportional to the pulse shortening. Consequently, it will degrade sensing performances of BOTDA system in terms of measurement accuracy, increasing standard deviation.
Recently, dynamic Brillouin grating (DBG)-based distributed sensing (DS) system using polarization maintaining fibers has been experimentally demonstrated, resulting in a best spatial resolution of 5 mm, ever reported in time domain sensing systems. Unlike the typical BOTDA system, two distinct physical processes: generation of Brillouin grating and interrogation of grating properties are entirely separated in this type of sensing system. This way the trade-off relation between high spatial resolution and high measurement accuracy could be no longer correlated. However, two actual limitations are apparently present in this type of sensing system. First, the states of polarization (SOP) of optical waves can be maintained during longitudinal propagation over less than 1 km, strictly limiting a maximal achievable measurement range. Second, from a practical point of view, the complexity of the sensing system may act as an actual limitation for its implementation in real applications.
In addition to the previous cited sensing systems another category of sensors has been developed, namely Fiber Bragg Grating (FBG) sensors.
“Bragg gratings” are reference points along the sensing fibers. They usually consist of laser engraved patterns which have been imprinted along the whole optic fiber length at specific and pre-defined distances.
Because of these Bragg gratings, an undamaged testing fiber generates a predetermined and specific return signal to the OTDR testing tool. If the optic fiber sensor is subject to mechanical strain (due to thermal expansion, damage, break, heat, pressure, magnetic or electric field etc.), the OTDR receives a modified return signal and can determine the location of the damaged point if a Bragg grating is coincidentally present at this point.
Such FBG sensors are disclosed in the following two patents: U.S. Pat. Nos. 4,996,419 5,684,297. The fibers show a plurality of separate Fiber Bragg Gratings distant from each other. Each FBG has a relatively short length. As pointed out in U.S. Pat. No. 5,684,297, the spectral width of a short-length FBG is so large, so a long frequency scan of probe pulse is required. Furthermore, the power dissipation of the pulse is also significant since the pulse spectrum is much shorter than the FBG reflection spectrum.
The state-of-the-art FBG sensors show several disadvantages. They often require a pre-calibration of the relation between FBG peak frequency shift and detected optical power difference. Furthermore, changes of temperature and strain are not uniform along the fiber, which makes the initial FBG spectrum (measured as a reference) distorted. It means that the pre-calibration would turn to be ambiguous, which will definitely degrade the measurement accuracy.
There is therefore a need to improve existing FBG sensors.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide an improved Fiber Sensing System based on Bragg OTDR.
Another objective is to provide a higher efficiency of light back-scattering
Another objective is to eliminate the essential need of optical pump waves used to generate a dynamic acoustic grating in fibers.
In that regard the invention concerns an optical fiber as defined in the claims.
One of the essential features of the invention is the continuous, i.e. distributed, presence of a FBG covering the entire fiber length which is designated for sensing and along which spatially resolved measurements are preformed.
Preferably the fiber grating according to the invention has a low reflectivity. The overall integrated reflectivity along the entire FBG is preferably less than 20%.
A signal pulse launched into the sensing fiber according to the invention is continuously back-reflected by the FBG written along the fiber while propagating through the fiber. Then the central frequency of the signal pulse will be swept in the vicinity of the Bragg reflection spectrum (BRS). This way accurate information on local temperature or strain along the FBG can be interrogated since the central frequency of the local FBG has a linear dependence on changes of external temperature and/or strain applied to the FBG, showing a typical value of −1.4 GHz/K or 140 MHz/με, respectively. Consequently, the measured peak frequency of BRS imposes information of local temperature/strain along the whole length of the sensing fiber.
One further advantage of the proposed invention is to provide an extremely high spatial resolution, readily reaching sub-cm. Due to the continuity of Bragg grating along the entire length of the sensing fiber, the distribution sensing can be realized with spatial resolution of a few millimeter, which makes the sensing system enable to monitor the structural heath of compact structures and/or integrated circuits.
Another advantage of the system according to the invention is to provide a simplified configuration since optical pump sources are no more required. A key to realize distributed sensing is based on the presence of the continuous back-scattering of the incident pulse, which propagates through a sensing fiber, which is secured along a structure under monitoring. After analyzing the optical properties of the back-scattered light the information about distortion along the structure such as a change in temperature and strain can be quantitatively determined. However, existing FBG-based sensing systems install a single or multiple individual FBGs along the structure under monitoring and launch an optical pulse that has time duration shorter than the interval between adjacent FBGs to interrogate the properties of local FBGs. It means that this type of sensing system cannot detect any changes in temperature and strain, which occur in regions where FBGs are absent, especially along the distance between two adjacent FBGs. The present invention can overcome this type of blind zone, simply by creating a weak FBG continuously along the entire sensing fiber. Therefore, the incident pulse provides a continuously back-scattered signal while propagating through the sensing fiber. So, this invention can make it possible to alarm a warning without blind zones when compared to the sensing systems disclosed in prior art.
The invention will be better understood below with a more detailed description, together with non-limiting examples.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : Schematic diagram representing a preferred embodiment of the invention
FIG. 2A : Photo of the optic fiber sensor
FIG. 2B : Photo of the measured reflection in absence of an external hot spot
FIG. 2C Photo of the measured reflection in presence of an external hot spot
DETAILED DESCRIPTION
Referring now to the drawings, FIG. 1 depicts a preferred schematic diagram of the proposed distributed sensing system to interrogate distributed temperature and/or strain along the fiber using a long and weak fiber Bragg grating.
A weak and long fiber Bragg grating is used as a sensing fiber and the temperature dependence of the peak frequency of the FBG is measured to be −1.23 GHz/K. A FWHM 50 ps signal pulse was generated after passing through a pulse shaping device that can be an electro-optic modulator (EOM) and then launched into the FBG. In turn, the central frequency of the pulse was incremented by steps of several MHz in the vicinity of the FBG reflection spectral window, simply by changing the frequency of the tunable laser source (TLS), and detected by the reflection measuring means, for example the Optical Time Domain Reflectometer (OTDR).
In FIG. 2( a ) the FBG being used as a distributed sensor is shown. A hot spot is generated and can be precisely located using a distributed FBG according to the invention.
FIG. 2( b ) shows a measured distributed reflection spectrum of a FBG sensor according to the invention as a function of the fiber distance, in absence of any external hot spot and strain applied to the FBG sensor. The information delivered to the Optical Time-Domain Reflectometer (OTDR) corresponds to the return signal based on the original Bragg frequency shift. So, the measured distribution of FBG reflection spectrum is used as reference, so that any change in local Bragg frequency in consequent measurements can indicate qualitatively a change in temperature and strain at that position. However, it must be pointed out that FIG. 2( b ) provides another important information about the uniformity of fabricated long FBG and frequency chirp information along the FBG based on the distribution of Bragg frequency in distance.
FIG. 2( c ) shows a measured distributed reflection spectrum of a FBG sensor according to the invention as a function of the fiber distance in presence of an external hot spot ( FIG. 2 c ) along the long FBG. It is clearly observed that the presence of an hot spot leads to a measurable shift in the Bragg frequency. The amount of temperature change can be simply estimated as a result of the linear relationship of −1.23 GHz/K.
In this embodiment, the FBG was uniform, which means that the Bragg frequency over the whole length of the grating is nearly constant. However, it is not a necessary condition for this invention. For instance, the distribution of Bragg frequency along the grating can be linearly varied with respect to the distance or step-wised over the distance.
It must be also specified that an absolute continuity of the FBG along the covered sensing range is not strictly required and short segments of fiber without imprinted FBG may be present, since in most fabrication processes FBGs can be imprinted only along a finite length. It may therefore be required to append many gratings to extend the sensing length and a gap between gratings can be intentionally or accidentally be present. It is sufficient to require that this distance gap is smaller than the spatial resolution of the interrogating system to implement the invention. This case will be indistinctively identified as a continuous FBG in the description of this invention.
It is also not strictly required to shape the interrogating light signal as a single pulse, but other coding techniques can be implemented, such as multiple pulse coding or radio-frequency modulation scanning of the input light signal to retrieve the time-domain information via a Fourier transform.
Various modifications and variations to the described embodiments of the invention will be apparent to those skilled in the art without departing from the scope of the invention as defined in the appended claims. 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 embodiment.
REFERENCES
[1] T. Horiguchi and M. Tateda, “Optical-fiber-attenuation investigation using stimulated Brillouin scattering between a pulse and a continuous wave,” Opt. Lett. 14, 408-410 (1989).
[2] M. Ahangrani Farahani and T. Gogolla, “Spontaneous Rman scattering in optical fibers with modulated probe light for distributed temperature Raman remote sensing,” J. Lightwave Technol. 17, 1379-1391 (1999).
[3] T. Horiguchi, T. Kurashima, and M. Tateda, “A technique to measure distributed strain in optical fibers,” Photon. Technol. Lett. 2, 352-354 (1990).
[4] T. Kurashima, T. Horiguchi, and M. Tateda, “Distributed-temperature sensing using stimulated Brillouin scattering in optical silica fibers,” Opt. Lett. 15, 1038-1040 (1990).
[5] K. Y. Song, S. Chin, N. Primerov and L. Thevenaz, “Time-domain distributed fiber sensor with 1 cm spatial resolution based on Brillouin dynamic grating,” J. Lightwave Technol. 28, 2062-2067 (2010).
[6] M. durkin, M. Ibsen, M. J. Cole and R. I. Laming, “1 m long continuously-written fiber Bragg gratings for combined second and third order dispersion compensation,” Electron. Lett. 33, 1891-1893 (1997).
[7] U.S. Pat. No. 4,996,419, “distributed multiplexed optical fiber bragg grating sensor arrangement,” Filed Dec. 26, 1989.
[8] U.S. Pat. No. 5,684,297, “Method of detecting and/or measuring physical magnitudes using a distributed sensor,” Nov. 15, 1995.
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Optic fiber sensor characterized in that the sensing fiber is provided with a continuous Bragg grating covering the entire fiber length which is dedicated to sensing and along which spatially resolved measurements are performed.
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FIELD OF THE INVENTION
The present invention relates to electronic connecting devices and, more particularly, to an electronic connecting device with a high compatibility.
DESCRIPTION OF RELATED ART
Portable computers, such as notebook computers and personal digital assistants (PDAs), are popular and commonly used devices that provide users with mobile computing power in small, lightweight, portable packages. The portable computer usually offers less functionalities than what a desktop computer brings because the portable computer may lack certain peripheral devices (e.g. a CD-ROM drive or a floppy drive).
A docking station has been developed to enhance and extend functions found in a desktop computer to a portable computer. The docking station typically provides a connector connecting a connector of the portable computer, thereby establishing an electronic connection between the portable computer and the docking station.
However, connectors' heights of docking stations and connectors' heights of portable computers are not always compatible. Various docking stations accommodate connectors with different heights. Heights are so different that docking stations generally must pair up with a specific type of portable computers. Compatibilities of different type docking stations are greatly decreased.
Therefore, an electronic connecting device with a high compatibility is desired.
SUMMARY OF THE INVENTION
An electronic connecting device includes a plate defining an opening therein, a connector for being movable along the opening, a controller for shifting the connector to different height positions.
Other advantages and novel features will become more apparent from the following detailed description of preferred embodiments when taken in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of an electronic connecting device for an electronic apparatus in accordance with an exemplary embodiment;
FIG. 2 is an exploded, isometric view of the electronic connecting device of FIG. 1 ;
FIG. 3 is a cross-sectional view of the electronic connecting device of FIG. 1 taken along line III-III thereof, with a connector being in a first height position;
FIG. 4 is a cross-sectional view of the electronic connecting device of FIG. 1 taken along line III-III thereof, with the connector being in a transitional position;
FIG. 5 is a cross-sectional view of the electronic connecting device of FIG. 1 taken along line III-III thereof, with the connector being in a second height position;
FIG. 6 is an isometric view of a portable computer and a docking station employing the electronic connecting device of FIG. 1 ; and
FIG. 7 is an isometric view of a controlling portion of an electronic connecting device in accordance with a second exemplary embodiment.
DETAILED DESCRIPTION OF THE INVENTION
In the following embodiments, a docking station for a portable computer is used as an example for illustration. It is noted that electronic apparatuses in these embodiments may be portable computers, cell phones, power chargers, or any other portable electronic apparatuses.
Referring to FIGS. 1 and 2 , an electronic connecting device 10 according to a first embodiment is illustrated. The electronic connecting device 10 includes a plate 110 , a connector 120 , a positioning pin 130 , a first supporting portion 140 , a second supporting portion 160 , two first springs 170 , a second spring 180 , and a controller 200 .
An opening 112 and a positioning hole 114 are defined in the plate 110 . Referring also to FIG. 3 , two posts 116 protrude from a bottom side of the plate 110 and respectively arranged at two opposite sides of the opening 112 for the two first springs 170 to be assembled thereon. The connector 120 passes through the opening 112 and is capable of ascending or descending along an axial direction X. The positioning pin 130 , which is surrounded by the second spring 180 , is inserted in the positioning hole 114 and is capable of ascending or descending along an axial direction Y.
The first supporting portion 140 is approximately wedge-shaped, and includes a first top surface 141 for the connector 120 to be fixed thereon, a first bottom surface 142 , and a first inclined surface 144 adjoined to the first bottom surface 142 . Two first springs 170 are located on the first top surface 141 . The second supporting portion 160 is approximately similar to the first supporting portion 140 and includes a second top surface 161 for the positioning pin 130 to be fixed thereon, a second bottom surface 162 , and a second inclined surface 164 connected to the second bottom surface 162 . The second top surface 161 supports the second spring 180 engaging around the positioning pin 130 .
The controller 200 includes a slat portion 220 , a first lifting portion 240 corresponding to the first supporting portion 140 , a second lifting portion 260 corresponding to the second supporting portion 160 , and a handle 280 perpendicularly extending for a distal end of the slat portion 220 . The first lifting portion 240 and the second lifting portion 260 are aligned on the slat portion 220 . The first lifting portion 240 is approximately wedge-shaped and conforms to the first supporting portion 140 . The first lifting portion 240 includes a third top surface 242 parallel to the first bottom surface 142 and a third inclined surface 244 parallel to the first inclined surface 144 . The second lifting portion 260 is also wedge-shaped and includes a fourth top surface 262 parallel to the second bottom surface 162 and a fourth inclined surface 264 parallel to the second inclined surface 164 .
The first springs 170 are assembled on the posts 116 correspondingly and restricted between the plate 110 and the first supporting portion 140 for keeping restoring forces that is capable of pushing the connector 120 towards the slat portion 220 . The second spring 180 is installed on the positioning pin 130 and confined between the plate 110 and the second supporting portion 160 for keeping restoring forces that is capable of pushing the positioning pin 130 towards the slat portion 220 .
A protruding height of the connector 120 relative to the plate 110 is adjustable. Referring to FIG. 3 again, the connector 120 is at a first height position when the first bottom surface 142 of the first supporting portion 140 is in contact with the slat portion 220 . Similarly, the positioning pin 130 is also at a lowered height position when the second bottom surface 162 is in contact with the slat portion 220 .
Referring also to FIG. 4 , when the handle 280 is drawn along a first direction 222 , the first lifting portion 240 follows the motion of the slat portion 220 . The third inclined surface 244 conforms to the first inclined surface 144 so that the first lifting portion 240 can smoothly slide the first supporting portion 140 upwards. The connector 120 rises along with the first supporting portion 140 . The first springs 170 are compressed to restore energy so that restoring forces can be kept. A motion of the positioning pin 130 is similar to that of the connector 120 . The second spring 180 is also compressed.
Referring also to FIG. 5 , the handle 280 is further drawn along the first direction 222 , the first bottom surface 142 is supported by the third top surface 242 , the connector 120 is at a second height position. Similarly, the second bottom surface 162 is supported by the fourth top surface 262 and thus the positioning pin 130 also arrives at a greater height position.
The handle 280 is pushed along a second direction 444 which is opposite to the first direction 222 when the connector 120 needs to be adjusted from the second height position to the first height position. The positioning pin 130 can also be simultaneously adjusted from the greater height position to a lower height position.
Referring also to FIG. 6 , an assembly of a portable computer 30 and a docking station 40 is illustrated. The portable computer 30 includes a bottom plate 320 , a connector 322 fixed on the bottom plate 320 . A positioning hole 324 is defined in the bottom plate 320 . The docking station 40 includes the previously described electronic connecting device 10 and a housing 42 for accommodating the electronic connecting device 10 . The portable computer 30 and the docking station 40 may be electronically interconnected via an engagement of the connector 322 and the connector 120 of the electronic connecting device 10 . The positioning pin 130 is inserted in the positioning hole 324 for guiding the engagement of the connector 322 and the connector 120 . The protruding height of the connector 120 relative to the plate 110 can be adjusted in order to conform to a certain height of the connector 322 of the portable computer 30 . Therefore, a high compatibility between the docking station 40 and different type portable computers can be achieved.
Referring also to FIG. 7 , an electronic connecting device 50 in accordance with a second exemplary embodiment is illustrated. The electronic connecting device 50 includes a plate 510 , a connector 520 , a positioning pin 530 , two supporting portions 540 and 560 , three springs 570 , 580 , and a controller 600 . Two protrusions 542 are secured on the supporting portion 540 . Two protrusions 562 are secured on the supporting portion 560 . The controller 600 includes a slat portion 620 , two lifting portions 640 and 660 fixed on the slat portion 620 , and a handle 680 connected to a distal end of the slat portion 620 . The lifting portion 640 includes a pair of side portions arranged at two opposite sides of the supporting portion 540 . A pair of stepped slots 642 are defined in each sidewall (not labeled) for the corresponding protrusion 542 to ride thereon. The lifting portion 660 also includes a pair of side portions arranged at two opposite sides of the supporting portion 560 . A pair of approximately stepped slots 662 are defined in each sidewall (not labeled) for the corresponding protrusion 562 to slid therein. When the handle 680 is pulled outward or pushed inward, the protrusions 542 and 562 are movable along the slots 642 , 662 respectively. Accordingly, the connector 520 and the positioning pin 530 can be moved up and down to achieve different protruding heights.
The embodiments described herein are merely illustrative of the principles of the present invention. Other arrangements and advantages may be devised by those skilled in the art without departing from the spirit and scope of the present invention. Accordingly, the present invention should be deemed not to be limited to the above detailed description, but rather by the spirit and scope of the claims that follow, and their equivalents.
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An electronic connecting device includes a plate defining an opening therein, a connector for being movable along the opening, a controller for shifting the connector to different height positions.
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RELATED APPLICATIONS
[0001] This Application is a Continuation Application of the Co-pending application Ser. No. 09/588,686 entitled “DENTITION CLEANING DEVICE AND SYSTEM”, filed Jun. 5, 2000, which is a Continuation-in-part of application Ser. No. 09/330,704 entitled “SQUEEGEE CLEANING DEVICE AND SYSTEM” filed Jun. 11, 1999 and now U.S. Pat. No. 6,319,332. The application Ser. No. 09/588,686, entitled “DENTITION CLEANING DEVICE AND SYSTEM”, filed Jun. 5, 2000 and the application Ser. No. 09/330,704 entitled “SQUEEGEE CLEANING DEVICE AND SYSTEM” filed Jun. 11, 1999, now U.S. Pat. No. 6,319,332, are both hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to dentition cleaning devices and dentition cleaning systems. More specifically the invention relates to dentition cleaning devices and dentition cleaning systems that clean teeth, gums and dentures through contact.
BACKGROUND
[0003] The toothbrush is the most common instrument for cleaning teeth, gums, and other areas of the mouth. A toothbrush, unfortunately, is an inefficient device for removing plaque and stains from the enamel surfaces of teeth and is poorly suited for cleaning the surfaces of gum tissue. The inefficiency arises because plaque, while relatively soft, strongly adheres to enamel surfaces of the teeth. Because, plaque strongly adheres to enamel surfaces of teeth, brushing convection does not readily remove plaque. In order to remove all the plaque from the enamel surfaces of the teeth, bristles must contact each point on the surfaces of the teeth. Even where bristles contact the enamel surfaces of the teeth during a cleaning operation, the toothbrush generally fails to remove stains.
[0004] A further disadvantage of toothbrushing is the tendency of the toothbrush to cause gum abrasion, or toothbrush abrasion. The main symptom of toothbrush abrasion is gingival recession, or receding gums, often found in people who brush their teeth frequently. As the gums recede, sensitive parts of the teeth are exposed, generally resulting in painful reactions to hot and cold foods. Frequent brushing of the teeth, even with a very soft bristle toothbrush can lead to a condition of gingival recession. Furthermore, gingival recession is a progressive condition: it never improves but only worsens with time. In fact, toothbrushing as the leading cause of gingival recession is the subject of a current national class action lawsuit against toothbrush manufacturers, Trimarco vs. Colgate Palmolive et al., filed in Cook County, Ill. More information about toothbrush abrasion can be found at the Internet address www.toothbrushlawsuit.com. Although the connection between toothbrushes and receding gums has been documented for over half a century, progress in the field of dentition cleaning devices designed to reduce or eliminate receding gums has been tortuously slow.
[0005] In addition to causing gingival recession, toothbrushes are difficult to keep clean, because the bristles have a tendency to accumulate and trap debris. Further, toothbrushes have the propensity to retain water and remain moist long after brushing thus providing an excellent place for the cultivation of bacteria, germs and the like.
[0006] There have been several attempts to improve oral hygiene by providing cleaning devices that help remove plaque from the tongue, the gums and the palate. For example, Vezjak describes an oral hygiene brush in U.S. Pat. No. 4,610,043 that comprises a toothbrush and a rigid plaque scraper mounted on the side of the toothbrush head. The plaque scraper is engineered for removing plaque from the tongue, and Vezjak's device requires that a toothbrush still be used for cleaning teeth. Herrera, in U.S. Pat. No. 5,032,082 discloses a device for removing denture adhesive from the palate. The device comprises ahead that has several lines of projections extending from a common surface. The projections are made of a material whose flexibility is temperature dependent, so that submerging the projections in hot water makes them more pliable, and placing them in cold water makes them more rigid. This device is tailored toward removing adhesive from the mouth, and cannot be effectively used for cleaning teeth. Tveras, in U.S. Pat. No. 5,810,856 discloses an oral scraping device having at least one wiping element. Each wiping element is flexible, and has at least one scoop-like side that terminates in a wiping edge in an undercutting fashion. This device is designed for scraping the tongue, and in the preferred embodiment, is mounted on a toothbrush handle on the end opposite the toothbrush head. Thus, using the device of Tveras, teeth must still be cleaned with a toothbrush.
[0007] The effects of gum stimulators were studied recently by M. J. Cronin et al., “Anti-Gingivitis Efficacy of Toothbrushing Compared to Toothbrushing and Gum Stimulation,” Journal of Dental Research 78 (Special Issue), 1999, p. 149. In this study, a group of test subjects used selected toothbrushes and gum stimulators regularly, and were compared to a control group that used the toothbrushes alone. The researchers found that the toothbrushes provided the same benefit in reducing gingival bleeding as the toothbrushes and gum stimulators combined. However, this study did not address the problem of gingival recession, nor did it provide an alternative to toothbrushing for cleaning teeth.
[0008] What is needed is an efficient contact dentition cleaning device and system that provides an alternative to using a toothbrush for cleaning teeth and that is capable of reducing bristle abrasion to the surrounding gum tissue.
SUMMARY OF THE INVENTION
[0009] The invention is a dentition cleaning device and system that provides an alternative to using a bristle-only toothbrush. The dentition cleaning device has at least one squeegee that contacts the surface of the teeth during a cleaning operation. The squeegee may be used in combination with bristles or bristle sections that also contact teeth during cleaning. The bristle sections clean the teeth with brushing convection, much like a conventional tooth brush, while the squeegee wipes the surfaces of the teeth to improve the efficiency of teeth cleaning. Alternatively, the squeegee is configured to confine bristle portions of the device from directly contacting the gum tissue, while a squeegee messages the gums during cleaning of the teeth.
[0010] In alternative embodiments, a continuous squeegee encircles the outer portion of the cleaning head allowing the device to be used in conjunction with low viscosity cleaning solutions or allows the cleaning head to be equipped with a sealed cap that can be removed when the device is ready for use. Sealing the cleaning head with a cap can help to keep the cleaning head sanitary during storage and/or can help enclose an oral cleaning material within the cleaning head making the device particularly useful and convenient to used during traveling, camping and the like.
[0011] Several embodiments of the invention provide for a plurality of squeegee cleaning directions that enhance the efficiency of cleaning dentition. The plurality of cleaning directions is achieved by supplying several elongated squeegees having different orientations or at least one squeegee that curves, as described in detail below.
[0012] Other embodiments of the present invention provide a dentition cleaning device and system that utilize squeegees that extend in several directions and form squeegee channels or compartments. The channels or compartments are preferably capable of holding water or cleaning solutions, allowing the device to wet the surface of dentition during cleaning.
[0013] Yet other embodiments of the invention provide for oral squeegee cleaning in a plurality of wiping planes. Because several wiping planes are provided, the device and system is capable of simultaneously contacting non-planar dentition surfaces or irregular dentition surfaces with edges of the squeegees. Configuring the device with different squeegee heights, different squeegee protruding directions, contoured squeegee edges, or combinations thereof, which provides for the plurality of squeegee wiping planes.
[0014] Still other embodiments of the invention do not utilize bristles or bristle sections. These embodiments utilize only squeegee cleaning elements to provide a dentition cleaning device. Such bristle-free embodiments provide for a dentition cleaning device and system that is highly sanitary because the cleaning head is less likely to trap debris and moisture which can lead to bacterial to growth between uses of or during storage of the device.
[0015] Still other embodiments of the invention, provide for a device and system that stores an oral cleaning substance in a handle portion of the device. The cleaning substance is delivered to the cleaning head of the device through apertures at or near the cleaning head. The handle is preferably equipped with a pumping mechanism to deliver the oral cleaning substance to the cleaning head. Alternatively the cleaning substance is delivered to the cleaning head by squeezing a compressible handle.
[0016] Other embodiments of the invention provide oral cleaning heads that are attachable to electric or motorized handles. The electric handles provide back and forth or rotational agitation during cleaning of dentition.
[0017] Still other embodiments of the invention utilize cleaning heads with a squeegee element that has bristles that are attached to the squeegee element. The squeegee element helps to guide the bristles into sections of dentition that require detailed or special cleaning. These embodiments are especially useful for persons that wear corrective braces or other corrective devices on their teeth.
[0018] The dentition cleaning device and system of the current invention has many useful applications besides cleaning of dentition. Bristle-free embodiments of the invention are useful as general tissue massagers to message any soft or delicate tissue where a bristle device is undesirable. For example, the device is useful to messages sore gums of teething babies or adults after oral surgery. Embodiments of the invention are useful as applicators to apply plaque removers, sealants, glues, medications and other substances to dentition.
[0019] In the most preferred embodiments of the current invention the dentition cleaning system and device is a manual hand-held system and device with an elongated handle attached to the dentition cleaning head. The handle and the cleaning head are configured to be detachable so the different dentition cleaning heads may be used with a single handle. The dentition cleaning head is preferably similar in size to a conventional toothbrush cleaning head for easy and comfortable insertion into a human oral cavity. It is, however, understood that there may be reasons to miniaturize or enlarge the system and device for a particular application at hand.
BRIEF DESCRIPTION OF THE FIGURES
[0020] [0020]FIG. 1 a shows a cleaning device configured with bristle sections and linear elongated squeegees.
[0021] [0021]FIG. 1 b illustrates a dentition cleaning device with bristle sections and linear elongated squeegees in accordance with current invention.
[0022] [0022]FIG. 2 a illustrates a perspective view of an elongated squeegee member.
[0023] [0023]FIG. 2 b illustrates a perspective view of an elongated curved squeegee member.
[0024] [0024]FIG. 2 c compares the primary squeegee directions provided by the linear squeegee member of FIG. 2 a and the curved squeegee member of FIG. 2 b.
[0025] [0025]FIGS. 3 a - o show a top perspective views of several squeegee configurations in accordance with the current invention.
[0026] [0026]FIGS. 4 a - d show several top perspective views of squeegee configurations that have directionally dependent squeegee cleaning action.
[0027] [0027]FIGS. 5 a - d show several squeegee configurations with bristle sections incorporated.
[0028] [0028]FIGS. 6 a - d show cross-sectional view of squeegees with continuous squeegees walls protruding from a single squeegee member.
[0029] [0029]FIGS. 7 a - f show several squeegee segments with contoured cleaning edges used in the dentition cleaning system and device of the current invention.
[0030] [0030]FIGS. 8 a - f show several squeegee segments with contoured or modified squeegee walls used in the dentition cleaning system and device of the current invention.
[0031] [0031]FIGS. 9 a - b illustrate a perspective view and a top perspective view of a continuous squeegee member with contoured squeegee walls and a contoured squeegee cleaning edge.
[0032] [0032]FIG. 10 illustrates a motorized rechargeable dentition cleaning device in accordance with the current invention.
[0033] [0033]FIGS. 11 a - d show perspective views of a dentition cleaning head according to a preferred embodiment of the current invention.
[0034] [0034]FIG. 12 illustrates a perspective view of a manual hand held dentition cleaning device according to a preferred embodiment of the present invention.
[0035] [0035]FIGS. 13 a - b illustrate a dentition cleaning system with a hand held dentition cleaning device and a low viscosity dentition cleaning solution that is deliverable through a container equipped with a pump.
[0036] [0036]FIGS. 14 a - b illustrate a dentition cleaning device with a removable seal according to an embodiment of the current invention.
[0037] [0037]FIGS. 15 a - b illustrate the cleaning head portion of a cleaning device with a cavity and apertures for delivering cleaning solution to the cleaning head.
[0038] [0038]FIGS. 16 a - b illustrate cross-sectional views of squeegee configurations that provide for primary squeegee cleaning in a plurality of non-coincident wiping planes.
[0039] [0039]FIG. 17 illustrates a perspective view of a soft tissue massager according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0040] Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following preferred embodiment of the invention is set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.
[0041] [0041]FIG. 1 a shows a cleaning head 50 configured with rows bristle sections 12 , 14 , 16 and 18 protruding from a surface 19 of a support member 10 . Protruding in a similar direction to the rows of bristle section, are squeegee segments 13 , 15 and 17 . The bristle sections 12 , 14 , 16 and 18 and the squeegee segments 13 , 15 and 17 are preferably capable of contacting a surface (not shown) simultaneously during a cleaning operation.
[0042] [0042]FIG. 1 b illustrates a dentition cleaning device 100 according to one embodiment of the current invention. The dentition cleaning device 100 employs a cleaning head configuration with a design that is similar to that shown in FIG. 1 a. The bristle sections 50 , 52 , 54 and 56 protrude from a surface or support 59 in a bristle protruding direction. The bristles are preferably made of synthetic or natural bristle materials well known in the art, such as plastics or natural course hair. The dentition cleaning device 100 also has squeegee members 53 , 55 and 57 that protrude from the surface 59 in a squeegee protruding direction that is substantially similar to the bristle protruding direction. Preferably, the bristles and squeegee members are both capable of connecting surfaces of dentition during cleaning operations. FIG. 1 b is set forth herein for illustrative purposes and a number of different bristle section configurations and squeegee configurations are considered to be within the scope of the current invention.
[0043] Again referring to FIG. 1 b, in one embodiment of the current invention an outer continuous squeegee member (not shown) encircles the bristle sections 50 , 52 , 54 and 56 and/or the linear squeegee members 53 , 55 and 57 to help prevent the bristles sections 50 52 , 54 and 56 from contacting the surfaces of gum tissues during cleaning of the teeth, while the outer continuous squeegee member messages gum tissue. A continuous outer squeegee member also serves the purpose of containing or holding low viscosity cleaning solutions as described in later embodiments. Alternatively, squeegee segments (not shown) protrude from or near the edges of the surface 59 , for the purpose of protecting the gums from contact with the bristle and for messaging the gums while cleaning the teeth.
[0044] Still referring to FIG. 1 b, in a particular embodiment of the invention the surface 59 of a support section 60 is made from a soft malleable material to which the bristle sections and the squeegee section are attached. The support section 60 is then attached to the toothbrush body 51 by any means known in the art. The support section 60 provides a suspension for the bristle sections 50 , 52 , 54 and 56 and for the squeegees 53 , 55 and 57 such that the bristle sections and squeegees are capable of being partially displaced from their resting positions when pressure is applied to the cleaning tips of the bristles or cleaning edges of the squeegees. The support section 60 thus provides a mechanism for the bristle sections and the squeegees to conform to irregular surfaces of dentition during cleaning.
[0045] Again referring to FIG. 1 b , the dentition cleaning device 100 , as shown, has a handle 49 integrated with a body 51 . While the dentition cleaning device 100 is shown as a monolithic unit, it will be clear to one of average skill in the art that the handle 49 and body 51 may be configured to be detachable so that several dentition cleaning heads can be used with a single handle 49 . Further, the body head 51 maybe configured to be detachably fastened to a motorized handle (not shown) for providing agitation to dentition similar to an electric toothbrush. It should also be noted that the support member 60 may be detachably fastened to the body head 51 such that the support member 60 and its attached cleaning elements (i.e. bristles and squeegees) are replaceable.
[0046] [0046]FIG. 2 a shows a perspective view of a squeegee structure 99 with a squeegee member 98 that protrudes from a support member 102 in a protruding direction 108 . The squeegee member 98 has a protruding edge, or cleaning edge, 101 that contacts a surface during a cleaning operation. The squeegee member 98 is elongated in an elongation direction 107 with two elongated squeegee walls 103 / 104 . At any point on the surface of the squeegee walls 103 / 104 , the squeegee member 98 has a squeegee wall thickness 105 . The primary squeegee direction 109 is defined, herein, as any co-linear direction that is normal to the elongation direction 107 at each point along elongation direction 107 . Strictly speaking, for any elongated squeegee there will be at least two wiping directions, corresponding to a back and forth cleaning motion along the line of primary squeegee direction 109 . For the sake of simplicity and for this description, squeegee action along any straight line of motion is referred to as a single direction. Thus, the linear elongated squeegee 98 provides for one primary squeegee direction, regardless of a protruding angle 97 or curvature of the squeegee wall in the protruding direction 108 . Further, for clarity and descriptive purpose, elongated squeegees and squeegee supports are usually described as separated elements herein. However, it is clear that squeegees and squeegee supports may be monolithic and made of the same or different materials. Further, the shapes of supports are not limited to circles or squares as generally described herein; squeegee supports may take any shape or form that is reasonable for the application at hand.
[0047] The current invention utilizes elongated squeegees in the numerous configurations described below to provide an effective dentition cleaning device. The elongated squeegees are preferably made from a soft flexible, pliable or malleable material such as rubber, latex, urethane, silicone and the like. The flexibility, pliability or malleability of the squeegees are preferably in the range between 10 to 50 Shore A durometers as measured with durometer gauges well known in the art. The dimensions of the squeegees can vary in the numerous ways described below but preferably protrude from a support surface by an average distance of 0.1 to 3.0 cm in the squeegee protruding direction 108 . Further, while the squeegee wall thickness 105 can vary at any point between the squeegee walls 103 and 104 , the squeegee wall thicknesses are preferably within the range of 0.1 to 5.0 mm.
[0048] [0048]FIG. 2 b illustrates a squeegee structure 110 with a curved squeegee member 121 that is curved in the elongation directions 127 . Curved squeegee members, such as 121 are particularly useful in the current invention. Geometric considerations will reveal that each point on the curved squeegee wall 122 / 123 corresponds to a primary squeegee direction in the direction that is normal to a tangent line of the squeegee curvature. For example points 131 , 133 and 135 have tangent lines of curvature 151 , 153 and 155 , respectively, and corresponding primary squeegee directions 141 , 143 and 145 .
[0049] [0049]FIG. 2 c compares the primary squeegee directions provided by the linear squeegee member of FIG. 2 a and the curved squeegee member of FIG. 2 b. It can be seen from FIG. 2 c, that the curved squeegee member 121 can be moved in a set of directions 165 normal to the protruding direction 128 to contact a single point 163 in a primary squeegee direction. However, the linear squeegee 98 can only be moved in one direction 160 normal to the elongation direction 128 to contact a point 161 in a primary squeegee direction.
[0050] For descriptive purposes squeegees are classified as the following: squeegee segments have at least two terminus ends; continuous squeegees have no ends; and squeegee networks have squeegee walls that are shared by one or more adjacent squeegee enclosures or compartments. Squeegees can also have a single terminus end, wherein the squeegee forms and squeegee enclosure or compartment, but does not connect end-to-end.
[0051] [0051]FIGS. 3 a - o illustrate top perspective views of several alternative squeegee configurations that provide for a plurality of primary squeegee directions. FIG. 3 a shows a squeegee configuration 200 with two elongated squeegee members 199 / 201 that protrude from a support member 21 . Because the squeegee members 199 / 201 are positioned in an angled fashion, the squeegee configuration 200 provides for two primary squeegee directions that are substantially normal to the two corresponding elongation directions of the squeegee members 199 and 201 . FIG. 3 b shows a squeegee configurations 202 with a plurality of linear squeegee segment members 203 / 205 positioned at alternating angles and protruding from several positions of a support member 23 . FIG. 3 c illustrates a squeegee configuration 204 with a curved elongated squeegee member 207 that protrudes from a support member 25 . The curved or cupped squeegee configuration 204 provides for primary squeegee directions all directions of a plane substantially containing the squeegee member 207 elongation directions. However, the squeegee configuration 204 does not provide for equal squeegee actions in all directions, because the squeegee member 207 will squeegee a surface twice each time the squeegee member 207 is moved with a sideways cleaning motion, but will squeegee a surface once for each up or down cleaning motion. Thus, the squeegee configuration 204 provides for a plurality of directionally dependent primary squeegee directions. FIG. 3 d illustrates a squeegee configuration 206 with several cupped squeegee members 209 / 211 that protrude from a support member 27 with the squeegee members 209 and 211 cupped in opposite directions. FIG. 3 e shows a squeegee configuration 208 with a continuous circular squeegee member 213 protruding from a support member 22 . The continuous circular squeegee member 213 forms an inner squeegee region 232 and an outer squeegee region 234 . Like the cupped squeegee configuration 204 , the squeegee configuration 208 provides for primary squeegee directions in all directions of a plane substantially parallel to the elongation directions of the circular squeegee member 213 . However, the circular squeegee configuration provides for a plurality of directionally independent primary squeegee directions. FIG. 3 f illustrates a squeegee configuration 210 with several continuous circular squeegee members 215 , 217 and 219 protruding from a support member 24 that form a concentric set of squeegees with continuous circular channels 236 and 236 ′. The set of concentric continuous circular squeegee members provide for a plurality of primary squeegee directions in all directions of a plane substantially normal to the squeegee elongation directions. FIG. 3 g shows a squeegee configuration 212 with a spiraling squeegee member 221 protruding from a squeegee support member 26 . The spiraling squeegee member 221 forms a spiraling squeegee channel 238 and provides for a plurality of primary squeegee directions in all directions of a plane substantially normal to the squeegee elongation directions. FIG. 3 h shows a squeegee configuration 214 with a plurality of spiraling squeegee members, such as 223 and 225 protruding from a squeegee support member 28 to provide a plurality of primary squeegee directions in all directions of a plane substantially normal to the squeegee elongation directions. FIG. 3 i also shows a squeegee configuration 216 with a spiraling squeegee member 227 protruding from a squeegee support member 32 . The squeegee member 227 spirals in a substantially rectangular fashion and forms a rectangular-like squeegee channel 240 . The squeegee configuration 216 provides for directionally dependent squeegee action, wherein a diagonal cleaning motion will give a different squeegee action than a sideways or up and down cleaning motion. FIG. 3 j and FIG. 3 k illustrate squeegee configurations 218 and 220 that have squeegee segments protruding from squeegee support members 34 and 36 , respectively, where the squeegee segments are positioned at varying angles on the squeegee support members 34 / 36 . FIG. 3 j shows linear squeegee segments 229 and 231 positioned at or near to right angles relative to each other and forming a rectangular segmented squeegee configuration 218 . FIG. 3 k shows squeegee configuration 220 comprising squeegee segments 235 that are positioned within an inner squeegee region of a larger circular squeegee member 233 . FIG. 3 l and FIG. 3 m illustrate yet other squeegee configurations 222 and 224 that have squeegee members protruding from squeegee support members 38 and 42 . In FIG. 3 l the squeegee configuration 222 has cross-type squeegee segments 237 . The squeegee configuration 222 can also have a major squeegee member 239 , wherein the major squeegee member 239 comprises a long squeegee segment 243 intersected short squeegee segments 241 that are positioned at near to right angles relative to the long squeegee segment 243 . The squeegee configuration 224 of FIG. 3 m has a squiggling squeegee member 245 protruding from a squeegee support member 42 to provide several primary squeegee directions. Portions of squiggling squeegee member 245 ′ is configured to enclose inner squeegee regions 247 and 247 ′. Squiggling squeegee 245 ″ is configured to form a set of connected squeegee compartments 246 , 246 ′, 246 ″ and 246 ′″. In FIG. 3 n and FIG. 3 o, squeegees are configured to produce a variety of squeegee compartments. The squeegee configuration 226 illustrates a complex arrangement of squeegees that form scale-shaped squeegee compartments 249 within a circular squeegee 248 and with squeegees flaring out 251 from the circular squeegee 248 to add other cleaning features. The configuration 228 illustrates a continuous network of squeegee walls 255 that protrude from the support 46 and that forms an array of symmetrical squeegee compartments 253 .
[0052] [0052]FIGS. 4 a - d illustrate several squeegee configurations that provide for directionally dependent squeegee action. FIG. 4 a shows a squeegee configuration 300 with several circular squeegee members 303 , 303 ′ and 303 ″ protruding from a circular squeegee support member 301 . Within the inner squeegee region of the circular squeegee members 303 , 303 ′ and 303 ″ are linear squeegee segments 305 , 305 ′ and 305 ″, respectively. The linear squeegee segments 305 , 305 ′ and 305 ″ only provide for primary squeegee actions when the squeegee configuration 300 is moved on a surface with an upward or a downward cleaning motion, as indicated by the arrow W 1 . The linear squeegee segments 305 , 305 ′ and 305 ″ do not, however, provide primary squeegee actions when the squeegee configuration 300 is moved on the surface with a sideways cleaning motion, as indicated by the arrow W 2 . FIG. 4 b illustrates an alternative squeegee configuration 302 that provides for directionally dependent primary squeegee action. Linear squeegee segments 306 are positioned in the squeegee channel 308 of a spiraling rectangular squeegee member 309 . The squeegee segments 306 and the spiraling squeegee 309 protrude from a squeegee support member 307 . In this example, the linear segments 306 provide for primary squeegee actions when the squeegee configuration 302 is moved on a surface with a sideways cleaning motion, as indicated by the arrow W 2 , but do provide for primary squeegee action when the squeegee configuration 302 is moved on the surface with an upward or a downward cleaning motion, as indicated by the arrow W 1 . FIG. 4 c shows a squeegee configuration 304 with two non-concentrically positioned circular squeegee members 315 and 317 protruding from a circular squeegee support member 313 . In the squeegee configuration 304 , it is the non-uniform channel spacing 314 between the squeegee members 315 and 317 that provides for directionally dependent primary squeegee actions, wherein the number of squeegees edges that contact a surface by moving the squeegee configuration 304 in with a sideways cleaning motion, as indicated by the arrow W 2 , is different that the number of squeegee edges that contact the surface by moving the squeegee configuration 304 in a sideways cleaning motion, as indicated by the arrow W 2 . FIG. 4 d shows a different squeegee configuration 306 that provides for directionally dependent squeegee action. The squeegee configuration 306 comprises two rectangular squeegee members 320 and 322 . The longer squeegee walls 321 and 323 of the rectangular squeegees, 320 and 322 , are thinner than the shorter squeegee walls, 319 and 325 . In this way the primary squeegee action is made to be different by virtue of alternating squeegee wall thicknesses or physical properties of the squeegees 320 and 322 . In this embodiment, the thicker squeegees 319 and 325 exhibit primary squeegee action by moving the squeegee configuration 306 in an upward or downward cleaning motion, as indicated by the arrow W 1 , but do not provide for primary cleaning action when the squeegee configuration 306 is moved in with a sideways cleaning motion, as indicated by the arrow W 2 . It will be clear to one skilled in the art that there are many alternative squeegee configurations that can provide for directionally dependent squeegee actions. These variations can be achieved by varying squeegee geometries, squeegee configurations, squeegee thickness, squeegee materials and combinations thereof.
[0053] [0053]FIGS. 5 a - d show top views of several dentition cleaning heads configured with squeegee sections and bristles. FIG. 5 a shows a substantially rectangular cleaning head portion 400 with a spiraling rectangular squeegee 403 protruding from a rectangular support member 401 . In the rectangular-like squeegee channel 404 there are several brush sections such as 405 , 405 ′ and 405 ″ protruding from the surface 402 . FIG. 5 b illustrates an oval cleaning head configuration 410 with circular squeegee members 409 , 409 ′ and 409 ″ protruding from the surface 414 of a circular support member 413 . Within the inner squeegee region of the circular squeegee members 409 , 409 ′ and 409 ″ there are bristles sections 411 , 411 ′ and 411 ″. FIG. 5 c shows an elongated cleaning head configuration 415 comprising squeegee segments such as 416 and 417 protruding from a rectangular support member 418 and forming a segmented rectangular squeegee configuration. Within the segmented rectangular squeegee configuration, there is a substantially rectangular brush section 419 protruding from the support member 415 . FIG. 5 d illustrates a cleaning head configuration 420 with a spiraling squeegee member 423 protruding from a circular support member 421 and forming a spiral channel 422 .
[0054] There are several medium ports 425 , 425 ′ and 425 ″ positioned within the spiraling channel 422 . The medium ports 425 , 425 ′ and 425 ″ provide a means for directing a medium to dentition surfaces during cleaning or alternately for drawing a vacuum near a surface of dentition. The cleaning configuration 420 further includes a brush section 427 attached substantially central to the support member 421 . The configuration 420 is particularly useful where a cleaning medium such water is required or where vacuum convection is needed to remove cleaning solutions, saliva and the like. The cleaning configuration 420 can also be configured to attached to a rotary device to provide a rotary cleaning action to the surfaces of dentition during a cleaning operation. It is clear that any of the cleaning head configurations described herein are adaptable to have ports or apertures through which oral cleaning solutions can be delivered or through which a vacuum can be drawn to facilitate cleaning of dentition.
[0055] [0055]FIG. 6 a - d show cross-sectional views of several dentition cleaning head configurations with a squeegee member having continuous elongated squeegees. FIG. 6 a shows a cross-sectional view of a dentition cleaning head 602 with a squeegee member 622 attached to a support 62 . The squeegee member has four substantially circular protruding squeegee edges 619 , 621 , 623 and 625 . Positioned substantially in the center of the squeegee member 622 , is a brush section 620 . FIG. 6 b shows cross-sectional view of a dentition cleaning head 604 with a squeegee member 632 attached to a support 64 . The squeegee member 632 has four substantially circular protruding squeegee edges 631 , 633 , 635 and 637 . The protruding squeegee edges protrude in an alternating fashion with the cleaning edges of squeegees 633 and 637 protruding farther than the cleaning edges of squeegee 631 and 635 . Positioned substantially in the center of the squeegee member 632 is a brush section 630 . FIG. 6 c shows cross-sectional view of a dentition cleaning head 606 with a squeegee member 642 attached to a support 66 . The squeegee member 642 has four continuous protruding squeegees 641 , 643 , 645 and 647 . The cleaning edges of the squeegees 641 , 643 , 645 and 647 protrude in a cascade fashion with the edge of squeegee 641 protruding farthest and the edge of squeegee 647 protruding the least. Positioned substantially in the center of the squeegee member 642 is a brush section 640 .
[0056] [0056]FIG. 6 d shows a cross-sectional view of a dentition cleaning head 608 with a squeegee member 652 attached to a support 68 . The squeegee member 652 has three continuous protruding squeegee edges 651 , 653 , and 655 . The edges of the squeegees edges 651 , 653 , and 655 are spatially displaced such that the distance between the squeegees 651 and 653 is greater than the distance between the squeegees 653 and 655 . The dentition cleaning head configuration 608 has two brush section 650 and 660 . The brush section 650 is positioned substantially in the center squeegee member 652 while the brush section 660 is a continuous brush section that positioned in the squeegee channel defined by protruding squeegees 651 and 653 .
[0057] All of the dentition cleaning heads detailed and described, herein can be configured to have bristles or bristle sections integrated into the cleaning head, attached to the squeegee members themselves or attached to another portion of the cleaning device. For some applications of the invention the combination of a squeegee or squeegees and bristles is preferred. In one embodiment of the invention a squeegee section encircle bristle sections or portions thereof to reduce potential contact of the bristles with soft gum tissue while messaging the gums during cleaning of the teeth.
[0058] [0058]FIGS. 7 a - f illustrate squeegee segments with contoured squeegee cleaning edges that are useful in the dentition cleaning device and system of the current invention. FIG. 7 a shows a squeegee segment 75 with a planar protruding edge 76 . FIG. 7 b illustrates a squeegee segment 77 with a V-shaped cleaning edge 78 ; FIG. 7 c illustrates a squeegee segment 79 with a curved, convex contoured cleaning edge 80 ; FIG. 7 d shows a squeegee segment 81 with a concave contoured squeegee edge 82 ; FIG. 7 e shows a squeegee segment 83 with a diagonally contoured cleaning edge 84 ; and FIG. 7 f shows a squeegee segment 85 with a pointed cleaning edge 86 .
[0059] [0059]FIGS. 8 a - f illustrate several squeegee segments with contoured squeegee walls. FIG. 8 a illustrates a squeegee segment 170 with a planar protruding edge 171 and a concave squeegee wall 172 ; FIG. 8 b illustrates a squeegee segment 173 with a planar pointed protruding edge 174 and tapered squeegee walls 175 / 184 ; FIG. 8 c illustrates a squeegee segment 177 with a planar protruding edge 178 and concave V-shaped squeegee walls 179 / 180 ; FIG. 8 d illustrates a squeegee segment 181 with a jagged protruding edge 182 and a grooved squeegee wall 183 grooved in the squeegee protruding direction; FIG. 8 e illustrates a squeegee segment 184 with a planar cleaning edge 185 and walls 186 / 187 , with smaller squeegees 188 , 188 ′ and 188 ″ attached to the wall 187 ; and FIG. 8 f shows a squeegee segment 189 with a planar cleaning edge 190 and planar squeegee walls 192 / 193 with bristles 194 , 194 ′ and 194 ″ attached to and protruding from the squeegee wall 193 .
[0060] [0060]FIGS. 9 a - b show a continuous squeegee with a contoured squeegee cleaning edge and contoured squeegee walls. FIG. 9 a shows a perspective view of a substantially circular squeegee member 261 with a contoured protruding squeegee edge 262 and a contoured squeegee wall 263 / 264 . The squeegee cleaning edged 262 and the squeegee walls 263 / 264 are contoured in a corrugated wave-like fashion. FIG. 9 b shows a top view of the squeegee member 261 illustrating the corrugated wave-like contouring of the squeegee member walls 263 / 264 .
[0061] [0061]FIG. 10 illustrates an electric dentition cleaning device 270 that utilizes a dentition squeegee cleaning head 271 according with a preferred embodiment of the invention. The dentition cleaning head 271 several continuous squeegee members positioned in a substantially concentric fashion wherein smaller squeegee members are positioned within the next larger squeegee element as shown. The dentition cleaning head 271 is attached to a body 272 . The body 272 is attached to a motorized handle 273 that provides agitation to the cleaning head 271 through the body 272 . The motorized handle 273 is preferably capable of being turned on and off through the switch 275 and is powered by an internal battery (not shown) that is rechargeable through the contacts 276 and 276 ′ with a properly configured battery charger (also not shown).
[0062] [0062]FIGS. 11 a - d illustrate several views of a dentition cleaning head configured according to a preferred embodiment of the current invention. FIG. 11 a shows a top view of a dentition cleaning head 350 . The dentition cleaning head has a base portion 353 , a continuous outer squeegee member 351 , two curved squeegee segments 355 / 355 ′, and two oval squeegee members 357 / 359 with the smaller squeegee member 359 positioned concentrically within the inner squeegee region of the larger squeegee member 357 . FIG. 11 b illustrates a side view 370 of the squeegee cleaning head 350 . The outer squeegee member 351 preferably extends farther from the base 353 than the inner squeegee members 355 , 355 ′, 357 , and 359 and has a squeegee cleaning edge 356 that is contoured as shown. The contoured squeegee cleaning edge 356 facilitates the ability of the squeegee 351 to penetrate grooves of teeth and spaces between teeth. Further, its is believed that a contoured squeegee cleaning edge 356 will facilitate the ability of the squeegee 351 to penetrates spaces between the gum line and teeth during a cleaning operation. The cleaning head 350 may also have a cavity 363 to increase the flexibility of the dentition cleaning head 350 . FIG. 11 c illustrates a cross sectional view 380 of the cleaning head 350 shown in FIG. 11 a. All of the squeegee members 351 , 355 , 355 ′, 357 and 359 preferably have tapering wall thicknesses, being thicker near the surface 373 and thinner near the cleaning edges. The length of the dentition cleaning head 368 is preferably in a range of 1.0 to 4.0 cm. The outer squeegees squeegee member 351 preferably does not protrude a distance 362 father than 1.5 cm from the bottom of the base support 353 or a distance 364 more than 1.0 cm from the inner surface 373 . The tops of the squeegee cleaning edges are preferably less than 0.5 mm in thickness and most preferably less than 0.2 mm. The average separation 360 between adjacent squeegee members is preferably in the range of 1.0 cm to 0.05 cm and most preferably between 0.3 and 0.1 cm. However, the preferred separation 360 will vary depending on the cleaning solution used. The average separation 360 is preferably chosen such that water or a liquid oral cleaner is retained in the squeegee channels of the dentition cleaning head 350 even when the dentition cleaning head 350 is inverted, but such that cleaning solutions and debris are easily rinsed away under running water. FIG. 11 d shows an end view 390 of the dentition cleaning head 350 . The width of the dentition cleaning head 366 is preferably in the range of 0.5 cm to 2.0 cm. Side squeegee edge 358 of the squeegee member 351 is also preferably contoured as shown. FIGS. 11 a - d are set forth as an example of the preferred embodiment. It is clear that the dimensions of the dentition cleaning head 350 can altered in many ways depending on the application at hand. For example, larger devices are useful for providing oral care for other animals including horses and dogs, while smaller devices are useful for cleaning the gums and teeth of infants or small children.
[0063] [0063]FIG. 12 illustrates a perspective view of a hand-held manual dentition cleaning device 450 configured with a cleaning head 451 similar to that described in FIGS. 11 a - d. The dentition cleaning head 451 is preferably formed from soft flexible non-toxic material such as rubber, latex, silicon or polyurethane. The dentition cleaning head 451 is attached to a handle 453 by any suitable method known in the art, but is preferably co-molded to the handle during manufacturing of the device 450 . Holes may be provided in the preformed plastic handle 453 prior to co-molding the dentition cleaning head 450 to the handle 453 to ensure that dentition cleaning head 451 remains secured to the handle 453 . A second smaller dentition cleaning head may also be attached to the opposite side of the handle or the device may be equipped with a bristle section on the opposite end of the handle 453 or on the other side of the handle (not shown) to provide a multi-functional dentition cleaning device.
[0064] [0064]FIGS. 13 a - b illustrate a cleaning system according to the present invention. FIG. 13 a shows a perspective view 500 of the dentition cleaning device 450 described in FIG. 12 being prepared for a cleaning operation. Oral cleaning solution 501 is dispensed by a conventional pump device onto the cleaning head 451 with the cleaning head 451 in an upright position as shown. FIG. 13 b shows a perspective view 510 of the oral cleaning device 450 having the oral cleaning solution 501 held within the squeegee cavity of the cleaning head 451 . Because the cleaning head 451 provides a containing structure, the device 450 can be used with low viscosity oral cleaning solutions. Low viscosity oral cleaning solution have several advantages over conventional tooth pastes including being easier to clean from a sink and/or counter surfaces. Further, because low viscosity oral cleaning solutions can be dispensed from a conventional pump device, as shown, the solution can be sold in bulk and the container can be refilled, thus providing potential economic and environmental benefits. While the preferred system of the invention utilizes a low viscosity oral cleaning solutions, the dentition cleaning device 450 can be used with conventional tooth pastes known in the art.
[0065] [0065]FIGS. 14 a - b illustrate a dentition cleaning device that is similar to the device 450 shown in FIG. 12 which is further equipped with a removable cover 521 . FIG. 14 a shows a dentition cleaning device 520 with a cleaning head 523 that is configured with continuous outer squeegee. The inner portion of the cleaning head is sealed with a removable cover 521 . Preferably, the inner portion of the cleaning head 523 is sealed with the cover 521 by a sticky adhesive that sticks to the edge 524 of the outer squeegee to hold the cover 521 in place. The cover 521 has a tab 522 that can be grabbed to remove the cover 521 from the cleaning head 523 . The adhesive preferentially remains attached to the cover 521 when it is removed from the edge 524 of the outer squeegee. In FIG. 14 b, the cover 521 is partially removed form the head 523 by pulling the tab 522 as shown. The cover 521 keeps the interior portion 526 of the head 523 sanitary during storage or while transporting the device 520 . Prior to sealing the cover 521 on the head 523 , cleaning substances, including liquids or powders, can be placed in the interior portion 526 of the head 523 and stored there until the device 520 is ready for use. This embodiment is particular useful for as travel dentition care kit. The device 520 can be made to be disposable after a single used or made to be reusable. Further, the cover 521 may be made to be resealed on the head 523 after use or the device 520 may be equipped with a more elaborate cover.
[0066] [0066]FIGS. 15 a - b illustrate an embodiment of the current invention that is particularly useful in clinical environments. FIG. 15 a shows a perspective view of a device 800 that has applications for cleaning wounds and incisions before, during or after medical procedures. The device 800 has a cleaning head 803 with several continuous squeegee members 805 , 807 , 809 , 811 and 813 . The squeegee members 805 , 807 , 809 , 811 and 813 are preferably positioned concentricity with the smaller squeegees positioned inside of the wall of the next largest squeegee member. The cleaning device 800 is attachable by the end 801 of its neck 806 to a solution delivery system or a vacuum suction system (not shown). FIG. 15 b illustrates a cross sectional view 810 of the device 800 . Solution or vacuum is delivered to the cleaning head 803 through the channel 804 and the reservoir 802 . Solution or vacuum is then delivered between the squeegee members 811 and 183 through the apertures 817 , 819 and 821 . A health care profession or user contacts the squeegee portion of the device against the wounds or incision and applies a cleaning solution or a vacuum depending on the intended outcome of the procedure. The cleaning device 800 shown in FIGS. 15 a - b is also useful as a dentition cleaning device or for oral procedures where solution and vacuum must be applied to dentition.
[0067] Embodiments illustrated in the preceding Figures have shown squeegee walls that protrude in direction substantially parallel with respect to each other. Such devices provided a plurality of primary squeegee cleaning actions in a plurality of wiping directions contained in a single wiping plane or in a plurality of co-linear wiping planes. However, it will be clear from the following description that these embodiments previously described can also include squeegee walls that protrude at nonzero angles relative to each other in order to provide for primary squeegee cleaning action in a plurality of non-coincident wiping planes. Further, it will be clear for the following description that oral cleaning devices and other cleaning devices can be configured with squeegee elements that provide for a plurality of squeegees cleaning actions in a plurality of wiping directions within a plurality of non-coincident wiping planes.
[0068] [0068]FIG. 16 a illustrates a cross-sectional view of a squeegee configuration 925 with squeegee walls 929 , 931 , 933 and 935 that protrude from a squeegee support member 927 . The squeegee walls 929 and 935 protrude in a squeegee protruding direction that is at an angle θ 1 from the squeegee support member 927 and provide for primary squeegee directions in the non-coincident squeegee wiping planes indicated by the arrows 930 and 928 , respectively. The angle θ 1 , can be any angle between 180 and 90 degrees. The squeegees walls 931 and 933 protrude from the squeegee support 927 in a squeegee protruding direction that is at an angle θ 2 relative to the squeegee support 927 to provide for a primary squeegee direction in the wiping plane indicated by the arrow 926 . Angle θ 2 can also be any angle between 90 and 180 degrees that is different from angle θ 1 such as to provide primary squeegee directions in a plurality of non-coincident wiping planes 930 , 926 and 928 .
[0069] [0069]FIG. 16 b illustrates a cross-sectional view of an alternative squeegee configuration 950 . The squeegee configuration 950 has squeegee walls 954 , 956 , 958 and 960 that protrude in squeegee protruding directions at the angles θ 1 , θ 2 , θ 3 and θ 2 relative to a contoured squeegee support member 952 . The squeegee configuration provides primary squeegee direction in the wiping planes indicated by the arrows 953 , 955 , 957 and 959 , respectively. The squeegee walls described in FIGS. 16 a - b can belong to individual squeegee segments, continuous squeegees, squeegee networks, squeegee elements with a single terminus end or any combination thereof.
[0070] Squeegee configurations with squeegee walls that protrude in non-parallel squeegee protruding directions are utilized in cleaning devices that provide for primary squeegee directions in a plurality of non-coincident wiping planes. Extending, the principles illustrated in FIGS. 16 a - b, squeegee configurations that have a plurality of squeegee walls that protrude in each of a plurality of squeegee protruding directions provide for a plurality of primary squeegee directions in each of the plurality of non-coincident wiping planes.
[0071] [0071]FIG. 17 illustrates a perspective view of a general tissue massager 900 in accordance with the current invention. The tissue massager 900 has a network squeegee cleaning edge surfaces 903 and depressed inner squeegee regions 901 . The continuous squeegee walls 906 protrude from a mushroom shaped squeegee support 905 . Continuous squeegee walls 906 extend from the recessed inner squeegee regions 901 to form the network squeegee edge surfaces 903 . Portions of the network squeegee edge surface 903 between any adjacent depressed inner squeegee regions, indicated by the arrows 902 and 904 , provide for squeegee edges that contact and squeegee surfaces during use. The squeegee configuration 900 is one of a number of squeegee configurations that provided for a plurality primary squeegee directions in a plurality of non-coincident planes. Other embodiments are round or have any other three dimensional shapes suitable for the application at hand. Further, three dimensional devices with squeegee segments, continuous squeegee elements, squeegee elements with a single terminus end and combinations thereof, are used within devices to provide for a plurality primary squeegee directions in a plurality of non-coincident wiping planes. A handle (not shown) can be attached to the massager 900 to enhance the functionality or use of the device 900 . In a particular embodiment of the invention the device 900 is made from a hard rubber material and is a chewing toy and tooth cleaning device for pets such as dogs. Alternatively, the device 900 is made of soft rubber, silicone of latex and is a gum massager/chewing toy for teething babies.
[0072] It will be clear to one skilled in the art that the above embodiment may be altered in many ways without departing from the scope of the invention. For example the dentition cleaning heads can be made to be any variety of color that make the particularly attractive for children. Accordingly, the scope of the invention should be determined by the following claims and their legal equivalents.
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A dentition cleaning device and system is disclosed for cleaning teeth, gums and dentures. The dentition cleaning device utilizes squeegees that protrude from a cleaning head to provide efficient contact of dentition surfaces during cleaning. The dentition cleaning device is particularly useful for cleaning teeth because the squeegee contact surfaces and remove residues, such as plaque, without causing significant abrasion to surrounding gum tissue which can lead to gum recession. The dentition cleaning device can be configured with bristle sections or with squeegees that are configured to retain water in squeegee channels. The dentition cleaning device is adaptable to water assisted tooth cleaning system and motorized electric teeth cleaning systems. The dentition cleaning device is also particularly useful to be used in conjunction with a low viscosity tooth cleaner that is capable of being delivered through a conventional pump dispenser.
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This application claims the benefit of co-pending U. S. Provisional Application No. 60/013,789 filed Mar. 21, 1996.
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for producing mattress borders.
BACKGROUND OF THE INVENTION
Automated machines been used for decades to measure and cut mattress borders to length. Cord handle grommets and backbars have been automatically installed in advance of a measuring drive on many machines. Other machines have finished border edges by using drive rollers to pull border material through sergers. Fabric handles; have been made manually from separate material stock and attached to borders.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the present invention is to provide an automated means and method of attaching handles to a border, the handles being made from the same border material used to make the border itself.
According to the invention, a method of manufacturing mattress borders comprises advancing a strip of border material severing first relatively short lengths of the border material for forming handles, and second relatively longer lengths of the border material for forming mattress borders, folding and hemming the relatively short lengths to form tubular handles, temporarily storing the formed handles out of the path of advance of the strip of border material, aligning formed handles so that their tubular axes extend laterally across the longer lengths of material at desired handle positions, and serging ends of the handles to edges of the longer lengths of material to form mattress borders with handles.
The invention also extends to apparatus for forming mattress borders, comprising means for advancing a strip of mattress border material through metered lengths, means for severing the advanced and metered material into first relatively shorter and second relatively longer lengths, means for folding and hemming the first lengths of border material to form tubular handles and means to store the tubular handles out of a path of advance of the strip to form said second lengths, means to align tubular handles to extend transversely across the strip at predetermined intervals in the formation of said second lengths, means to advance the aligned handles with the strip, and sergers aligned with each edge of the strip and located downstream of said alignment means to secure ends of the aligned tubular handles to longitudinal edges of the strip.
Further features of the invention will be apparent from the following description of a presently preferred embodiment thereof.
SHORT DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic embodiment of the mechanical elements of the present invention.
FIG. 2A and 2B are plan and edge views of a portion of a mattress border made by the method of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows schematically an embodiment of apparatus in accordance with the invention. In order to simplify the drawing and facilitate explanation, actuators and supporting structure associated with certain components are shown schematically by arrows indicating that an actuator or actuators is or are provided for supporting and moving the component along or about the axis indicated by the associated arrow or arrows, as identified further below.
A border material and cutting station Comprises a pair of drive rollers 1, nipping a strip B of border material level cross its width. A drive 1A feeds and meters border material through the roll nip, which is followed by a guillotine 2 for cutting off a length of border material, the guillotine having an actuator schematically illustrated by the arrow 2A.
A handle making station comprises a tongue 3, a paddle 4, a needle rake 5, a traction belt 6, a serger 7, chopsticks 8 and a tucker 9.
The tongue 3 is a thin flat length of metal in front of the guillotine 2, parallel to the drive rollers 1, and just below the border material path, extending to beside the needle 7A of the serger. The width of the tongue is less than the width of a handle.
The paddle 4 is a thin flat piece of metal parallel to the tongue 3, extending across and above the border material path. The paddle is rotationally mounted and has an actuator 4A to pivot it about an axis parallel to the tongue 3 to a position where the top (previously the bottom) of the paddle is at a level below the tongue and part of the paddle is visible on the guillotine 2 side of the tongue when looking from above.
A first needle rake 5 supports a row of pins across and above the border material path, the pins pointing down towards that part of paddle 4 which, when rotated, is visible from above. A first actuator 5A supports and moves the rake in a vertical direction so that it may be lowered to a position where the pins just clear the top of the rotated paddle. An actuator 5B supports and moves the rake in a horizontal direction parallel to the tongue 3 so that it may be moved to a position clear of the border material path when viewed from above.
The traction belt 6 is a belt about the length of rake 5, supported on pulleys at each end of which pulley 6A is a driving pulley, and extends outside of the path of the strip and parallel to the rake 5 on a line between the rake and the guillotine 2, at a level above the path of the border material. The traction belt has an actuator 6B to move it in a vertical direction and may be lowered to a position where the bottom of the traction belt just clears the level of the top of the paddle 4 when the latter is rotated, such that it draws material off the paddle.
The serger 7 is a commercial sewing machine for sewing together an/or finishing fabric edges. The serger is located so that the material path through the serger is parallel to the traction belt 6, and at a level such that a cloth plate 7B of the serger is the same level as the top of the paddle when rotated. The serger cloth plate is extended forward of the serger to the end of the paddle, when rotated, and passes under the traction belt. The serger presser foot 7C faces the end of the traction belt, the serger needle 7A being located approximately in the center of the presser foot.
The chopsticks 8 are a pair of steel rods of diameter similar to the thickness of the tongue 3, with a length equal to the width of the border material. Their normal position is in line with the tongue as shown. Each chopstick is individually movably mounted by an actuator mechanism 8C for movement in a horizontal direction parallel to the axis of motion of the border material. The lead chopstick 8A furthest from the serger needle 7A may be moved away from the serger to a store position, over a distance twice that between the guillotine 2 and the furthest edge of the tongue in the direction of border material flow. The chopstick 8B closer to the serger needle may be moved so that at a store position there is a space between the chopsticks less than the distance between the guillotine and the furthest edge of the tongue in the direction of border material flow.
The tucker 9 is a rectangular rubber block, parallel to the chopsticks 8, of chopstick length and of a width less than half the chopstick separation at the store location. It is located slightly above the chopsticks at the store location with its edge furthest from he serger 7 over the lead chopstick 8A at its store location. The tucker is mounted for movement in a vertical direction by an actuator 9A and may be raised to a level high enough to disengage from material supported by the chopsticks.
A storage and retrieval station comprises a needle rake 10, elevator 11 and platform 12. The needle rake 10 has a row of pins, pointing down and connected to each other at their top ends by a backbar of length equal to the width of border material. Rake 10 is located just clear of and parallel to the tucker 9 on its side facing serger 7, at a level where the bottom of the pins is clearly above the level of the border material. Rake 10 is movably mounted by actuator 10A for movement in a vertical direction and may be lowered to a position where the pins engage material supported on the chopsticks 8μ. At Rake 10 is also movably mounted by an actuator 10B for movement in a horizontal direction, parallel to the tongue 3, and may be moved to a location between the chopsticks 8 when at the store location, to a location adjacent the elevator 11, or a location adjacent the platform 12.
The elevator 11 has a series of identical shelves 11A with springs 11B, stacked on top of another facing the chopsticks 8 at their store position. The shelf length is equal to the horizontal separation between the ends of the chopsticks adjacent the store and the nearer edge of the border material path P through the apparatus. The shelf width is about the distance between the guillotine 2 and the furthest edge of the tongue 3 in the direction of border material flow. The shelf separation is greater than the total vertical travel of rake 2. Several leaf springs 11B are located just above each shelf. The leaf springs may be compressed upwards by the double thickness of the border material and are angled to permit material movement off the chopsticks and towards the border material path. The leaf springs viewed from above, are parallel to and just clear of the rake 10 on side of the tucker 9. The stack of shelves and springs forming the elevator mounted, for movement as a unit in the vertical direction, by an actuator 11C. The top of each shelf may be brought by the actuator to a level just below that of the chopsticks, or level with the platform 12.
The platform 12 is a plate of the same width as a shelf 11A, with a length equal to the border material width. It is located just above the border material path adjacent the elevator 11.
A handle attachment station comprises a feed roll 13, and left and right sergers 14. The feed roll 13 is a rubberized roller of about the same diameter as the width of the tucker 9. Viewed from above, it extends parallel to and just clear of rake 10 on the tucker side. It is located above the platform 12 at a level such that the bottom of the roller is at least at a height of the needles of the rake 10 when in a raised position. The roll 10 is supported for vertical movement by an actuator 13A which lowers it towards the platform.
The left and right sergers 14 are located opposite each other on either side of the border material path so as to serge the edges of the border material, at a level such that the serger cloth plates 14A are just beneath the edges of the border material. The serger needles 14B are located a horizontal distance from the nearer edge of the platform 12 that is less than the distance between the guillotine 2 and the furthest edge of the tongue 3 in the direction of border material flow.
In operation of the apparatus, handles H (See FIGS. 2A and 2B) are made first from a length of border material B and attached to a mattress border formed from the same material. The handles are formed and attached as follows.
The rollers 1 feed a first relatively short metered length of border material through the guillotine 2 and over the tongue 3. The paddle 4 folds the material around the tongue. The pins of rake 5 are pressed through both material layers by actuator 5A. The actuator 2A causes the guillotine to cut off the piece. Actuator 5B causes rake 5 to move the folded piece laterally under the traction belt 6 which is lowered by actuator 6B to hold the piece. Rake 5 is lifted and withdrawn and returned for the next piece by actuators 5A and 5B.
The traction belt 6 is advanced to feed the folded piece into a serger 7. The serger sews the adjacent edges of the piece together to make a tubular handle which it feeds onto the pair of chopsticks 8. Actuator 8C causes the chopsticks to move the tubular handle forward, parallel to the path of movement of the strip of border material. The leading chopstick 8A passes below the tucker 9 that engages the material of the tubular handle forcing it to roll around the chopsticks to bring the hem underneath.
The pins of rake 10 are inserted in the handle by the actuator 10A and the tucker 9 raised by actuator 9A. The actuator 10B causes the rake 10 to move the handle into the elevator 11 onto a shelf 11A where it is held by springs 11B. The rake 10 is withdrawn. The elevator shelves are indexed by actuator 11C after rake 10 returns or the next handle.
As many handles are made as are required for a finished mattress border, before the border itself is formed. If the capacity of the elevator is sufficient, handles for several borders may be made before forming several borders to which to attach them.
Borders are made as follows. When the handle piece for the last of a series of handles is at the traction belt 6, the rollers 1 feed a second, relatively greater length of border material through the guillotine 2 and over the tongue 3 to the left and right sergers 14. The sergers draw the border material through and sew its edges.
Handles stored in the elevator 11 are retrieved for attachment to the mattress border as follows. A shelf 11A with a handle is moved to the level of the platform 12 above the border material path. The pins of rake 10 are reinserted in the handle by actuator 10A and actuator 10B causes the rake to move the handle to the platform. Roll 13 is lowered by actuator 13A to hold the handle, and the rake pins are withdrawn. The elevator 11 is indexed and the rake 10 returns for the next handle.
The roll 13 feeds the first handle off the platform 12 onto the moving border and into the sergers, and is then raised. The left and right sergers 14 sew the ends of the tubular handle H to the border with the hems S hidden beneath the handles. Subsequent handles are sewn in the border at intervals to provide a border as shown in FIGS. 2A and 2B. The feed rollers and sergers are stopped when a sufficient length of material has been fed to form the border and the guillotine 2 cuts the border to length. Serging is restarted and the trailing end of the border finished.
The mattress border apparatus may be used to make mattress borders of various lengths and widths with differing numbers of handles. The apparatus may also be used to make borders without handles or to make handles alone. Provision may be made to give extra support and guidance to very flexible border material. In order to strengthen the handle, a reinforcing core of cord or webbing may be folded into the tubular handles H.
Although a preferred technique for handle attachment has been described, variations are possible. Thus handles may be rotated for attachment to line up with the direction of border material flow, and attached to the border by a sewing machine, gluing, welding, clipping or other means. Finished border material may be used for the input border material strip.
While presently preferred instrumentalities have been described for performing each of the functions comprised by the method and apparatus of the invention, each of these instrumentalities may be substituted by alternative instrumentalities capable of performing an equivalent function, and all such substitutions are to be considered within the scope of the appended claims.
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Mattress borders are manufactured by advancing and severing a strip of border maerial into first relatively short lengths of the border material for forming handles, and second relatively longer lengths of the border material for forming mattress borders, folding and hemming the relatively short lengths to form tubular handles, temporarily storing the formed handles out of the path of advance of the strip of border material, aligning formed handles so that their tubular axes extend laterally across the longer lengths of material at desired handle positions, and serging ends of the handles to edges of the longer lengths of material to form mattress borders with handles. The invention also extends to apparatus for performing this method. The disclosed method and apparatus enable mattress borders complete with handles to be formed from a single strip of material
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FIELD OF THE INVENTION
This invention pertains to plugs for well conduits, and more particularly to plugs employed in access ports of wellheads of subterranean wells.
BACKGROUND OF THE INVENTION
The wellhead and tree are frequently the top most components of subterranean wells. The wellhead can be used to provide several connections and access ports. A typical connection will be to a pipe conduit for transport of produced fluids away from the well. A top entrance port is also generally provided for allowing access into the well from above. The access port will be used for entering the well during completion and production phases of the well, but must be reliably closed when not in use. The wellhead plug provides such a closure when locked in sealing engagement within the access portion of the wellhead. The length of the segment of the wellhead in which the plug is lodged is partially dependent upon the length of the plug itself. The wellhead plugs described herein will typically be used in 37 horizontal" and SPOOLTREE wellheads.
The materials used in the construction of a wellhead are of high-quality and therefore expensive. The high cost is warranted because the wellhead provides a barrier between potentially polluting fluids carried within the well and the environment. The expensive nature of the constituent materials of the wellhead and the fact that a segment of the wellhead is dependent upon the length of the plug precipitates a common goal in wellhead plug design which is minimizing the length of the plug to reduce construction costs of the wellheads. This is particularly true when more than one plug is used within a wellhead for sealing redundancy; in that case, the savings will multiply.
Referring to FIG. 3, a known wellhead plug is illustrated. While it has been desirable to have such wellhead plugs as short as possible, typical embodiments of the illustrated version still have lengths exceeding twelve inches. The shortest known example of the illustrated wellhead plug exceeds eleven inches, regardless of the number and type of sealing means utilized. The difficulty to further decrease the length of the plug is due to construction features embodied therein.
A lengthening feature of the wellhead of FIG. 3 is the arrangement in longitudinal series of several of the wellhead plug's construction characteristics. As an example, the housing/cap thread connection is longitudinally positioned between the seal and anchor means so that the entire length of the thread connection contributes directly to the overall length of the plug assembly. A further detriment of the illustrated configuration stems from the fact that the length of the thread connection increases as the diameter of the plug increases. The increase in thread length is required to provide sufficient structural soundness to the assembly. Greater forces are applied to larger plugs because of the increased area upon which pressures act. If the thread connection is not lengthened, there is a risk that the structural integrity of the plug assembly will falter; that is, the mating threads may strip out and the connection separate. An additional disadvantage of directly increasing the overall length of the plug with elongations of the thread connection is that plugs for different diameter wellheads will have different lengths and lack desired uniformity which increases design time and costs.
In the illustrated configuration of FIG. 3, the length of the plug assembly increases by an amount equal to the distance over which relative motion is required between the expander sleeve and retainer housing. Like the thread connection, this results because the motion limiting connection is in series with the anchor and seal means.
Operational drawbacks may also be encountered in plugs made according to the example of FIG. 3 wherein the expander sleeve is retained within the plug body by a retaining lip positioned at the upper end of a top extension of the key retainer housing. The lip creates a restraining cavity that may become fouled by solid debris that inhibits relative motion between the expander sleeve and the plug body.
In summary, it has been appreciated for some time that a primary goal of wellhead plug design is to shorten the overall length of the plug; in view of known designs, the lower limit has previously exceeded eleven inches.
SUMMARY OF THE INVENTION
Under present circumstances, there can be great return for reducing the length of a wellhead plug to as short as eight inches. As discussed above, this is a goal that previously known designs have not been able to meet. The plug assembly disclosed hereinafter is capable of achieving shortened lengths of about eight inches in several diameter sizes.
A goal of this improved design is to reduce the overall length (L T ) of the wellhead plug assembly to as close as possible to the combined length of the anchor means (L A ) and the length of the sealing means (L S ). This comes from the fact that both the sealing means and anchoring means must be located in series and about the exterior surface of the wellhead plug. This configuration is shown in FIG. 2. For this reason, the seal means and the anchor means have been collectively designated a length extending means because each is located in longitudinal series with the other and must be positioned at the exterior of the plug body for engagement with the wellbore. Therefore, to shorten the plug's length it is necessary to reduce the distances between the keys and seals and to reduce or eliminate structural extensions on either end of the plug beyond those indispensable components. To achieve this, the motion limiting connection between the plug body and the expander sleeve and the housing/cap thread connection have been located out of longitudinal series and into a tandem orientation with the anchor and/or seal means. By tandem it is meant that two or more components are longitudinally coincident, and may be radially offset. In several instances of the present invention, tandem components will be at least partially radially above and below one another. As a result, the combined lengths of the sealing means and anchor means compose a majority of the overall length of the plug assembly. That is, fifty percent or more of the overall longitudinal length of the wellhead plug is attributable to the collective exterior lengths of the sealing and anchoring means. Referring to FIG. 2, this relationship may be seen as:
0.5×L.sub.T <L.sub.A +L.sub.S
Because the housing/cap thread connection is now carried in tandem with the anchor and/or seal means, the connection may be extended for different diameter plugs without effecting the overall length of the plug. This means that plugs having similar longitudinal lengths may be provided for different diameter wellhead bores.
To further shorten the wellhead plug, the expander lock assemblies are shown as being placed between the keys, and substantially tandem thereto. For purposes of this invention, the lock assembly may be completely interiorly positioned to the keys, in the longitudinal direction, so that there is no required extension of the plug to accommodate the lock assembly.
The combined affects of the several shortening features produce appreciably shorter length wellhead plugs than those previously known. Additionally, consistent lengths between different sizes of the wellhead plugs are achievable; that is to say, plugs suitable for closing bores having different internal diameters will have similar lengths. Obviously, this gives great benefit in the larger wellheads where length reduction permits maximum savings.
An additional benefit of eliminating the top end extension and the sliding recess for the expander sleeve is the deletion of the debris receptacle. It has also been contemplated that a sand barrier may be created through the use of o-rings positioned about the interior and exterior diameters of the retainer housing. These o-rings create seals that prevent the introduction of damaging solids into the working mechanisms at the top end of the plug assembly.
Benefits also run from the fact that the instant devices are run into, and retrieved from the wellhead on wireline. This is a more cost effective method of setting and retrieving wellhead plugs than the presently used rod or tubing methods.
Regarding the dual wellhead plug assembly of FIGS. 4 and 5, the primary benefits are the ability to provide redundant sealing capabilities and to longitudinally fix the dual plug assembly within the wellhead bore without any play whatsoever. The absence of play is desired to assist the functionality of the sealing means. In some applications, there may be play between the plug and the landing nipple. This play will allow the plug to move very slightly with respect to the nipple. There are some metal-to-metal (MTM) seals that may be ill-affected by this play, therefore it is desired to prevent the relative motion.
In one preferred embodiment, a wellhead plug assembly is provided that includes a wellhead plug body with a seal means positioned upon an exterior surface of the plug body for sealing engagement with an interior surface of a wellhead bore. There is also an anchor means positioned at the exterior surface of the plug body and adjacent to the seal means which is used for locking the plug body into engagement with the wellhead bore. In this configuration, the seal means and the anchor means are arranged in longitudinal series and therefore their combined longitudinal lengths provide a majority of the wellhead plug's length. These plug assemblies will have lengths less than eleven inches and be appropriate for use in well bores having minimum interior diameters greater than one and one-half inches.
In another embodiment, the wellhead plug assembly includes a plug body having a cap plug that is threadedly connected to a key retainer housing by a housing/cap thread connection. At the exterior of the plug is a seal means for sealing engagement with an interior surface of the wellhead bore and an anchor means positioned adjacent thereto for locking engagement with the wellhead bore. The seal means and anchor means are arranged in longitudinal series. The anchor means has exterior contoured profiles constructed for face-to-face mating engagement with contoured nipples of the wellhead bore. When assembled the housing/cap thread connection is tandemly and radially interiorly positioned to the seal means. An expander sleeve is positioned within the plug body for actuating the anchor means into locking engagement with the wellhead and is connected to the plug body by a motion limiting connection. The motion limiting connection is radially and interiorly positioned to the seal means and the profiles of the anchor means. Also in this configuration, the seal means and the anchor means are arranged in longitudinal series and therefore their combined longitudinal lengths provide a majority of the wellhead plug assembly's longitudinal length. These plug assemblies will have lengths less than eleven inches and be appropriate for use in well bores having minimum interior diameters greater than one and one-half inches.
In yet another embodiment, a wellhead plug assembly including a wellhead plug body having a cap plug threadedly connected to key retainer housing by a housing/cap thread connection is found. The seal means and anchor means are longitudinally arranged and are positioned upon an exterior surface of said plug body for sealing and locking engagement with the wellbore. The anchor means includes lockable keys that are restrained within a key retainer housing and are actuatable by an expander sleeve. The expander sleeve is connected to the wellhead body by a motion limiting connection having a cross pin fixed to the wellhead body and extending into a slot in the expander sleeve for restricted relative motion therein. The seal means and anchor means together make up a length extending means of the plug since each is in longitudinal series, one to the other, and located at the exterior surface of the plug body. The pin of the motion limiting connection and the housing/cap thread connection are each at least partially carried in tandem to the length extending means. Like the others, these plug assemblies will have lengths less than eleven inches and be appropriate for use in well bores having minimum interior diameters greater than one and one-half inches. Still further, there is an expander lock assembly positioned at least partially in tandem with the anchor means so that a majority of the longitudinal length of the lock assembly is longitudinally coincident with the longitudinal length of the anchor means. In this embodiment the seal means includes a non-elastomeric packing stack. It may also, or alternatively, include a MTM seal. The exterior surface of the plug body upon which the seal means are positioned is located on said cap plug. These portions are also referred to as the seal seats.
Regarding the dual plug configuration, there is a bottom wellhead plug and a top wellhead plug positioned in end-to-end abutment. Each wellhead plug has anchor means and may have a seal means positioned at the exterior surface of the plug body. Each anchor means has exterior contoured profiles for face-to-face engagement with contoured nipples in the wellhead bore. The top wellhead plug has an expansion means for radially expanding the anchor means of that plug which results in the application of a compression force between the abutting top and bottom plugs so that downwardly facing profile surfaces of the bottom plug's anchor means abuttingly engage upwardly facing surfaces of a lower contoured nipple while upwardly facing profile surfaces of the top plug's anchor means abuttingly engage downwardly facing surfaces of an upper contoured nipple. This action longitudinally fixes the dual wellhead plug assembly within the wellhead bore and prevents transverse movement of the seal means with respect to the wellhead bore during use. In this embodiment, the expander sleeve has a wedge shaped exterior surface that serves as a ramp beneath the keys of the anchor means for radially actuating those keys. The keys have an inclined interior surface for face-to-face engagement with said wedge shaped expander sleeve. The expander sleeve acts as a locking wedge and is urged toward a locked position by a spring.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross-sectional drawing of a preferred embodiment of the wellhead plug assembly with the bottom half of the figure taken at a 135 degree radial departure from the top half and showing seal seats for one packing stack and two MTM seals.
FIG. 2 is a longitudinal cross-sectional drawing of an alternative embodiment of the wellhead plug assembly with the bottom half of the figure taken at a 135 degree radial departure from the top half and showing a seal seat for one packing stack and with the packing nut being an integral part of the cap plug.
FIG. 3 is a longitudinal partial cross-sectional drawing of a known wellhead plug showing the motion limiting connection and the housing/cap thread connection, among others, in series with the anchor and seal means.
FIG. 4 is a longitudinal cross-sectional drawing of a dual wellhead plug assembly with the bottom half of the figure showing an unset top plug in the wellbore and with the top half showing the top plug set and forcibly pressing against the bottom wellhead plug.
FIG. 5 is two partial longitudinal cross-sectional drawings of a dual wellhead plug assembly showing a pressure actuated piston that initiates elongation of the top plug causing it to forcibly press against the bottom wellhead plug to induce a compression force within the dual assembly.
FIG. 6 is cross-sectional view of the key retainer housing showing the lines upon which the half sections of FIGS. 1 and 2 are taken.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a preferred embodiment of a wellhead plug assembly 10 is shown. It should be appreciated that many components of the wellhead plug assembly 10 are cylindrical in shape and concentrically oriented. As a result, many share a common longitudinal center line. In many cases throughout the following description, components will be referred to as having longitudinal lengths, as being oriented for relative longitudinal motion, or otherwise be comparatively described as being longitudinally related. In each instance, it should be understood that longitudinal references relate generally to lines parallel to the longitudinal center line of the plug assembly 10.
In typical applications and uses of the wellhead plug assembly 10, the plug 10 will be lowered into a wellhead bore 02 on wire line and when positioned at the appropriate location, locked into contoured nipples 04 for sealing engagement with the bore 02. Each nipple 04 has multiple angled surfaces. Among those surfaces are upwardly facing surfaces 06 and downwardly facing surfaces 08. During use of the plug 10, portions of the plug 10 will abut either the upwardly facing surfaces 06 or the downwardly facing surfaces 08, depending upon the direction of pressure being restrained by the plug 10.
The wellhead plug assembly 10 comprises a wellhead plug body 12 having two primary components; a cap plug 20 and a key retainer housing 46. An exterior surface 14 surrounds the plug body 12. The exterior body surface 14 carries seal means 22 for sealing engagement with the wellhead bore 02. It is contemplated that the seal means 22 may be made up of any appropriate seal which will prevent fluid flow between the wellhead plug assembly 10 and the wellhead bore 02. In the illustrated embodiments of the present invention, the seal means 22 comprises combinations of packing stacks 24 and/or MTM seals 34. The MTM seals 34 may serve as redundant seal means 22 to the packing stack 24 and may be oriented to seal against pressure in one direction. Alternatively, several seal means 22 may be oriented opposingly so that pressure is sealed against in different (both) directions. In actual practice, the well operator will most often be interested in containing pressure from below.
The exterior surface of the plug body may be configured in any way that accommodates the desired seal arrangements. It may be desired that other types of seal means 22 be employed; all that must be included on the plug body is a proper seating receptacle for that seal. This provides versatility. Seal seats 23 upon the exterior surface 14 of the wellhead plug body 12 serve as receivers for the packing stacks 24 and MTM seals 34. The seal seats 23 appear as recesses upon the plug body 12 and restrain the seal means 22 therein.
A conventional packing stack 24 will include in series a metal female adapter ring 26 that is in abutting engagement at a top end with a retainer ring 36 that also supports the bottom of the MTM seal 34. The retainer ring 36 is removably connected to plug body 12 by retainer ring/body thread connection 92. Adjacent to the adapter ring 26 will be a backup ring 28, which is constructed from RYTON in the preferred embodiment. Adjacent to the backup ring 28 is one or more non-elastomeric v-packing rings 30 which are preferably constructed from TEFLON. Adjacent to packing rings 30 is elastomeric o-ring 32 which serves as the center component of the packing stack 24. Below the o-ring 32, a lower half of the packing stack 24 is symmetrical to the upper half; that is, there will next be a series of the packing rings 30, a backup ring 28, and then the metal female adaptor ring 26. The v-shaped packing rings 30 are c-shaped on one side and oppose pressures being applied upon that c-shaped side. Typically, there will be two or more v-packing rings 30 installed together; those in the top half of the stack 24 will be oppositely oriented to the rings 30 of the bottom half. This way, pressures in both directions are contained by the packing stack 24.
A packing nut 16 is threadedly connected to a bottom end of the cap plug 20 at a packing nut/body thread connection 94. The packing nut 16 secures the packing stack 24 upon plug body 12. In the preferred embodiment, the packing nut 16 is threadedly connected to the body 12 to facilitate installation of the packing stack 24. The cylindrical or ring shaped components of the packing stack 24 will be slid upon the recessed seal seat 23 of the exterior surface 14. It is contemplated, however, that the packing nut 16 could be an integral part of the cap plug 20, as illustrated in FIG. 2, provided means for installing the packing stack 24 upon the plug 10 is provided.
A hexagonal nut head 18 is positioned at the lower most end of the plug body 12 to facilitate assembly and disassembly of the wellhead plug 10. Because many of the connections between the several components of wellhead plug 10 are threaded connections, many relative turns must be completed to assemble and disassemble the plug 10. Furthermore, after the plug is retrieved from a well, the several threaded connections may be tight. By inclusion of the nut head 18, a wrench maybe easily connected to the wellhead plug for rotating the threaded components relative one to the other.
In the preferred embodiment of FIG. 1, the MTM seal 34 is positioned above the packing stack 24. As previously described, the retainer ring 36 abuts a top end of the packing stack 24 and a lower end of the MTM seal 34. Above the retainer ring 36, the MTM seal 34 comprises a bottom MTM c-shaped seal ring 38, a top MTM c-shaped seal ring 42, spacing lip 40 between the bottom and top seal rings 38 and 42, and a spacer ring 44 at a top end of the MTM seal 34. The spacing lip 40 projects from and about the cap plug 20 thereby producing recessed seats 23 for the MTM seal rings 38 and 42. The spacer ring 44 is merely a ring that is positioned between the top seal ring 42 and a lower shoulder of the key retainer housing 46. The purpose of the spacer ring 44 is to longitudinally fix the top seal ring 42 upon the cap plug 20. Referring to the preferred embodiment of FIG. 1, there need only be a minimum length spacer ring 44 between the keys 64 and seal means 22 to prevent interference therebetween. In the accompanying drawings, however, a distance between the plug body and the keys is shown as a middle portion of the key retainer housing. This has been included for machinability, but is not required for the functionality of the plug.
The key retainer housing 46 and the cap plug 20 are connected by housing/cap thread connection 90. As shown, the thread connection 90 is radially interior to the exterior surface 14 of the plug body 12 and substantially beneath the seating areas of the seal seats 23; in other words, partially in tandem therewith.
Anchor means 62 is located near a top end of the wellhead plug assembly. The anchor means 62 is used to lock the plug assembly 10 at a desired location within the wellhead bore 02. In this manner, the plug 10 may be longitudinally fixed with respect to the bore. Keys 64 are retained within an upper portion of the key retainer housing 46. In the preferred embodiment, there is a set of four keys 64, each having a key retainer tab 66 and exterior contoured profiles 68. The contoured profiles 68 are constructed for lockable mating engagement with the contoured nipples 04 of the wellbore 02. Each contoured profile comprises downwardly facing surfaces 70 and upwardly facing surfaces 72. The contoured profiles 68 of the keys 64 are designed to engage the contoured nipples 04 in such a manner upon expansion that the plug 10 is not lifted up off of a no-go shoulder 09 upon which the plug comes to rest at no-go shoulder 61 of the plug 10.
The keys 64 project through key windows 47 that extend through the key retainer housing 46. A key retainer tab recess 48 maybe found at a lower end of the window 47 which receives key retainer tab 66 therein. The purpose of the tab 66 in recess 48 configuration is retention of the keys 64 within the retainer housing 46. Also found at the exterior surface 14 of the key retainer housing 46 is leaf spring recess 50 which provides an indentation into which leaf spring 84 of an expander lock assembly 82 is sunk.
The expander lock assembly 82 comprises the leaf spring 84 which has a lower end fixed to the retainer housing 46 by a securing screw 85 that is anchored in securing screw bore 57. An end of the leaf spring 84 opposite the securing screw 85 is connected to an outer end of lock pin 86. The pin 86 extends through lock pin bore 52 of the retainer housing 46 and is biased radially inward by the spring 84. The expander sleeve 74 has a lock pin recess 88 into which an interior end of the lock pin 86 is received.
The expander sleeve 74 is disposed within the interior of the wellhead body 12 so that an exterior surface of the expander sleeve 74 contacts interior surfaces of the keys 64. The expander sleeve 74 is connected to the plug body 10 by a motion limiting connection 76. The motion limiting connection includes a cross pin 78 that extends within cross pin bore 54 through retainer housing 76 and is stationarily connected thereto. An interior distal end of the cross pin 78 extends into an expander slot 80 of the sleeve 74. The slot 80 has a longitudinal length greater than the diameter of the cross pin 78 and thereby provides means for limited relative longitudinal movement between the expander sleeve 74 and the retainer housing 46.
A hollow within the wellhead plug assembly 10 provides a running tool core hollow 96. The core 96 provides a receptacle for a running tool that is used to run the plug assembly 10 into the wellhead bore 02, set the plug assembly I 0, and eventually retrieve the plug assembly 10, if required. A lower end of the running tool will project into the tool core hollow 96 and be connected therein by a shearable running tool connection pin. The connection pin 98 projects through a running tool pin bore 56 through the key retainer housing 46 and into a receiving bore on the running tool.
Interior sand barrier recess and exterior sand barrier recess are located at the upper end of the key retainer housing 46 for receiving o-rings which seal against debris which may enter into the working mechanisms of the plug assembly 10. Sand barrier comprises an exterior o-ring barrier that creates a seal between the exterior surface 14 of the wellhead plug body 12 and the wellhead bore 02. Interior o-ring barrier is positioned between the retainer housing 46 and the expander sleeve 74. In each case, the o-ring barriers 102 and 104 allow relative motion between the adjacent components while maintaining a seal against debris that may foul the operation of the wellhead plug assembly 10.
A dual wellhead plug assembly 106 is shown in FIG. 4. In the embodiment depicted therein, a bottom wellhead plug 108 is anchored to a lower contoured nipple 04 below a top wellhead plug 110 which is set in an upper countered nipple 104 above the bottom plug 108. The bottom plug 108 is typical of the wellhead plug assemblies 10 described hereinabove. The top wellhead plug 110, however, differs from the bottom plug 108 in that the expander sleeve 78b is wedge shaped for ramped sliding engagement with an interior inclined surface of the key 64. The expander sleeve 78b and inclined keys 64 are components of an expansion means 112 that drives the two plugs 108 and 110 toward each other and into abutting engagement. The two plugs 108 and 110 press one against the other with sufficient force to induce an outward compression force at the two lock points between the key 64 and nipples 04 of both the bottom and top plugs 108 and 110.
The wedge shaped expander sleeve 78b acts as a locking wedge because of its low degree of incline or departure from the longitudinal direction. Once the dual wellhead plug assembly is properly engaged, the sleeve 78b will not retract on its own because the friction force between the sleeve 78b and the inclined interior surface of the key 64 is sufficient to prevent relative movement between the two components. To further assure that the sleeve 78b does not back out from under the keys 64, a biasing string 113 is provided which urges the sleeve 78b downward.
It should be appreciated that the primary purpose of the top wellhead plug 110 is to induce the compression force within the dual wellhead plug assembly 106 thereby preventing relative motion between the assembly 106 and the wellhead bore 02. Seal means 22 may, however, be carried on an exterior surface 12 of the top plug 110 and provide a redundant sealing feature in the system. If that is the case, it should be understood that a hydraulic lock may occur between the bottom plug 108 and the top plug 110 as the top plug 110 is being lowered into position. Should this occur, the trapped hydraulic fluid between the two plugs 108 and 110 will prevent further progression of the descending top plug 110. Therefore, an equalization port maybe provided through the cap plug 20 of the top plug 100 to allow the trapped fluid to vent through the core of the top plug 110. For the top plug 100 to act as a fluid barrier, the equalizing ports must then be plugged. A bar stem may then be run down into the core of the top plug 100 after the running tool is removed that plugs the ports.
Referring to FIG. 5, an alternative embodiment of the dual wellhead plug assembly 106 is shown. Once again, the bottom plug 108 is typical of those described herein. The top plug 110, however, has a transversely acting piston that is pumped by fluid pressure from a locked position to an unlocked position. When unlocked, an expansion spring is allowed to activate a transverse wedge which results in an elongation of the top plug 110. By elongating the top plug 110, a compression force is once again created between the anchor means 62 of the bottom and top plugs 108 and 110.
The procedure for assembling the plug assembly 10 as illustrated in FIG. 1 begins with installing the bottom MTM seal ring 38 into a seal seat 23 below and adjacent to the spacing lip 40. The retainer ring 36 is then threadedly connected to the cap plug 20 at the ring/body thread connection 92. The ring 36 is then advanced upon the threads to secure the bottom MTM seal 38 in place. The packing stack 24 is then installed upon the cap plug 20. The components of the stack 24 are ring and cylindrically shaped and are installed in a seal seat 23 created between a bottom side of the retainer ring 36 and a top edge of the packing nut 16 in the following order: a metal female adapter ring 26, a RYTON backup ring 28, two or more of the TEFLON v-packing rings 30, the o-ring 32, two or more of the TEFLON v-packing rings 30, a RYTON backup ring 28, and a metal female adapter ring 26. Typically, the components above the o-ring 32 will face upward to resist pressures from above and the components below the o-ring 32 will face downward to resist pressure from below the plug 10. The packing nut 16 is then threadedly connected to the lower end of the plug body 12 at the nut/body thread connection 94. The nut 16 is then tightened so that it abuts the bottom of the packing stack 24 at a lower edge of a bottom metal female adapter ring 26 for snug engagement therewith. The top MTM c-shaped seal ring 42 is then installed into another seal seat 23 above the spacing lip 40 and the spacer ring 44 is positioned above that to secure the seal ring 42 in place. The upper portion of the plug assembly 10 must then be assembled. Initially, the keys 64 will be placed in the retainer housing 46 with the contoured profiles 68 extending through the key windows 47 to the exterior of the housing 46. The key retainer tab 66 of each key 64 is located in the retainer tab recess 48 of the window 47. The fishnecked sleeve 74 will then be positioned within the interior of the housing 46 so that the keys 64 are prevented from backing out of the windows 47. The running tool will then be inserted into the running tool core hollow 96 of the plug assembly 10 and shearably pinned to the retainer housing 46 by the running tool connection pin 98. The expander sleeve 74 is then connected to the retainer housing 46 by the motion limiting connection 76 during the attachment of housing 46 to the cap plug 20. Attachment of the housing 46 to the cap plug 20 is accomplished by the housing/cap thread connection 90. During the tightening of the parts at the connection 90, however, each cross-pin 78 is installed through a cross pin bore 54 so that a radially interior distal end of the pin 78 extends into the expander slot 80 of the sleeve 74. The position of the pin 78 is fixed by its enlarged head that abuts a recessed shoulder of the bore 54. In this way, the expander sleeve 74 is connected to the housing 46 for relative motion therewith. The housing/cap thread connection is then fully tightened so that the exterior end of the cross pin 78 is covered by a top end of the cap plug 20 and prevented from withdrawing. Upon ultimate tightening of the connection 90, the spacer ring is pushed down into snug abutment with the top MTM seal ring 42.
The process for installing the plug assembly 10 into a wellbore 02 beings with lowering the plug 10 into the well 02 on a running tool to which the plug 10 is pinned. The wellbore 02 includes a radial restriction known as a no-go shoulder 09. There is an engaging radial no-go 61 shoulder on the plug assembly 10. In the illustrated embodiment of FIG. 1, the no-go shoulder 61 is on the retainer housing 46 and constitutes the assembly's 10 largest exterior diameter. When the no-go shoulder 61 of the plug 10 and bore 02 contact, the downward progress of the plug 10 is stopped. The plug assembly 10 is thereby properly positioned to be locked into place. In this configuration, the contoured profiles 68 of the keys 64 are correctly placed adjacent to the contoured nipples 04 of the wellhead bore 02 for locking engagement therewith. Simultaneously, the seal means 22 have progressed into sealing engagement with a polish bore section of the wellhead bore, just below the no-go shoulder 09. The keys 64 are then radially expanded into nipples 04 by pushing the expander sleeve 74 into the plug assembly 10. This is accomplished by hammering or "jarring" through wireline means upon the top end of the sleeve. In this way, ramps upon interior surfaces of the keys 64 ride up on a ramped exterior surface of the advancing sleeve 74. Complete expansion is achieved when a lower end of the sleeve 74 abuts a shoulder of the retainer housing and is prevented from further advancement. At this fully expanded position, the expander lock assembly 82 actuates and prevents the sleeve 74 from withdrawing from within the retainer housing 46. To remove the running tool and leave the plug 10 in place, tension is place on the wireline to assure that the plug 10 is locked into place. The running tool is then "jarred" so that running tool connection pin 98 shears and releases the running tool from the plug assembly 10.
To release the plug assembly 10 and withdraw it from the wellhead bore 02, another tool is lowered into the interior of the expander sleeve 74 and connected to the fishneck which is contained therein. The sleeve 74 may then be "jarred" up, thereby allowing the keys to retract back into the housing 46 and release from the contoured nipples 04. The plug may then be removed from the well on the wireline.
Regarding the dual plug 106 embodiments shown in FIGS. 4 and 5, the top plug 110 will have to have an ultimate outer diameter that is just greater than the ultimate outer diameter of the bottom plug 108. This is because the no-go shoulder 61 of the bottom plug 108 must pass through the top landing nipple 04 before coming to rest upon bottom no-go shoulder 09 in the bore 02. The top plug 110 must then have a diameter sufficient to land upon the no-go shoulder 09 of the top nipple through which the lower plug has passed without impedance.
The first, or bottom plug 108 is run into the wellhead bore 02 and is seated in a nipple 04 so that lower face(s) of the key(s) will abut upper faces of the contoured landing nipple profiles when engaged. A second, or top plug 110 is run into the wellhead above the bottom plug 108 until a bottom end of the top plug 110 abuts a top end of the bottom plug 108. Because of the dimensions of the plug body 12 and key retainer housing 46 of the top plug 110, the keys 64 of the top plug 110 may already be in contact with the top surfaces of the appropriate landing nipple profile. The top plug 110 has a wedged expander sleeve 78b and the keys 64 have an interior surface that is angled, or inclined, to mate with the wedged sleeve 78b. As the wedged expander 78b is driven or "jarred" downward, the keys of the top plug 110 are driven radially outward and longitudinally upward because of the engaging tapered surfaces of the wedge sleeve 78b and the keys 64.
The above described configuration places the two plugs 108 and 110 in contact, one to the other, with an outward compression force being applied to the keys 64 upon the respective landing surfaces 04. This compression force assures that the dual plugs 106, as a system, do not move relative to the wellhead 02 and the seal means 22 remain longitudinally stationary during service.
It will be appreciated by those of skill in this particular art that the plug assemblies 10 disclosed herein have specific application in wellhead bores 02, but may be utilized in any well conduits in which the length of the plug 10 is critical and the diameter of the conduit being plugged is greater than one and one-half inches. Moreover, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims.
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A wellhead plug assembly having one or more plugs for plugging segments of a wellhead bore through which access during completion and production procedures is gained. Each plug has a shortened length that is achieved by positioning connections between several of the components of the plug assembly radially beneath the anchoring and sealing means. By placing the connections radially inward to, and in tandem with, the sealing and or anchoring means, the overall length of a given plug may be shortened to less than eleven inches for plugs to be used in conduits having internal diameters greater than one and one-half inch. Furthermore, the tandem orientation allows plug designs in which a majority of the overall longitudinal length of the plug comprises the collective longitudinal lengths of the seal and anchor means.
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FIELD OF THE INVENTION
This invention relates to an egg transfer device for collecting eggs such as hen's eggs which are delivered by an egg collecting belt from one- or multi-storied cages to one position.
BACKGROUND TECHNOLOGY
No difficulty is experienced in the transfer of eggs in the horizontal direction. Systems have been developed in which eggs placed on a horizontal transfer path are sent onto an inclined or vertical transfer path to be collected to an egg collecting stand, etc. positioned at a different height from the horizontal transfer path. Transfers in directions other than the horizontal have been difficult to carry out smoothly, often resulting in the breaking of the eggs. The need for inclined or vertical transfer between locations of different heights is a requirement to the poultry farming industry using multi-storied cages intended for receiving eggs.
A poultry farm using the multi-storied cage type hen house will be described as an example. Eggs borne by hens fed in each cage come out of each cage onto an egg collecting conveyer positioned along each cage for horizontal transfer and are sent to one section in the hen house. In this section the eggs are transferred to an egg collecting stand, etc. by means of an transfer device.
A conventional transfer device is shown in FIG. 8.
An egg collecting conveyer 1 is provided along cages 6. In a transfer device 2, a belt 4 is applied taut between an upper pulley 3a and an lower pulley 3b and projection-like mounting pieces 4a are provided on the belt 4 at prescribed intervals. Eggs are eventually collected on an egg collecting stand 5.
Mounting levers 6 in the shape of comb teeth are provided both at the front end of the egg collecting conveyer 1 and at the front end of the egg collecting stand 5.
Eggs delivered by the egg collecting conveyors 1 are put onto the mounting levers 6 and scooped and transferred by the projection-like mounting piece 4a on the belt 4 while turning.
At the top position of the belt 4 where the belt 4 is inverted from the cage side to the side of the egg collecting stand 5 (from up to down), each egg of the mounting piece rolls from the projection-like mounting piece 4a ascending to the projection-like mounting piece 4a descending to be held, and then received by the mounting lever 6 of the egg collecting stand 5.
The above transfer device 2 has a disadvantage that, during the inversion of the direction of the belt 4 from up to down, each egg rolls to the advancing projection-like mounting piece 4a, sometimes causing eggs to collide so strongly as to be cracked. This disadvantage cannot be avoided even if the projection-like mounting piece 4a is constructed to be U-shaped.
An inclined conveyor is disadvantageous in that it requires a large space for positioning the conveyor.
Eggs received by the mounting lever 6 of the egg collecting stand 5 are expected to roll down the inclined mounting piece 6 onto the egg collecting stand 5. However, some of the eggs will stay on the mounting lever 6 or will not roll forth on the egg collecting stand 5. In such a case, the next descending projection-like mounting piece 4a will hit the egg staying on the mounting lever 6. In addition, the eggs succeedingly received by the mounting lever 6, while rolling on the egg collecting stand 5, may collide with one another with the possible generation of cracks developing in the eggs.
OBJECTS OF THE INVENTION
The object of this invention is to provide an egg transfer device in which egg collecting shelves are suspended swingably at regular intervals on endless stripes circulating in a vertical plane. With this structure, the egg collecting shelf with eggs mounted thereon, even while the endless strip changes its movement direction from the ascending to descending side, will not change its axis direction under the weight of the eggs mounted (and the egg collecting shelf itself).
Another object is to provide an egg transfer device in which eggs are received in the ascending side and discharged in the descending side and in which eggs are scooped out of the egg collecting shelf at the discharge position of the egg collecting shelf. This device is characterized in that a scraping piece (discharge bar, etc.) which comes over the egg collecting shelf at the discharge position to scrape eggs is spanned between two rotary plates rotatably in the discharge direction of the eggs. The rotary plates are positioned in connection with a rotary mechanism to be synchronized with the movement of the egg collecting shelf.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 shows a schematic side view illustrating the entire system including the egg transfer device;
FIG. 2 shows a schematic perspective view of the transfer device;
FIG. 3 shows a cross-sectional plan view of the transfer device;
FIG. 4 shows a schematic side view of the upper sprocket section of the transfer device;
FIG. 5 shows a side view of the discharge section of the transfer device;
FIGS. 6(a) and (b) show a plan and a cross-sectional side views, respectively, of other scraping pieces;
FIG. 7 shows a cross-sectional side view illustrating the stopper mechanism; and
FIG. 8 shows a schematic side view of a conventional egg transfer device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of this invention will be described in detail by reference to the accompanying drawings.
FIG. 1 shows a schematic view of an overall mechanism including an egg transfer device, FIG. 2 shows a schematic perspective view of the transfer device, and FIG. 3 shows a plan view of a cross section showing the overall system.
An egg collecting belt 12 is provided along each cage. This embodiment refers to a cage having three stories. Eggs delivered by this egg collecting belt 12 are transferred to an egg collecting stand 16 by egg collecting shelves 14 on a transfer device 10.
The structure of the transfer device 10 will be described below.
As shown in FIG. 2, a pair of side walls 10a and 10b are provided vertically, and two pairs of sprockets 18a and 18b are placed at the upper and lower end sections of each side wall 10a and 10b. Each of chains 20 and 20 are endless chains which are provided taut on each pair of the sprockets 18a and 18b. The egg collecting shelves 14 are spanned between the chains 20, 20.
As illustrated in FIG. 2, each egg collecting shelf 14 includes side plates 14a and 14a (described later) and only a part of shelf pieces 14d. A coupling rod 14c is also illustrated by a one-dot-chain line.
As best illustrated in FIG. 4, a chain piece 20a at a suitable position on the chain 20 has an attaching plate 20b provided thereon. The attaching plate 20b is rotatably attached to a hanging shaft 14b which projects from the side plate 14a of the egg collecting shelf 14. Therefore, the egg collecting shelf 14 is capable of freely swinging about the hanging shaft 14b.
Next, the structure of the egg collecting shelf 14 will be described.
As illustrated in FIGS. 3 and 4, two side plates 14a and 14a are connected to each other by a coupling rod 14c at a forward lower portion thereof. The coupling rod 14c has a plurality of shelf pieces 14d fixed at regular intervals. The shelf piece 14d includes two inclined sections 14m and 14n formed in a V-shape with a plurality of concave sections 14e, opening upward, constituting a receiver 14f for holding an egg; one inclined section 14m is shorter than the other 14n and is connected to the coupling rod 14c.
An imaginary line connecting the deepest point of the receiving sections 14e and a hanging shaft 14b which suspend the egg collecting shelves 14 is lined vertically to stabilize the egg collecting shelves 14.
In the right-hand section of FIG. 3 the ascending side A of the egg collecting shelf 14 is illustrated wherein eggs delivered by the egg collecting belt 12 are scooped by the egg collecting shelf 14 while ascending.
The scooping by the egg collecting shelf 14 is carried out as follows. Eggs delivered by the egg collecting belt 12 are put on an egg holding section 22, which is located at the forward end of the egg collecting belt 12 and which is composed of a plurality of holding pieces 22a fixed in parallel with one another at regular intervals. The holding piece 22a is a thin plate of the same shape as the shelf piece 14d and is fixed, with a concave section 22e directed upwardly, on a fixing rod 22b at the forward end of the egg collecting belt 12. The shelf piece 14d is designed to pass through the gap between the holding pieces 22a of the holding section 22, with no contact of the holding piece 22a with the shelf piece 14d. Thus, an egg placed in a concave section of the holding section 22 formed by a plurality of the concave sections 22e of the holding piece 22a is scooped up by the shelf piece 14d during the passage of the egg collecting shelf 14; the coupling rod 14c of the egg collecting shelf 14 and the fixing rod 22b fix the back ends of the shelf piece 14d and holding piece 22a, respectively, so that the egg collecting shelf 14 may scoop up eggs with no contact with the holding section 22.
The left-hand side of FIG. 3 illustrates the descending side D of the egg collecting shelf 14. By reference to FIGS. 3 and 5 a description will be made of the egg discharging mechanism.
At a short distance from the front edge 16a of the egg collecting stand 16 there is a line of a plurality of inclined pieces 24a which elevate with increasing distance from the egg collecting stand 16, and which are fixed on a supporting rod 24b having its upper end section spanned on both the walls 10a and 10b of the transfer device 10. The inclined pieces 24a and the supporting rod 24b constitute a discharge section 24.
As the egg collecting shelf 14 passes through the discharge section 24, i.e., each shelf pieces 14d of the egg collecting shelf 14 passes between the inclined piece 24a of the discharge section 24, the eggs on the egg collecting shelf 14 are scooped up by the inclined pieces 24a and are caused to roll down the slope formed by the inclined pieces 24a onto the egg collecting stand 16.
Next, a description will be made of the control mechanism for stopping the transfer device 10. The discharge section 24 has a stopper bar 30 extending from the side of the supporting rod 24b. Near the end of the stopper bar 30, two control pieces 32a and 32b are provided to define the rotation range of the discharge section 24 about the supporting rod 24b. The end of the stopper bar 30 is pulled down by a spring 34 against the lower control piece 32b to limit the rotation range of the discharge section 24. In case any contaminants such as feathers of the hens are on the discharge section 24, the egg collecting shelf 14 which is descending cannot pass through the discharge section 24. This causes the discharge section 24 to be pushed down. At that time, the discharge section 24 is forced to rotate against the force of the spring 34, and the stopper bar 30 hits a switch 36. The switch 36, when activated, will stop the egg collecting shelf 14. This is a known electrical mechanism.
A rotary plate 26 is rotatably held on a fixing plates 10c and 10c projecting from the front edges of each of the side walls 10a and 10b. The rotary plate 26 has three arms 27 extending radially. The arms 27a, 27b and 27c on the pair of rotary plates 26a and 26b facing each other have discharge bars 28 spanned between their ends. The dashed line in FIG. 5 indicates the circular locus of the end of the arms 27.
One arm 27a of the rotary plate 26 will be positioned to extend into the space formed between the egg collecting shelf 14A at the discharge position and the overhead egg collecting shelf 14B. As this egg collecting shelf 14B descends, the coupling rods 14c exert a pressure on the base section of the arm 27a, causing the rotary plate 26 to rotate. The arm 27a is then pushed (outward) toward the egg collecting stand 26 in the direction of egg discharge over the locus l of the coupling rod 14c (in FIG. 5 the rotational locus of the arm 27a is indicated by a dashed line). At the same time, the discharge bar 28 sweeps the space immediately over the egg collecting shelf 14A at the discharge position or the inclined piece 24a. The next arm 27b in turn comes into the space over the descending egg collecting shelf 14B (in FIG. 5 the rotational locus of the arm 27b is indicated by the dashed line). Similarly in sequence, the egg collecting shelves 14C, etc. descend, causing the rotary plate 26 to rotate.
Side walls 16b and 16b are provided vertically on the side edges of the egg collecting stand 16, a rod 60b is hung on the side walls 16b and 16b, and swing pieces 60a are suspended from the rod 60b swingably toward the egg collecting stand 16, thus constituting a nonreturn section 60.
The swing piece 60a is designed to be capable only of swinging in the direction of discharging the eggs. Therefore, an egg discharged from the egg collecting shelf 14 is allowed, under the action of the discharge bar 28, to roll on the egg collecting stand 16 over the nonreturn section 60, i.e., out of the sweep space of the discharge bar 28, with no possibility to return.
Now, a description will be made of the action of the egg transfer device with the above-described structure.
Eggs delivered by the egg collecting belt 12 are caused to roll down and settle in the concave sections 22e of the holding pieces 22a in the holding tables 22.
The shelf pieces 14d of the ascending egg collecting shelf 14 pass between the holding pieces 22a of the holding tables 22, during which passage the eggs are scooped up by the shelf pieces 14d.
The egg collecting shelf 14 is capable of passing the upper sprocket 18a followed by descent without inversion, since the egg collecting shelf 14 is attached swingably to the chain piece 20a by the hanging shaft 14b, with weight balance maintained.
While the descending egg collecting shelf 14 passes the discharge position, i.e., the shelf pieces 14d pass between the inclined pieces 24a of the discharge section 24, the eggs are scooped up by the inclined pieces 24a. The slopes formed by the inclined pieces 24a are descendent toward the egg collecting stand 16 so that the eggs having been scooped on the inclined pieces 24a are caused to roll onto the egg collecting stand 16. At the same time, the arm 27a of the rotary plate 26 enters the space between the egg collecting shelf 14A at the discharge position and the egg collecting shelf 14B immediately overhead to the shelf 14A, the coupling rod 14c of the egg collecting shelf 14B pushes down the arm 27a, and the discharge bar 28 sweeps the space over the inclined pieces 24a, thus causing any eggs, if staying on the inclined pieces 24a or between the inclined pieces 24a and the egg collecting stand 16, to roll onto the egg collecting stand 16. Egg discharge from the egg collecting shelf 14 is continued in the same way.
The eggs allowed to roll onto the egg collecting stand 16 push up the swing piece 60a of the nonreturn section 60 to pass the nonreturn section 60, never to be returned.
The eggs collected on the egg collecting stand 16 are accommodated in boxes as required.
In the above embodiment, the discharge bar 28 is provided as a scraper at the ends of arms of the rotary plates 26a and 26b. However, instead of the discharge bar 28, a brush 29 formed by positioning coarse hairs 29b on a platelike base 29a may be attached as shown in FIG. 6(a) so as to sweep (scrape) over comb teeth or inclined pieces.
Alternatively, as shown in FIG. 6(b), a plate piece 34 may be set on the arm 27 along its front end section so as to scrape out eggs. Various shape modifications may be applied on the plate piece 34, such as a plate piece having through-holes bored suitably or formed in a net; the number of arms 27 may also be varied suitably.
In the above embodiment, the synchronous rotation of the rotary plate with the movement of the egg collecting shelf 14 is effected by the use of the coupling rod 14c of the egg collecting shelf 14. However, the rotary plate may be driven by a separate driving source. The inclined piece 24a of the discharge section 24 does not need to always be inclined. The scraping out of eggs is possible by use of scraping pieces.
When contaminants such as hen's feather are positioned on the inclined pieces 24a, the descending egg collecting shelf 14 will push down the discharge section 24. This causes the discharge section 24 to rotate against the force of the spring 34 about the supporting rod 24b until the stopper bar 30 activates the switch, with resulting stop of the egg collecting shelf 14. After this stop the contaminants are to be removed.
FIG. 7 shows another embodiment for the control mechanism.
A belt 40 has a plurality of holding pieces 42 projecting like comb teeth, and eggs are mounted on the holding pieces 42.
A plurality of discharge pieces 46 are provided on the front edge 44a of an egg collecting stand 44 with ascending inclination. On the other hand, each discharge piece 46 extends down vertically along the front edge 44a until it is supported rotatably by a supporting rod 48. Thus, providing a discharge section 50.
A stopper bar 52 extends from the discharge section 50 and is pulled by a spring 54. The force of this spring 54 maintains every discharge piece 46 in contact with the front edge 44a of the egg collecting stand 44, thus maintaining the state of slope. The rotation of the discharge section 50 by the existence of any contaminants causes the stopper bar 52 to actuate a switch 56. This arrangement results in the same action and effect as the preceding embodiment.
This invention affords a number of remarkable advantages. Since egg collecting shelves are attached swingably on an endless stripe, no inversion of the egg collecting shelves occurs and accordingly no collision, etc. among eggs takes place to cause eggs to be cracked or broken while the egg collecting shelves deliver to the discharge position the eggs which they have scooped up at the holding section. In addition, the endless stripe may be positioned vertically, thus only a small space is required for setting. Further, the control mechanism may be activated to stop the transfer device when contaminants have been brought onto the discharge or receiving section so that no transfer of eggs may be performed, no breakage of the eggs will occur in the discharge section or the receiving section. Finally, the positioning of the egg collecting shelf at the discharge position may be accompanied with a scraping-out of eggs, thus the discharge of eggs may be facilitated.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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This invention relates to an egg transfer device capable of collecting and transferring eggs delivered from cages without breaking the eggs. Egg collecting shelves are suspended swingably on an endless strip. Eggs are received at a receiving section of the egg collecting shelves and discharged at a discharge section. The receiving section of the egg collecting shelf, the holding section, and the discharge section are all formed with fork-shaped comb-like teeth. The capability of the egg collecting shelves to swing freely causes no eggs transferred by the egg collecting shelves to be cracked or broken. Scraping-out pieces are provided to facilitate eggs to be sent onto the egg collecting stand when the egg collecting shelf has reached the discharge position. Moreover, a stopper mechanism is provided to stop the endless strip when contaminants, if brought onto the discharge section, have disabled the discharge of eggs from the egg collecting shelf.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a novel vinyl ether compound, its synthetic intermediates and a processes for producing the same, and more particularly to a novel vinyl ether compound effective as a copolymer component of fluorine-containing elastomer, its synthetic intermediates and a processes for producing the same.
2. Related Art
Fluorine-containing elastomers are distinguished not only in the heat resistance, but also in the oil resistance and chemical resistance. Recently, bifunctional vinyl ethers copolymerizable as cross-linking site monomers into fluorine-containing elastomers having such distinguished charactristics have been highlighted.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a novel bifunctional vinyl ether compound having an aromatic ring, which can serve as an effective vinyl ether compound as a copolymer component of fluorine-containing elastomer.
A novel vinyl ether compound according to the present invention can be represented by the following general formula:
CF.sub.2 ═CFO(CF.sub.2).sub.n CF.sub.2 C.sub.6 H.sub.3 (COOR).sub.2
where R is a hydrogen atom or a lower alkyl group and n is an integer of 1 to 5.
DETAILED DESCRIPTION OF THE INVENTION
The vinyl ether compound according to the present invention can be produced by a series of the following steps:
CF.sub.2 ═CFO(CF.sub.2).sub.n COOR'→CF.sub.2 XCFXO(CF.sub.2).sub.n COOR' (1)
The halogen addition reaction can be readily carried out by bubbling a chlorine gas into a lower alkyl ester compound or dropwise adding bromine thereto, preferably under ultraviolet irradiation. The lower alkyl ester compound used as a starting material can be prepared by subjecting FOC(CF 2 ) n COOR', where m: n-1, to addition reaction with hexafluoropropeneoxide and subjecting the resulting FOCCF(CF 3 )O(CF 2 ) m COOR' to heat decomposition in the presence of an alkali metal carbonate. The initial starting material FOC(CF 2 ) m COOR' can be obtained by reaction of FOC(CF 2 ) m COF with R'OH.
CF.sub.2 XCFXO(CF.sub.2).sub.n COOR'+MgBrC.sub.6 H.sub.3 (CH.sub.3).sub.2) →CF.sub.2 XCFXO(CF.sub.2).sub.n COC.sub.6 H.sub.3 (CH.sub.3).sub.2( 2)
The Grignard reagent MgBrC 6 H 3 (CH 2 ) 2 can be obtained generally by reaction of bromobenzene having 3,4-dimethyl groups with metallic magnesium. Reaction of the ester compound with the Grignard reagent can be carried out by dropwise addition of the Grignard reagent to a solution of the ester compound, using an ether compound such as tetrahydrofuran, diethyl ether, etc. as a solvent, while keeping the temperature at about -60° to about -50° C., followed by stirring at a temperature of about -60° to 0° C. for about 1 to about 2 hours.
CF.sub.2 XCFXO(CF.sub.2).sub.n COC.sub.6 H.sub.3 (CH.sub.3).sub.2 →CF.sub.2 XCFXO(CF.sub.2).sub.n CF.sub.2 C.sub.6 H.sub.3 (CH.sub.3).sub.2 ( 3)
The reaction can be readily carried out by dropwise addition of diethylaminosulfur trifluoride (C 2 H 5 ) 2 NSF 3 under a cooling condition with iced water, followed by stirring at a temperature of about 10° to about 20° C.
CF.sub.2 XCFXO(CF.sub.2).sub.n CF.sub.2 C.sub.6 H.sub.3 (CH.sub.3).sub.2 →CF.sub.2 XCFXO(CF.sub.2).sub.n CF.sub.2 C.sub.6 H.sub.3 (COOR).sub.2 ( 4)
The reaction is carried out firstly by conversion of methyl groups to carboxyl groups through stepwise addition of oxygen at a temperature of about 100° to about 200° C. in an autoclave, using a solvent such as acetic acid, etc. and a catalyst such as cobalt acetate, manganese acetate, etc. in the presence of an aqueous hydrobromic acid solution capable of enhancing the catalytic activity, and then by esterification reaction. The esterification reaction can be carried out according to any desired procedure, for example, by reaction with a lower alkyl halide under basic conditions, using an aprotic polar solvent such as hexamethylphosphorylamide. The reaction products includes a R═H compound.
CF.sub.2 XCFXO(CF.sub.2).sub.n CF.sub.2 C.sub.6 H.sub.3 (COOR).sub.2 →CF.sub.2 ═CFO(CF.sub.2).sub.n CF.sub.2 C.sub.6 H.sub.3 (COOR).sub.2 ( 5)
Dechlorination reaction or debromination reaction for the vinyl etherification can be carried out by charging powdery zinc, a solvent such as demethyl formamide, dimethyl acetamide, methanol, ethanol, etc. and iodine as a zinc activating agent into a reactor, heating the reactor to a temperature of about 20° to about 150° C., and then dropwise addition of a solution of the ether compound dissolved in the solvent thereto.
The novel vinyl ether compound obtained by a series of these steps is copolymerized with tetrafluoroethylene and perfluoro(lower alkyl vinyl ether) or perfluoro(lower alkoxy-lower alkyl vinyl ether) to form a fluorine-containing elastomer copolymer.
For the perfluoro(lower alkyl vinyl ether), perfluoro-(methyl vinyl ether) can be usually used. For the perfluoro-(lower alkoxy-lower alkyl vinyl ether), the following compounds an be used:
______________________________________CF.sub.2 = CFOCF.sub.2 CF(CF.sub.3)OC.sub.n F.sub.2n+1 (n:1 ˜ 5)CF.sub.2 = CFO(CF.sub.2).sub.3 OC.sub.n F.sub.2n+1 (n:1 ˜ 5)CF.sub.2 = CFOCF.sub.2 CF(CF.sub.3)O(CF.sub.2 O).sub.m C.sub.n F.sub.2n+1 (n:1 ˜ 5; m:1 ˜ 3)CF.sub.2 = CFO(CF.sub.2).sub.2 OC.sub.n F.sub.2n+1 (n:1 ˜ 5)______________________________________
Among these compounds, those whose C n F 2n+1 group is a CF 3 group are preferably used.
Copolymerization can be carried out according to any desired procedure, for example, by emulsion polymerization, suspension polymerization, solution polymerization, bulk polymerization, etc., using about 30 to about 70% by mole of tetrafluoroethylene, about 65 to about 25% by mole of perfluoro (lower alkyl vinyl ether) or perfluoro(lower alkoxy-lower alkyl vinyl ether) and about 0.1 to 5% by mole of the present vinyl ether compound, sum total being 100% by mole.
Among them, emulsion polymerization is preferable from the view point of economy. Emulsion polymerization reaction can be carried out generally at a temperature of about 40° to about 85° C. under a pressure of about 3 to about 8 MPa, using a water-soluble inorganic peroxide or its redox system as a catalyst and ammonium perfluorooctanoate, etc. as a surfactant. The terpolymer can be further copolymerized with a fluoroolefin, an olefin, a vinyl compound, etc. to such an extent as not to inhibit the copolymerization reaction and deteriorate physical properties of vulcanization products, for example, not more than about 20% by mole, on the basis of the resulting fluorine-containing elastomer copolymer.
Vulcanization of the resulting fluorine-containing elastomer copolymer can be carried out by adding about 0.5 to about 5 parts by weight, preferably about 1 to about 2 parts by weight to 100 parts by weight of the terpolymer, of an aliphatic diamine such as hexamethylenediamine, ethylene diamine, etc., or an aromatic diamine represented by the following general formula: ##STR1## where R is CF 2 , C(CF 3 ) 2 , O, SO 2 , etc., followed by press vulcanization at a temperature of about 160° to about 250° C. If required, oven vulcanization (secondary vulcanization) can be carried out. Carbon black, silica, etc. can be added as a filler to the mixture for vulcanization, if required.
The present invention provides a vinyl ether compound represented by the following general formula:
CF.sub.2 ═CFO(CF.sub.2).sub.n CF.sub.2 C.sub.6 H.sub.3 (COOR).sub.2
where R is a hydrogen atom or a lower alkyl group and n is an integer of 1 to 5, which can act as a cross-linking site for the vulcanization, when copolymerized into a fluorine-containing elastomer.
PREFERRED EMBODIMENTS OF THE INVENTION
The present invention will be described in detail below, referring to Example and Reference Example.
EXAMPLE
(1) 964.5 g (2.558 moles) of CF 2 ═CFO(CF 2 ) 3 COOCH 3 was charged into a reactor having a capacity of 2 liters and subjected to reaction by bubbling 248 g (3.493 moles) of chlorine therein over 5 hours, while keeping the reactor inside temperature so as not to exceed 80° C. After the reaction, the reaction mixture was washed once with an aqueous sodium hydrogen carbonate solution and then twice with water, followed by drying over magnesium sulfate and distillation under reduced pressure, whereby 819.5 g of CF 2 ClCFClO(CF 2 ) 3 COOCH 3 was obtained as a fraction of boiling point of 105° C./80 mmHg (yield: 71.5%)
(2) 54 g (2.261 mole) of Mg was charged into a reactor having a capacity of 2 liters. Then, the reactor was flushed with a nitrogen gas, and a solution containing 597 g (2.260 mole) of 1-bromo-3,4-dimethylbenzene dissolved in 500 ml of tetrahydrofuran was dropwise added to the reactor over about 3 hours, while keeping the reactor inside temperature so as not to exceed 60° C. After the dropwise addition, the mixture was stirred for one hour, while checking whether the metallic Mg substantially disappeared to prepare a Grignard reagent.
Then, 774 g (2.055 moles) of the chlorine adduct obtained in the foregoing step (1) and 1 liter of tetrahydrofuran were charged into a reactor having a capacity of 5 liters and the reactor was cooled down to -60° C. with dry ice/methanol. Then, the Grignard reagent was dropwise added thereto over about 2 hours and the mixture was stirred for one hour, while keeping the same temperature as above. Then, the mixture was subjected to temperature elevation to 0° C. at a temperature elevation rate of 10° C./30 min, and then stirred for one hour. The reaction was completed by addition of 1.2 liters of 2N hydrochloric acid thereto.
The resulting reaction mixture was decanted, and the organic layer was washed with an aqueous sodium chloride saturated solution. The washing solution and the aqueous layer were joined together and subjected to extraction with the same volume of ethyl acetate. The extract was washed with an aqueous sodium chloride saturated solution, and the washed extract and the organic layer was joined together, and dried over magnesium sulfate. After removal of the solvent by distillation, 503.8 g of the following compound IV! was obtained as a fraction of boiling point 135° C./3 mmHg (yield : 54.4%):
______________________________________.sup.19 F-NMR (CF.sub.3 COOH base): ##STR2##1 34.3 ppm (2F)2 46.3 ppm (2F)3 5.3 ppm (2F)4 -1.0 ppm (1F)5 -11.7 ppm (2F).sup.1 H-NMR (TMS base): ##STR3##1 7.80 ppm (1H, d, J=9.0Hz)2 7.27 ppm (1H, d, J=9.0Hz)3 7.84 ppm (1H, s)4 2.31 ppm (3H, s)5 2.32 ppm (3H, s)Infrared absorption spectrum:2975 cm.sup.-1 (CH.sub.3)1705 cm.sup.-1 (CO)1605 cm.sup.-1 (aromatic ring)1570 cm.sup.-1 (aromatic ring)______________________________________
(3)319 g (0.708 moles) of reaction product IV! from the foregoing step (2) was charged into a reactor having a capacity of 1 liter and cooled with iced water, and then 128 ml (0.970 mole) of diethylaminosulfur trifluoride was dropwise added thereto over about 30 minutes. After the dropwise addition, the mixture was stirred at room temperature overnight, and then the reaction mixture was slowly poured into an aqueous sodium hydrogen carbonate solution. The resulting organic layer was washed with water, dried over magnesium sulfate and distilled under reduced pressure, whereby 185.4 g of the following compound III! was obtained as a fraction of boiling point 110° C./3 mmHg yield: 55.4%!:
______________________________________.sup.19 F-NMR (CF.sub.3 COOH base): ##STR4##1 31.5 ppm (2F)2 42.5 ppm (2F)3 45.5 ppm (2F)4 4.8 ppm (2F)5 -1.5 ppm (1F)6 -7.0 ppm (2F).sup.1 H-NMR (TMS base): ##STR5##1 7.30 ppm (1H, d, J=7.7Hz)2 7.22 ppm (1H, d, J=7.7Hz)3 7.33 ppm (1H, s)4 2.31 ppm (6H, s)______________________________________
(4)2.8 g of cobalt acetate, 2.7 g of manganese acetate and 112.6 g (0.238 moles) of reaction product III! from the foregoing step (3) were charged into an autoclave having a capacity of 500 ml, and the autoclave was subjected to pressure reduction. Then, 2.2 ml (14.6 millimoles) of an aqueous 47% hydrobromic acid solution and 150 ml of acetic acid were charged thereto by spontaneous suction. The reaction temperature was elevated to 110° C., and stepwise addition of oxygen was repeated until no more pressure decrease occurred even if the gauge pressure was ultimately elevated to 13 kg/cm 2 . After release of the autoclave inside pressure at room temperature by purging, the reaction mixture was subjected to temperature elevation to 110° C., and stepwise addition of oxygen was repeated also throughout next day until no more pressure decrease occurred. After the reaction, the reaction mixture was washed three times with 150 ml of water and insoluble matters were dissolved in 300 ml of ethyl acetate. Then, the ethyl acetate solution was washed with the same volume of an aqueous sodium chloride saturated solution, dried over magnesium sulfate and subjected to removal of the solvent by distillation.
202 g of the thus obtained crude product, 400 ml of hexamethylphosphoramide and 182 ml of an aqueous sodium hydroxide solution were charged into a reactor having a capacity of 2 liters, and 137 ml of methyl iodide was dropwise added thereto over about 30 minutes, while cooling the reactor with iced water. After the dropwise addition, the mixture was stirred at room temperature overnight, and then 600 ml of 2N hydrochloric acid was added thereto, followed by extraction with ethyl acetate. The extract was washed with water, dried over magnesium sulfate, and subjected to removal of the solvent by distillation and to purify the residue by column chromatography developing solvent: solvent mixture of ethyl acetate/n-hexane (1:5 by volume)!, whereby 41.9 g of the following reaction product II! was obtained (yield: 31.4%):
______________________________________.sup.19 F-NMR (CF.sub.3 COOH base): ##STR6##1 32.0 ppm (2F)2 42.5 ppm (2F)3 45.0 ppm (2F)4 5.3 ppm (2F)5 -1.6 ppm (1F)6 -12.1 ppm (2F).sup.1 H-NMR (TMS base): ##STR7##1 7.80 ppm (1H, d J=8.25Hz)2 7.83 ppm (1H, d J=8.25Hz)3 8.01 ppm (1H, s)4 3.95 ppm (6H, s)Infrared absorption spectrum:2952 cm.sup.-1 (CH.sub.3)1738 cm.sup.-1 (CO)1618 cm.sup.-1 (aromatic ring)1578 cm.sup.-1 (aromatic ring)______________________________________
(5)9.3 g (110 millimole) of zinc powder and 50 ml of dimethyl formamide were charged into a reactor having a capacity of 200 ml and the mixture was subjected to temperature elevation to 110° C. Then, a solution containing 62 g (110 millimole) of reaction product II! from the foregoing step (4) dissolved in 10 ml of dimethyl formamide was dropwise added thereto over about 30 minutes. After the dropwise addition, a solution containing 1.4 g of iodine dissolved in 5 ml of dimethyl formamide was poured therein, and the mixture was stirred at 11° C. for 2 hours. After the reaction, the reaction mixture was decanted, and the residual zinc was washed with 20 ml of dimethyl formamide. The washing dimethyl formamide solution and the decanted dimethyl formamide solution were joined together, followed by neutralization with 2N hydrochloric acid and extraction with n-hexane. The extract was washed with water, dried over magnesium sulfate and subjected to removal of the solvent by distillation and to purify the residue by column chromatography developing solvent: the same as used in the foregoing step (4)!, whereby 42.3 g of the following reaction product I! was obtained (yield: 78.0%):
______________________________________.sup.19 F-NMR (CF.sub.3 COOH base): ##STR8##1 30.8 ppm (2F)2 41.7 ppm (2F)3 43.3 ppm (2F)4 6.6 ppm (2F)5 33.0 ppm (1F)6 40.3 ppm (1F)7 53.2 ppm (1F)______________________________________
REFERENCE EXAMPLE
(1) 60.3 ml of distilled water, 1.55g of ammonium perfluorooctanoate and 2.72 g of Na 2 HPO 4 ·12H 2 O were chrged into a stainless steel autoclave having a capacity of 500 ml, and the autoclave was flushed with a nitrogen gas and then subjected to pressure reduction. Then, 22.5 g (0.225 moles) of tetrafluoroethylene and 37.4 g (0.225 moles) of perfluoro(methyl vinyl ether)were successively charged therein, and the mixture was subjected to temperature elevation to 50° C. 4.51 g (9.2 millimoles) of ultimate reaction product I! obtained in the foregoing Example was charged therein by a pressure feed pump, then 0.47 g of sodium sulfite and 2.33 g of ammonium persulfate were charged therein as 43 ml of aqueous solutions, respectively, to initiate polymerization reaction. After continuation of polymerization reaction for 6 hours, the autoclave was cooled and the residual gas was purged therefrom to obain an aqueous latex.
The thus obtained aqueous latex was added to 2 liters of an aqueous sodium chloride saturated solution at 70° C. to coagulate the formed polymers. The coagulates were recovered by filtration, washed with water and dried at 70° C. under the normal pressure for 12 hours and 120° C. under reduced pressure for 12 hours, whereby 38.2 g of white, rubbery terpolymer was obtained. By infrared absorption spectrum it was found that the terpolymer had absorptions at 1578 cm -1 and 1618 cm -1 and that the compound I! was copolymorized in the terpolymer.
______________________________________Polymer composition by .sup.19 F-NMR:______________________________________Tetrafluoroethylene 53.1% by molePerfluoro(methyl vinyl ether) 45.1% by moleCompound I! 1.8% by mole______________________________________
Reduced viscosity η sp/c: 0.6 dl/g, as measured at 35° C. for 0.1 wt % solution in perfluoro(2-butyltetrahydrofuran)
(2) 5 parts by weight of MT carbon black and 1.4 parts by weight of 4,4'-diaminodiphenyl ether were added to 100 parts by weight of the resulting terpolymer, and the mixture was kneaded through two rolls rubber mill. Increase in vulcanization torque was found by measuring torque at 200° C. for 60 minutes by Curastometer V (made by Oriontex K.K., Japan), showing that the vulcanization reaction was under way.
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(1) CF 2 ═CFO(CF 2 ) n COOR is allowed to react with chlorine or bromine to obtain CF 2 XCFXO(CF 2 ) n COOR', (2) which is allowed to react with a Grignard reagent MgBrC 6 H 3 (CH 3 ) 2 to convert the terminal group to --COC 6 H 3 (CH 3 ) 2 , (3) followed by reaction with diethylaminosulfur trifluoride to convert --COC 6 H 3 (CH 3 ) 2 to --CF 2 C 6 H 3 (CH 3 ) 2 , (4) followed further by oxidation of the resulting methyl group and by esterification to convert the methyl group to --CF 2 C 6 H 3 (COOR) 2 and (5) followed by dechlorination or debromination to obtain CF 2 ═CFO(CF 2 ) n CF 2 C 6 H 3 (COOR) 2 . The resulting bifunctional vinyl ether compound having an aromatic ring is a novel compound and can be used as a copolymer component for fluorine-containing elastomers.
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FIELD OF THE INVENTION
The present invention relates to a method for sectioning a substrate wafer into a plurality of substrate chips
BACKGROUND INFORMATION
Microelectronic components, such as computer chips or electronics chips, are typically produced within the framework of so-called planar technology. In this context, the substrate wafers made of a material suitable as a carrier material for the component, such as silicon, are coated in a series of subsequent coating and patterning steps with a suitable sequence of layers of the respective material later active in the component. In this context, after coating with a material, this material layer patterned, e.g., using patterning methods based on photoresist. The patterning ensures that the final material layer only covers those parts of the component-chip surface that require coating by the particular material for functional reasons.
Especially in the field of the mass production of components, a plurality of components is typically produced in parallel in one operation, in a particularly timesaving and cost-effective manner of manufacture. In this context, a comparatively large substrate wafer having a diameter of about 6 or 8 inches, for example, is coated according to the described method, a plurality of components being ultimately disposed next to one another on the surface of the substrate wafer. In other words, the multi-layered patterns necessary for a plurality of components are simultaneously produced by coating the substrate wafer.
Subsequent to the coating and patterning process, the components are present on one single substrate wafer. Therefore, an additional step is necessary in which the substrate wafer is sectioned into a plurality of substrate chips in such a manner that, in each case, every substrate chip only carries the layer structure intended for an individual component.
For this purpose, the substrate wafer typically undergoes a saw process after coating and patterning are completed. In this process, the substrate wafer is cut by a diamond-covered saw blade first in a line-by-line manner and then in a column-by-column manner. For this purpose, the substrate wafer is laminated or mounted onto a carrier film. Rotating the typically ring-shaped saw blade at a frequency of up to 20,000 rpm results in an abrasive material removal along the so-called saw cut.
However, due to the necessary material removal in a horizontal as well as vertical direction, such a saw process requires at least two process steps and is, therefore, time-consuming. In addition, the saw process essentially permits only a rectangular surface area for the substrate chip produced by sectioning; due to the increased number of necessary cutting directions, a comparatively more complicated surface area, e.g., in the shape of a polygon, would result in an even more unfavorable expenditure of processing time. Thus, with respect to the attainable surface areas of the substrate chip, the saw process has only limited flexibility.
SUMMARY
An object of the present invention is to provide a method for sectioning a substrate wafer into a plurality of substrate chips, the method enabling a process management that is especially timesaving and flexible with respect to the producible substrate-chip surface areas.
With regard to the method, this objective is achieved according to the present invention in that the substrate chips are separated from one another by a selective deep patterning method.
In this context, a deep patterning method is a method in which a laterally bounded material removal can be adjusted in a targeted manner, there being a preferential direction of the material removal into the depth of the processed material. In a selective deep patterning method, the removal action is additionally limited to a defined group of target materials.
The present invention is based on the consideration that the particular time expenditure resulting from the typically provided saw process, on the one hand, and the limited flexibility, on the other hand, are dependent on the driving direction of this process, namely in a lateral direction or in a direction parallel to the surface of the substrate wafer. However, the substrate wafer can be sectioned in a manner that is timesaving as well as flexible with respect to the achievable surface areas for the substrate chips in that a process is provided for segmenting that has a driving direction leading into the substrate wafer and oriented in a direction perpendicular to its surface. This can be achieved by a deep patterning method having a preferential direction into the substrate wafer due to the physical-chemical marginal conditions.
For a particularly extensive possible scope of application, a silicon wafer is advantageously sectioned as the substrate wafer, a selective deep patterning method for silicon being used. In this context, a material having a particularly effective removal action especially for silicon due to its physical-chemical properties is used as the patterning agent or etchant.
In one embodiment, a plasma etching method is used as the deep patterning method. In such a plasma etching method, the substrate wafer to be sectioned is exposed to an atmosphere of a etching gas. By supplying energy into the etching gas, e.g., using microwave irradiation, the gas is partially ionized and, therefore, forms a plasma. A portion of the thereby produced plasma ions, e.g., the positively charged cations, are then accelerated by an accelerating voltage toward the substrate wafer and impinge in an almost vertical direction upon the wafer's surface. In response to the impingement, the ions accelerated in the plasma react with the material of the substrate wafer, volatile reaction products being produced, and the material of the substrate wafer being locally dissolved. Furthermore, the accelerated ions knock off debris from the surface of the substrate wafer, thereby employing an etching operation. In response to the surface areas of the substrate wafer that are not to be etched being suitably covered, this process can be restricted to the desired separation areas.
As a result of the impingement direction of the ions upon the surface of the substrate wafer, such a plasma etching process exhibits a characteristic preferential direction of the removal process into the depth of the substrate wafer and is, therefore, particularly suitable as a deep patterning method. In addition, all of the surface areas of the substrate wafer can be parallelly and simultaneously processed, without the etching action being affected, e.g., by the crystal directions of the substrate wafer. Thus, the most different substrate-chip surface areas can be produced in a particularly simple manner. When processing a substrate wafer made of silicon, an SF 6 plasma may be used as the etching plasma. In an additional or alternatively advantageous embodiment, the etching plasma includes xenon difluoride (X e F 2 ) or chlorine trifluoride (Cl F 3 ).
In a particularly advantageous further refinement, an etching step and a polymerization step, respectively, are carried out in an alternating sequence in the plasma etching method. In this context, the etching steps and polymerization steps are controlled independently of one another. In this context, a polymer is applied during every polymerization step, in a lateral region predefined by an etching mask, the polymer being removed again during the subsequent etching step. The sequence of separate etching steps and polymerization steps ensures, on the one hand, a particularly high degree of anisotropic etching with high selectivity, a simultaneous presence of etchants and polymer formers in the plasma being reliably prevented, on the other hand. Thus, a particularly high etch rate can be achieved, almost neutral etching edges being able to be produced in the substrate wafer.
For a particularly high level of variability in the sectioning method with respect to predefined process parameters, such as a maximum allowable processing time, the plasma pressure, the plasma power, and/or acceleration voltage U are advantageously controlled as operating parameters for adjusting a predefinable etch rate. In this context, an etch rate between 5 and 50 μ/min is set in a particularly advantageous manner by suitably selecting the plasma pressure and plasma power.
In a particularly advantageous manner, the sectioning method is used within the framework of the manufacture of microelectronic or microelectronic-mechanical components. In this context, the substrate wafer is advantageously first coated by a succession of coating steps and patterning steps in such a manner that a plurality of components limited only by the size of the substrate wafer and the number and position of the separating lines provided during the formation of the substrate chips are produced on the wafer's surface. Subsequently, the substrate wafer is sectioned into substrate chips by the deep patterning method in such a manner that every substrate chip supports a component.
Advantageously, the substrate wafer is coated with an etching mask prior to the deep patterning, in the regions intended for forming the substrate chips. It is, therefore, ensured that the etching operation is limited to only the desired separation areas between the substrate chips to be produced, in particular without possibly endangering the component patterns on the substrate chips. In this context, especially for processing substrate wafers made of silicon, a coating of SiO 2 is advantageously applied as an etching mask to the substrate wafer.
In particular, advantages targeted by the present invention include that all separating lines provided on the surface of the substrate wafer can be simultaneously processed due to the driving direction of the separating method, which is directed into the depth of the substrate wafer. Thus, a complete sectioning of the substrate wafer into substrate chips in a particularly short processing time is rendered possible even for substrate-chip surface areas deviating from a rectangular shape. In addition, the lateral expansion of the separating lines can be limited to a width of approximately 2 μm by the separating method. In comparison, a saw process results in a width of the separating lines of about 50 to 100 μm, so that in this case, only a correspondingly reduced overall surface is available for attaching components. Furthermore, using a deep patterning method, the separating method mechanically stresses the substrate wafer in a significantly reduced manner in comparison with a saw process, so that the danger of breaking during sectioning is decreased. The separating method, therefore, enables a particularly high manufacturing stability for the production of the substrate chips.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows a plasma etching system.
FIG. 2 shows a top view of a substrate wafer.
FIG. 3 shows a detail of the substrate wafer according to FIG. 2 .
FIG. 4 shows a cross-section of the substrate wafer according to FIG. 2 .
FIG. 5 shows a detail of the substrate wafer according to FIG. 4 in a pre-sectioning state.
FIG. 6 shows a detail according to FIG. 5 in a post-sectioning state.
FIGS. 7 a - 7 d each show a top view of a plurality of substrate chips.
DETAILED DESCRIPTION
Identical parts are provided with the same reference numerals in all of the figures.
Plasma etching system 1 according to FIG. 1 includes an etching chamber 2 designed as a vacuum chamber whose interior can be forced via a pump system 4 connected into a suction line 3 into a state of preselectable pressure that is low in relation to the external space. Arranged in etching chamber 2 is a substrate holder 5 on which a substrate wafer 6 can be attached for further processing. Furthermore, a microwave generator 8 is situated in etching chamber 2 . A gas line 10 for supplying a working gas A, whose flow rate can be adjusted via a control valve 12 , is connected to etching chamber 2 . In the exemplary embodiment, a mixture of sulfur hexafluoride (SF 6 ) and argon (Ar) is provided as working gas A or etching gas. However, another suitable working gas can also be used. Control valve 12 is connected on the incoming side via a data line 14 to a control device 16 to which microwave generator 8 is also connected. In addition, the electrical potential of substrate holder 5 can be set in relation to the ambient potential, and particularly in relation to the electrical potential of etching chamber 2 , in the form of an acceleration voltage U via control device 16 and a line 18 connected thereto.
Plasma etching system 1 is designed as a deep patterning method for implementing a plasma etching method. To implement the plasma etching method, the object to be etched is placed on substrate holder 5 . After completing the evacuation of etching chamber 2 , i.e., after setting, in etching chamber 2 , a maximum background pressure predefined, for example, by requirements for maintaining purity, working gas A is supplied as an etching gas via gas line 10 . In this context, working gas A is supplied via control valve 12 under fine adjustment monitored by control device 16 until a pressure level necessary for implementing the deep patterning is reached in etching chamber 2 .
To implement the actual etching process, energy is supplied in the form of microwaves to etching or working gas A via microwave generator 8 . As a result, working gas A is partially ionized and, thus, forms a plasma or etching plasma. Part of the thereby produced plasma ions, e.g., the positively charged cations, are then accelerated by acceleration voltage U toward substrate holder 5 and, thus, toward the object to be etched which is fastened thereto and impinge in the case of a corresponding assembly of substrate holder 5 in an almost vertical direction upon the surface of the object to be etched. In response to the impingement, the ions accelerated in the plasma chemically react with the material of the substrate wafer, volatile reaction products being produced, and the material of the substrate wafer being locally dissolved. Furthermore, they knock off debris from the surface of the object, thereby employing an etching operation. In response to the surface areas of the object that are not to be etched being suitably covered, this process is restricted to the surface areas to be etched. In this context, the etch rate, i.e., the thickness of the surface layer removed per time unit from the object to be etched, can be influenced by control device 16 as a result of regulating actions on the operating parameters, supply rate of working gas A into etching chamber 2 , pressure of the plasma or working gas A in etching chamber 2 , acceleration voltage U, and/or power input supplied via microwave generator 8 into the plasma.
The plasma etching system 1 designed as a deep patterning method for carrying out the plasma etching method is provided within the framework of a method for producing, among other things, substrate chips 20 carrying electronic components 19 to be used for sectioning substrate wafer 6 into a plurality of substrate chips 20 . For reasons of production engineering, it is provided in the manufacture of components 19 that the necessary material layers be deposited on a shared substrate wafer 6 , as shown from a top view in FIG. 2 and in greater detail in FIG. 3, according to conventional methods, in a succession of coating steps and patterning steps for a plurality of components 19 . After depositing the material layers for components 19 , it is provided that substrate wafer 6 be sectioned into a plurality of substrate chips 20 , each of which supports a component 19 . In this context, in the example according to FIGS. 2 and 3, separating lines 24 between substrate chips 20 can run in a rectangular pattern. In this instance, components 19 are positioned on substrate wafer 6 under consideration of the process parameters for the later sectioning among other things. In particular, width b of separating lines 24 to be considered in this context for the sectioning is taken into account.
A cross section of a substrate wafer 6 , which is already coated with the material for components 19 and is already prepared for sectioning, and a cross section of an enlarged detail of the substrate wafer is shown in FIG. 5 . Components 19 made of a plurality of material layers are deposited on substrate wafer 6 . The lateral spaces between components 19 are provided for accommodating separating lines 24 , which result from the subsequent sectioning. Test patterns 26 enabling a check of the maintenance of predefined directional quantities in an intermediate step of the entire production process can also be provided According their arrangement on substrate wafer 6 , test patterns 26 can be situated in the region of a separating line 24 and can be lost during sectioning or can, however, also be situated outside of separating lines 24 and, thus, retained even after sectioning.
Substrate wafer 6 according to FIGS. 4, 5 is mounted or laminated on a carrier film 28 , which is fixed in a frame 30 . In this context, frame 30 is designed as a metal frame in the exemplary embodiment. However, a plastic frame can also be provided. Every component 19 is covered by an etching mask 32 . In the exemplary embodiment, a coating of silicon dioxide (SiO 2 ) is applied in each case as etching mask 32 . Alternatively, another suitable etching mask can also be provided, e.g. a coating of Si 3 N 4 , nitride, polyamide, or photoresist. In the exemplary embodiment, etching masks 32 are applied by chemical vapor deposition (CVD) and subsequently patterned. Alternatively, another suitable coating method can also be used.
As is particularly recognizable in FIG. 5, etching masks 32 have a cut-out in a central region 34 , over every component 19 . Situated under this cut-out is a contact surface 36 , which allows the respective components 19 to be contacted in a later phase. These contact surfaces 36 , also called bond pads, are particularly designed for contacting by bonds. Etching masks 32 are laterally dimensioned in such a manner that a region 38 between two respective components 19 remains uncovered.
The substrate wafer 6 prepared in such a manner is attached for sectioning to substrate holder 5 and situated within etching chamber 2 . The deep patterning method, which represents a selective deep patterning method for silicon especially due to the use of a working gas A containing silicon hexafluoride, is implemented for sectioning the wafer into substrate chips 20 . In this context, those regions 38 are etched in which the silicon forming substrate wafer 6 is exposed to the etching plasma formed by working gas A. However, no etching occurs in those regions in which etching masks 32 are present. Due to the characteristic properties of this method, it has a driving direction, also referred to as anisotropy, mainly directed into the depth of substrate wafer 6 . In addition, all of the separating lines 24 provided on the surface of substrate wafer 6 can be simultaneously processed in a single operation. In response to the etching step being implemented, the plasma pressure, the plasma power, and acceleration voltage U are adjusted in such a manner that the result is an etch rate between 5 and 50 μ/min.
During the etching operation, an etching step and a polymerization step are carried out in an alternating manner. In each polymerization step, a polymerization mixture is let into etching chamber 2 . In the exemplary embodiment, a polymerization mixture of trifluoromethane (CH F 3 ) and argon (Ar) is provided. Alternatively, another suitable mixture based on perfluorinated aromatics having suitable side groups, such as perfluorinated, styrene-like monomers or ether-like fluoro compounds, can also be used. In this context, the polymerization mixture has a gas flow of 0 to 100 standard cm 3 and a process pressure of 0.01 to 0.1 mbar.
During the respective polymerization steps, the surfaces cleared in the previous etching step, i.e., particularly the surfaces of regions 38 as well as their lateral surfaces, are uniformly covered with a polymer. This polymer layer forms an effective, provisional etch stop for the subsequent etching step. In the following etching step, the polymer is removed again, the polymer from the surface of regions 38 being deposited in the immediate vicinity, i.e., on the lateral surfaces or the etching edge, thereby protecting them. This additional protection of the edges increases the already present, desired anisotropy of the actual etching step.
After the etching operation is completed, separating lines 24 form in the regions not covered by etching masks 32 , as shown in FIG. 6 . In these lines, the silicon of substrate wafer 6 is completely removed; the etching operation is first stopped on the boundary surface to carrier film 28 . Thus, substrate wafer 6 is completely sectioned into substrate chips 20 . The lateral expansion of separating lines 24 can be restricted to a width b of about 2 μm. In comparison, when sectioning substrate wafer 6 into substrate chips 20 , a saw process results in separating lines 24 having a width of approximately 50 to 100 μm, so that in this case, only a correspondingly reduced overall surface is available for attaching components 19 to substrate wafer 6 .
In this method, the form and adjustable pattern of separating lines 24 on the surface of substrate wafer 6 are independent of the crystal directions of substrate wafer 6 , and the material of substrate wafer 6 can be removed independently of the lateral position. As a result, the method permits the manufacture of substrate chips 20 having diverse designs, a few of which are shown in FIGS. 7 a - 7 d , for example.
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A method for sectioning a substrate wafer into a plurality of substrate chips enables a process management that is particularly timesaving and flexible with respect to the producible surface areas of the substrate chips. For this purpose, the substrate chips are separated from one another by a selective deep patterning method, a plasma etching method in particular.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 13/806,325, filed Dec. 21, 2012, which is a U.S. National Phase Application pursuant to 35 U.S.C. §371 of International Application No. PCT/EP2011/060507 filed Jun. 22, 2011, which claims priority to European Patent Application No. 10167495.0 filed Jun. 28, 2010, European Patent Application No. 10167500.7 filed Jun. 28, 2010, and European Patent Application No. 10187528.4 filed Oct. 14, 2010. The entire disclosure contents of these applications are herewith incorporated by reference into the present application.
TECHNICAL FIELD
[0002] The invention relates to an auto-injector for administering a dose of a liquid medicament.
BACKGROUND
[0003] Administering an injection is a process which presents a number of risks and challenges for users and healthcare professionals, both mental and physical.
[0004] Injection devices (i.e. devices capable of delivering medicaments from a medication container) typically fall into two categories—manual devices and auto-injectors.
[0005] In a manual device—the user must provide the mechanical energy to drive the fluid through the needle. This is typically done by some form of button/plunger that has to be continuously pressed by the user during the injection. There are numerous disadvantages to the user from this approach. If the user stops pressing the button/plunger then the injection will also stop. This means that the user can deliver an underdose if the device is not used properly (i.e. the plunger is not fully pressed to its end position). Injection forces may be too high for the user, in particular if the patient is elderly or has dexterity problems.
[0006] The extension of the button/plunger may be too great. Thus it can be inconvenient for the user to reach a fully extended button. The combination of injection force and button extension can cause trembling/shaking of the hand which in turn increases discomfort as the inserted needle moves.
[0007] Auto-injector devices aim to make self-administration of injected therapies easier for patients. Current therapies delivered by means of self-administered injections include drugs for diabetes (both insulin and newer GLP-1 class drugs), migraine, hormone therapies, anticoagulants etc.
[0008] Auto-injectors are devices which completely or partially replace activities involved in parenteral drug delivery from standard syringes. These activities may include removal of a protective syringe cap, insertion of a needle into a patient's skin, injection of the medicament, removal of the needle, shielding of the needle and preventing reuse of the device. This overcomes many of the disadvantages of manual devices. Injection forces/button extension, hand-shaking and the likelihood of delivering an incomplete dose are reduced. Triggering may be performed by numerous means, for example a trigger button or the action of the needle reaching its injection depth. In some devices the energy to deliver the fluid is provided by a spring.
[0009] US 2002/0095120 A1 discloses an automatic injection device which automatically injects a pre-measured quantity of fluid medicine when a tension spring is released. The tension spring moves an ampoule and the injection needle from a storage position to a deployed position when it is released. The content of the ampoule is thereafter expelled by the tension spring forcing a piston forward inside the ampoule. After the fluid medicine has been injected, torsion stored in the tension spring is released and the injection needle is automatically retracted back to its original storage position.
[0010] The post published European Patent Application No. 092908482 discloses an auto-injector for administering a dose of a liquid medicament, comprising:
an elongate housing arranged to contain a syringe with a hollow needle and a stopper for sealing the syringe and displacing the medicament, the housing having a distal end and a proximal end with an orifice intended to be applied against an injection site, wherein the syringe is slidably arranged with respect to the housing, spring means capable of, upon activation: pushing the needle from a covered position inside the housing into an advanced position through the orifice and past the proximal end, operating the syringe to supply the dose of medicament, and retracting the syringe with the needle into the covered position after delivering the medicament, activating means arranged to lock the spring means in a pressurized state prior to manual operation and capable of, upon manual operation, releasing the spring means for injection,
[0017] The spring means is a single compression spring arranged to be grounded at a distal end in the housing for advancing the needle and for injecting the dose of medicament via a plunger and wherein the compression spring is arranged to have its ground in the housing switched to its proximal end for retracting the syringe.
SUMMARY
[0018] It is an object of the present invention to provide an auto-injector with simplified handling.
[0019] The object is achieved by an auto-injector according to claim 1 .
[0020] Preferred embodiments of the invention are given in the dependent claims.
[0021] In the context of this specification the term proximal refers to the direction pointing towards the patient during an injection while the term distal refers to the opposite direction pointing away from the patient.
[0022] According to the invention an auto-injector for administering a dose of a liquid medicament comprises:
an elongate main body arranged to contain a syringe with a hollow needle and a stopper for sealing the syringe and displacing the medicament, the main body having a distal end and a proximal end with an orifice intended to be applied against an injection site, wherein the syringe is slidably arranged with respect to the main body, spring means capable of, upon activation: pushing the needle from a covered position inside the main body into an advanced position through the orifice and past the proximal end, operating the syringe to supply the dose of medicament, and retracting the syringe with the needle into the covered position after delivering the medicament, activating means arranged to lock the spring means in a pressurized state prior to manual operation and capable of, upon manual operation, releasing the spring means for injection.
[0029] According to the invention the spring means is a single drive spring in the shape of a compression spring arranged to be grounded at a distal end in the main body for advancing the needle and for injecting the dose of medicament. The force of the drive spring is forwarded to the needle and/or the syringe via a plunger. The drive spring is arranged to have its ground in the main body switched to its proximal end for retracting the syringe when the injection of the medicament is at least nearly finished.
[0030] The single drive spring is used for inserting the needle, fully emptying the syringe and retracting the syringe and needle to a safe position after injection. Thus a second spring for withdrawing the syringe and needle, which is a motion with an opposite sense compared to advancing the syringe and injecting the dose, is not required. While the distal end of the drive spring is grounded the proximal end moves the syringe forward for inserting the needle and carries on to the injection by pushing on the stopper. When the injection is at least nearly finished the drive spring bottoms out at its proximal end, resulting in the proximal end being grounded in the main body. At the same time the distal end of the drive spring is released from its ground in the main body. The drive spring is now pulling the syringe in the opposite direction.
[0031] According to the invention the activating means comprises a trigger button in the shape of a wrap-over sleeve button arranged over the distal end of the auto-injector. The trigger button extends at least almost over the whole length of the auto-injector. The trigger button is arranged to release the drive spring upon translation in proximal direction. In order to trigger an injection the auto-injector has to be pressed against an injection site, e.g. a patient's skin. A user, e.g. the patient or a caregiver, grabs the wrap-over sleeve button with their whole hand and pushes against the injection site. Consequently, the trigger button translates in proximal direction and releases the drive spring for starting the injection cycle. The auto-injector according to the invention is particularly well suited for people with dexterity problems since, as opposed to conventional art auto-injectors, triggering does not require operation of small buttons by single fingers. Instead, the whole hand is used.
[0032] The auto-injector according to the invention has a particularly low part count compared to most conventional auto-injectors. The use of just one drive spring reduces the amount of metal needed and thus consequently reduces weight and manufacturing costs.
[0033] In one embodiment of the auto-injector at least one clip is arranged in the main body. The clip is arranged to lock the drive spring in the as delivered configuration. Furthermore, the clip is arranged to be unlocked under load of the drive spring by flexing outwards. The sleeve of the trigger button has a locking section with a reduced diameter arranged to prevent the clip from flexing outwards in the as delivered configuration, i.e. when the trigger button is not pushed. When the trigger button and the locking section are translated in proximal direction by being pushed onto the injection site the clip comes clear of the locking section and may now flex outwards under load of the drive spring thus releasing the drive spring for the injection. The clip and/or a component under load of the drive spring may have ramps for flexing the clip outwards.
[0034] In a preferred embodiment an interlock sleeve is telescoped with the proximal end of the main body, the interlock sleeve translatable in longitudinal direction between a proximal position and a distal position and biased in proximal direction in a manner to protrude from the main body in the proximal position, wherein in its proximal position the interlock sleeve is arranged to prevent translation of the syringe in proximal direction from its retracted position with respect to the main body and wherein the interlock sleeve in its distal position is arranged to allow translation of the syringe in proximal direction.
[0035] In the delivered state of the auto-injector the interlock sleeve is in its proximal position protruding from the proximal end of the main body. The syringe and needle are in their retracted position. In order to trigger an injection the auto-injector has to be pressed with its proximal end, i.e. the interlock sleeve against the injection site in a manner to translate the interlock sleeve in distal direction into the main body. Thus the syringe is unlocked from the main body may now translate so as to move the needle into its advanced position for piercing the patient's skin. Before the syringe and needle actually translate in proximal direction the activating means, i.e. the wrap-over sleeve trigger button has to be operated so as to release the drive spring. Both actions translating the interlock sleeve in distal direction and translating the trigger button in proximal direction require the user to grab the trigger button and press the auto-injector against the injection site. In order to ensure, that the interlock sleeve translates before the trigger button, the interlock sleeve may have a weaker spring means for biasing it than the trigger button. These two translations appear to the user like a two step translation with an increase in force between the steps.
[0036] In another preferred embodiment at least one resilient second clip is arranged on the main body. The second clip is biased so as to block the trigger button from being translated in proximal direction when the second clip is relaxed. In its distal position the interlock sleeve is arranged to push the clip against its bias so as to decouple it from the trigger button thus allowing translation of the trigger button in proximal direction. This embodiment ensures a sequenced operation with a higher reliability than the two differently strong spring means. The interlock sleeve has always to be translated into its distal position before the trigger button is unlocked.
[0037] It is desirable to trigger the retraction of the needle when the contents of the syringe have been entirely delivered to the patient, i.e. when the stopper has bottomed out in the syringe. Automatically triggering the retraction when the stopper exactly reaches the end of its travel is a problem due to tolerances when manufacturing the syringe and stopper. Due to these tolerances the position of the stopper at the end of its travel relative to the means triggering retraction is not repeatable. Consequently, in some cases the stopper would prematurely bottom out so the retraction would not be triggered at all. In other cases the retraction would be triggered before the stopper bottomed so residual medicament would remain in the syringe.
[0038] The retraction could automatically be triggered a certain amount of time or travel before the stopper bottoms out in the syringe. However this reliable retraction would be traded off for residual medicament in the syringe.
[0039] Thus, in a preferred embodiment the interlock sleeve is furthermore arranged to prevent release of the distal ground of the drive spring when in the distal position. This means, the drive spring remains distally grounded as long as the auto-injector is kept pressed against the injection site so the needle retraction can only start when the auto-injector is removed from the injection site and the interlock sleeve consequently returns into its proximal position and thus releases the distal ground. Full delivery of the medicament and reliable refraction are thus achieved by waiting for the user action of removing the auto-injector from the injection site.
[0040] A retraction sleeve may be axially movable arranged in the main body, wherein the drive spring is arranged inside the retraction sleeve with its distal end bearing against a distal end face and with its proximal end bearing against a thrust face of a decoupling member. At least one resilient wedge may be arranged at the proximal end of the retraction sleeve, wherein the main body has a respective recess for accommodating the resilient wedge when the retraction sleeve is in its proximal position. The interlock sleeve in its distal position may be arranged to support the resilient wedge from inside so as to prevent it from translating in distal direction. Thus, when the interlock sleeve is pressed against the injection site, the retraction sleeve is kept from retracting. Only after removal of the auto-injector from the injection site and consequent translation of the interlock sleeve into its proximal position the retraction sleeve may translate in distal direction and retract the needle into the main body.
[0041] A tubular syringe carrier may be arranged for holding the syringe and supporting it at its proximal end. Supporting the syringe at the proximal end is preferred over support at the finger flanges since the finger flanges are more frangible under load while the proximal or front end of the syringe is more robust. The syringe and the syringe carrier are arranged for joint axial translation. The syringe carrier is telescoped in the interlock sleeve, wherein at least one resilient second latch is arranged in the main body near the proximal end. In the as delivered state the resilient second latches extend inwards in a manner to prevent the syringe carrier from translating in proximal direction. The resilient second latches are arranged to be disengaged from the syringe carrier upon translation of the interlock sleeve in distal direction.
[0042] In a preferred embodiment at least one latch is provided for axially fixing the retraction sleeve in a maximum proximal position. The decoupling member is arranged to decouple the latch when being moved in proximal direction nearly into a maximum proximal position. When decoupled, the retraction sleeve is allowed to move in distal direction and retract the needle by means of the spring force which is no longer grounded at its distal end. Thus, retraction can only occur if the latches have been released and if the auto-injector has been removed from the injection site.
[0043] Preferably the plunger is arranged for pushing the syringe and/or the stopper in proximal direction. At least one, but preferably two or more resilient decoupling arms are arranged at the decoupling member. The decoupling arms exhibit inner ramped surfaces bearing against a first shoulder of the plunger in proximal direction. The resilient decoupling arms are supportable by an inner wall of the retraction sleeve in order to prevent the decoupling arms from being flexed outward and slip past the first shoulder. In this state the plunger may be pushed in proximal direction by the decoupling member pushing against the first shoulder in order to insert the needle and inject the dose. At least one aperture is arranged in the retraction sleeve allowing the decoupling arms to be flexed outward by the first shoulder thus allowing the first shoulder to slip through the decoupling arms in proximal direction. This may happen when the injection is at least nearly finished. The decoupled plunger allows the syringe and needle to be retracted since it is no longer bearing against the decoupling member.
[0044] The syringe may be arranged for joint axial movement with a syringe holder which is slidably arranged in the retraction sleeve. The syringe holder is provided with at least one, but preferably two or more resilient syringe holder arms arranged distally, the syringe holder arms having a respective inclined surface for bearing against a second shoulder, which is arranged at the plunger proximally from the first shoulder. The syringe holder arms are supportable by an inner surface of the main body in order to prevent them from being flexed outward. Thus, when the trigger button is pressed the spring force forwarded by the plunger does not yet press against the stopper but against the syringe for forwarding it. Consequently, a so called wet injection is avoided, i.e. the liquid medicament is not leaking out of the hollow needle before the needle is inserted. A widened portion is provided in the main body for allowing the syringe holder arms to flex outwards when the syringe holder has nearly reached a maximum proximal position thus allowing the second shoulder to slip through the syringe holder arms and to switch load of the drive spring from the syringe to the stopper. This allows for defining the moment to start injecting the medicament.
[0045] Usually the hollow needle is equipped with a protective needle shield for keeping the needle sterile and preventing it from being mechanically damaged. The protective needle shield is attached to the needle when the auto-injector or the syringe is assembled.
[0046] Preferably a cap is provided at the proximal end of the main body. A sheet metal clip is attached to the cap for joint axial movement and independent rotation. The sheet metal clip is arranged to extend through an orifice into the interlock sleeve when the cap is attached to the interlock sleeve. The sheet metal clip incorporates at least two barbs snapped into a circumferential notch or behind a shoulder of the protective needle shield. This allows for automatically engaging the sheet metal clip with the protective needle shield during assembly. When the cap is removed from the interlock sleeve in preparation of an injection the protective needle shield is reliably removed without exposing the user too high a risk to injure themselves.
[0047] The cap may be attachable to the main body by a screw connection. This allows for a low force removal of the protective needle shield.
[0048] The aperture in the retraction sleeve may extend at least almost to the position of the decoupling arms in the as delivered state up to their position at the end of dose. The aperture may be arranged to be angularly misaligned with respect to the decoupling arm when the retraction sleeve is in its proximal position so the plunger does not decouple from the decoupling member. The aperture and the refraction sleeve are also arranged to rotate so as to align the aperture with the decoupling arms upon translation of the refraction sleeve out of the proximal position in distal direction so the plunger and decoupling member decouple from each other thus allowing retraction of the plunger, stopper syringe and needle. This embodiment allows for starting the retraction at any point of the injection cycle.
[0049] The rotation into the aligned position may be achieved by a cam track arranged in the main body and a cam follower in the retraction sleeve. The cam track may be essentially parallel to a longitudinal axis of the auto-injector with a short angled section at its proximal end.
[0050] Alternatively the cam track may be arranged in the retraction sleeve and the cam follower in the main body.
[0051] The auto-injector may have at least one viewing window for inspecting the syringe.
[0052] The auto-injector may preferably be used for subcutaneous or intra-muscular injection, particularly for delivering one of an analgetic, an anticoagulant, insulin, an insulin derivate, heparin, Lovenox, a vaccine, a growth hormone, a peptide hormone, a proteine, antibodies and complex carbohydrates.
[0053] The cap with the sheet metal spring may also be applied with other auto-injectors and injection devices.
[0054] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE FIGURES
[0055] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:
[0056] FIG. 1A are is a longitudinal section of an auto-injector with a single drive spring for advancing a syringe with a needle, injecting a dose of medicament and retracting the syringe and needle, the auto-injector as-delivered,
[0057] FIG. 1B illustrates the device of FIG. 1A where the longitudinal section shown is rotated approximately 90°,
[0058] FIG. 2A is a longitudinal section of the auto-injector with a skin interlock shroud pressed against an injection site, and
[0059] FIG. 2B illustrates the device of FIG. 2A where the longitudinal section shown is rotated approximately 90°
[0060] Corresponding parts are marked with the same reference symbols in all figures.
DETAILED DESCRIPTION
[0061] FIGS. 1A and 1B shows two longitudinal sections in different section planes of an auto-injector 1 , the different section planes approximately 90° rotated to each other. The auto-injector 1 comprises an elongate main body 2 . A syringe 3 , e.g. a Hypak syringe, with a hollow needle 4 is arranged in a proximal part of the auto-injector 1 . When the auto-injector 1 or the syringe 3 is assembled a protective needle shield may be attached to the needle (not illustrated). A stopper 6 is arranged for sealing the syringe 3 distally and for displacing a liquid medicament M through the hollow needle 4 . The syringe 3 is held in a tubular syringe carrier 7 and supported at its proximal end therein. A single drive spring 8 in the shape of a compression spring is arranged in a distal part of the auto-injector 1 . A plunger 9 is arranged for forwarding the spring force of the drive spring 8 .
[0062] Inside the main body 2 a retraction sleeve 10 is slidably arranged. Before the injection is triggered the retraction sleeve 10 is in a maximum proximal position and prevented from moving in distal direction D by means of stops 11 caught behind latches 12 in the main body 2 . A distal end of the drive spring 8 bears against an end face 13 of the retraction sleeve 10 . Due to the stops 11 and latches 12 the force of the drive spring 8 is reacted into the main body 2 . The proximal end of the drive spring 8 bears against a decoupling member 14 arranged around the plunger 9 .
[0063] The decoupling member 14 comprises a thrust face 17 for bearing against a proximal end of the drive spring 8 . Proximally from the thrust face 17 two or more resilient decoupling arms 18 are provided at the decoupling member 14 , the decoupling arms 18 having inner ramped surfaces bearing against a first shoulder 19 in the plunger 9 in proximal direction P. The resilient decoupling arms 18 are supported by an inner wall of the retraction sleeve 10 in this situation so they cannot flex outward and slip past the first shoulder 19 . In the as delivered configuration the decoupling member 14 is latched to the main body 2 by resilient first clips 2 . 1 .
[0064] A trigger button 20 is arranged in the shape of a wrap-over sleeve button over the distal end D of the auto-injector 1 extending almost over the whole length of the auto-injector 1 . The sleeve part of the trigger button 20 has a locking section 20 . 1 with a reduced diameter arranged to keep the clips 2 . 1 from flexing outwards in the as delivered configuration shown in FIG. 1B . Thus the decoupling member 14 is prevented from translating in proximal direction P.
[0065] The syringe carrier 7 is engaged for joint axial movement with a syringe holder 22 which is slidably arranged in the retraction sleeve 10 . The syringe holder 22 is provided with two or more resilient syringe holder arms 23 arranged distally. The syringe holder arms 23 have a respective inclined surface for bearing against a second shoulder 24 in the plunger 9 arranged proximally from the first shoulder 19 . In the initial position shown in FIG. 1B the syringe holder arms 23 are supported by an inner surface of the main body 2 so they cannot flex outward and the second shoulder 24 cannot slip through. In order to support the syringe holder arms 23 at the main body 2 a respective number of apertures are provided in the retraction sleeve 10 .
[0066] Two resilient clips 10 . 1 are arranged at a proximal end of the retraction sleeve 10 . The main body 2 has two apertures arranged to accommodate the resilient clips 10 . 1 when the retraction sleeve 10 is in its proximal position.
[0067] A skin interlock sleeve 25 is arranged at the proximal end P. The skin interlock sleeve 25 has an outer wall 25 . 1 and an inner wall 25 . 2 with a space between them. The outer wall 25 . 1 and the inner wall 25 . 2 are connected to each other at the proximal end P by a front face 25 . 3 of the interlock sleeve 25 . An inner wall portion 25 . 2 . 1 is telescoped in the main body 2 (see FIG. 1A ). Another inner wall portion 25 . 2 . 2 is telescoped outside the main body 2 . The outer wall 25 . 1 is telescoped in the wrap-over trigger button 20 . An interlock spring 26 for biasing the interlock sleeve 25 in proximal direction P is hidden in the space between the inner wall 25 . 2 and the outer wall 25 . 1 . The syringe carrier 7 is telescoped in the inner wall 25 . 2 of the interlock sleeve 25 .
[0068] Two resilient second latches 27 are arranged in the main body 2 near the proximal end P. In the state as delivered the second latches 27 are relaxed and extend inwardly through respective apertures 25 . 4 in the interlock sleeve 25 in a manner to prevent the syringe carrier 7 from translating in proximal direction P by the syringe carrier 7 abutting against respective distal faces 27 . 1 of the second latches 27 . The syringe carrier 7 , the syringe 3 and the needle 4 can therefore not be forwarded when pushed by the plunger 9 . Two outwardly biased resilient second clips 2 . 2 are arranged on the main body 2 distally from the resilient second latches 27 . In the as delivered configuration the resilient second clips 2 . 2 are relaxed and extend outwardly in a manner to prevent the trigger button 20 from being translated in proximal direction P.
[0069] In order to start an injection the auto-injector 1 has to be pressed against the injection site, e.g. a patient's skin. For this purpose the auto-injector 1 is held by a caregiver or by the patient at the trigger button 20 which cannot translate relative to the main body 2 due to the clip 2 . 2 . Instead the interlock sleeve 25 translates in distal direction D into the main body 2 (see FIGS. 2A & 2B ). A proximal edge of the aperture 25 . 1 pushes against a proximal ramp 27 . 2 of the second latch 27 thereby flexing the second latch 27 outwards so the syringe carrier 7 comes clear of the distal faces 27 . 1 and may now translate in proximal direction P. At the same time a distal end of the inner wall portion 25 . 2 . 2 pushes the clip 2 . 2 inwards (see FIG. 2B ) in a manner to allow the trigger button 20 to translate with respect to the main body 2 .
[0070] When translated into the main body 2 as in FIG. 2A distal end of the inner wall 25 . 2 of the interlock sleeve 25 supports the resilient wedges 10 . 1 from inside so they cannot be flexed inwards thus preventing the retraction sleeve 10 from translating in distal direction D.
[0071] If the auto-injector 1 is removed from the injection site at this stage without further pushing the trigger button 20 the interlock sleeve 25 will translate back into its proximal position under load of the interlock spring 26 . The second latches 27 will flex inwards and block the syringe carrier 7 so the auto-injector 1 is in its as delivered state again. The clip 2 . 2 comes clear of the inner wall portion 25 . 2 . 2 and flexes outwards again thus blocking the trigger button 20 from translating in proximal direction P with respect to the main body 2 .
[0072] If the pressure on the trigger button 20 in proximal direction P is continued, the trigger button translates in proximal direction P thus moving the locking section 20 . 1 into a position allowing the first clips 2 . 1 to flex outwards. This occurs by the decoupling member 14 sliding along ramps of the clips 2 . 1 under load of the drive spring 8 . As the trigger button 20 approaches the end of travel it gets locked by engagement of catches 2 . 4 on the main body 2 and catches 20 . 2 on the trigger button 20 so it cannot translate back in distal direction D from this point. This prevents the main body 2 from floating inside the trigger button 20 during injection. Although the catches 20 . 2 and 2 . 4 are arranged near the distal end D the may likewise be arranged anywhere along the length of the sleeve of the trigger button 20 .
[0073] FIGS. 2A & 2B show the auto-injector 1 with the interlock sleeve 25 pushed into the auto-injector 1 and the trigger button 20 translated in proximal direction P and locked by the catches 20 . 2 , 2 . 4 .
[0074] The second shoulder 24 pushes the syringe holder 22 , syringe carrier 7 and syringe 3 forward while no load is exerted onto the stopper 6 . The hollow needle 4 appears from the proximal end P and is inserted into the injection site, e.g. the patient's skin.
[0075] The forward movement continues until the syringe holder 22 bottoms out at a first abutment 32 in the main body 2 . The travel from the initial position up to this point defines an injection depth, i.e. needle insertion depth.
[0076] When the syringe holder 22 has nearly bottomed out the resilient syringe holder arms 23 have reached a widened portion 2 . 3 of the main body 2 where they are no longer supported by the inner wall of the main body 2 . However, since the force required to insert the needle 4 is relatively low the second shoulder 24 will continue to drive forward the syringe holder 22 until proximal travel is halted at the first abutment 32 . At this point the syringe holder arms 23 are flexed out by the continued force of the second shoulder 24 and allow it to slip through. Now the plunger 9 no longer pushes against the syringe holder 22 but against the stopper 6 for expelling the medicament M from the syringe 3 and injecting it into or through the patient's skin.
[0077] When the stopper 6 has nearly bottomed out in the syringe 3 the decoupling member 14 has reached a position where it pushes against the latches 12 in a manner to decouple the refraction sleeve 10 from the main body 2 . Thus the drive spring 8 is no longer grounded with its distal end in the main body 2 by the latches 12 so the drive spring 8 is trying to pull the retraction sleeve 10 in distal direction D.
[0078] Although the latches 12 are disengaged now, the retraction sleeve 10 may not yet slide in distal direction D because of the resilient clips 10 . 1 being kept from flexing inwards by the interlock sleeve 25 as long as the interlock sleeve 25 is in its distal position by the auto-injector 1 being kept pushed against the injection site.
[0079] If the auto-injector 1 is taken away from the injection site the interlock sleeve 25 will return to its proximal position (as in FIGS. 1 A & 1 B) under load of the interlock spring 26 so the resilient clips 10 . 1 are no longer supported from inside. Since the drive spring 8 tries to pull the retraction sleeve 10 in distal direction D, distal ramps of the resilient clips 10 . 1 move along proximal edges of the recesses in the main body 2 thereby flexing the resilient clips 10 . 1 inwards as the retraction sleeve 10 starts translating in distal direction D. The retraction sleeve 10 moves to a point where the decoupling arms 18 reach an aperture 34 in the retraction sleeve 10 so they are no longer kept from being flexed outward. The decoupling arms 18 are thus pushed outward by the first shoulder 19 pushing against its ramped surfaces so the first shoulder 19 can slip through in distal direction D. The decoupling member 14 can move a small distance further in proximal direction P in order to bottom out at a second abutment 33 and give ground to the drive spring 8 at its proximal end in the main body 2 .
[0080] The retraction sleeve 10 , still moving in distal direction D catches the syringe holder 22 with its front face 35 and takes it along in distal direction D. Thus the syringe 3 and needle 4 are retracted into a safe position inside the main body 2 , e.g. into the initial position. The plunger 9 , no longer bearing against the decoupling arms 18 is pulled back too.
[0081] The latches 12 and the stops 11 at the retraction sleeve 10 are not absolutely required. Retraction can be triggered by removal of the auto-injector 1 from the injection site alone. However, in the as delivered state, the stops 11 and latches 12 are part of a loop statically resolving the load of the drive spring 8 , the loop comprising the decoupling member 14 , the clips 2 . 1 , the main body 2 , the latches 12 , the stops 11 and the retraction sleeve 10 . Hence, in the as delivered state no load is exerted on the plunger 9 .
[0082] If the auto-injector 1 is removed from the injection site prematurely, i.e. before the stopper 6 has bottomed out in the syringe 3 , the retraction will start only when the syringe 3 is emptied. Despite the fact that the retraction sleeve 10 is released by the interlock sleeve 25 returning into its proximal position the decoupling member 14 and the plunger 9 have not yet reached the point where the decoupling arms 18 meet the aperture 34 of the retraction sleeve 10 . Hence, the plunger 9 is still under load of the drive spring 8 and continues emptying the syringe 3 . However, as the retracting sleeve 10 is released it starts translating in distal direction D and fills the gap between the front face 35 and the syringe holder 22 . The actual retraction does not occur until the decoupling member 14 has bottomed out on the second abutment 33 thus giving ground to the proximal end of the drive spring 8 . In the mean time the load of the drive spring 8 is resolved in a sub assembly loop consisting of the proximal end of the drive spring 8 pushing against the decoupling member 14 , the plunger 9 , the stopper 6 , the syringe 3 , the syringe carrier 7 , the syringe holder 22 and the retraction sleeve 10 being pushed against by the distal end of the drive spring 8 . In other words, this sub assembly is floating inside the auto-injector 1 while the syringe 3 is being emptied. The decoupling member 14 continues travelling in proximal direction P, releases the plunger 9 when meeting the aperture 34 and bottoms out on the second abutment 33 . Hence, the proximal end of the drive spring 8 gets grounded in the main body 2 allowing the still expanding drive spring 8 and the retraction sleeve 10 to retract the syringe holder 22 , the syringe carrier 7 , the syringe 3 and the needle 4 into a needle safe position inside the auto-injector 1 .
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An auto-injector for administering a dose of a liquid medicament (M) is presented comprising an elongate housing arranged to contain a syringe with a hollow needle and a stopper for sealing the syringe and displacing the medicament (M), the housing having a distal end (D) and a proximal end (P) with an orifice intended to be applied against an injection site, wherein the syringe is slidably arranged with respect to the housing. The auto-injector contains a spring means capable of, upon activation, pushing the needle from a covered position inside the housing into an advanced position through the orifice and past the proximal end (P), operating the syringe to supply the dose of medicament (M), and retracting the syringe with the needle into the covered position after delivering the medicament (M). There is also an activating means arranged to lock the spring means in a pressurized state prior to manual operation.
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BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
The present invention relates to a metal laminate gasket for an internal combustion engine with an engaging device, such as a cylinder head gasket and a manifold gasket, which can be securely attached to dowels or bolts on an engine part.
When a cylinder head and a cylinder block are assembled together, the cylinder block is placed on a floor or a platform, and a gasket is placed on the cylinder block so that dowels formed on the cylinder block are located in dowel holes of the gasket. Then, the cylinder head is placed above the gasket, and the cylinder head and the cylinder block are tightened together by bolts.
In order to easily assemble the gasket on the cylinder block, the diameter or size of the dowel hole of the gasket is made slightly larger than the diameter of the dowel. Therefore, in case the cylinder block with the gasket thereon is shaken, the gasket may disengage from the cylinder block.
Especially, in a V-type engine, gasket attaching surfaces of the cylinder block incline downwardly. Therefore, even if the gaskets are installed on the gasket attaching surfaces of the cylinder block, the gaskets may disengage from the cylinder block.
Similarly, in case a manifold gasket is installed in the cylinder head having bolts for fixing a manifold to the cylinder head, the manifold gasket is placed on the cylinder head such that the bolts engage bolt holes of the manifold gasket. When the cylinder head with the manifold gasket thereon is shaken, the manifold gasket may disengage from the bolts.
In an automatic assembly line for engines, the engines are continuously or consecutively moved. In some cases, the engine parts are stopped for a while for assembly, and then moved. In the automatic assembly line, it is troublesome to check the gasket in each engine, and to install a gasket in case no gasket is placed on the engine part.
In order to solve the above problems, there had been proposed U.S. Pat. No. 5,083,801, No. 5,095,867, No. 5,096,325, No. 5,154,529 and No. 5,259,629.
In U.S. Pat. No. 5,095,867, No. 5,096,325 and No. 5,154,529, it is required to use specific dowel pins. In U.S. Pat. No. 5,083,801 and No. 5,259,624, although no specific dowel pins are required, if the gasket is shaken strongly, the gasket may still disengage from the dowel pins or bolts.
Accordingly, one object of the present invention is to provide a metal laminate gasket having an engaging device to prevent the gasket from accidentally disengaging from the engine part even if the gasket is strongly shaken.
Another object of the invention is to provide a metal laminate gasket as stated above, which can be easily installed on the engine without affecting sealing ability of the gasket.
A further object of the invention is to provide a metal laminate gasket as stated above, which can be easily and economically manufactured.
Further objects and advantages of the invention will be apparent from the following description of the invention.
SUMMARY OF THE INVENTION
In accordance with the invention, a metal laminate gasket is designed to be easily and firmly engaged with an engaging projection, such as a dowel pin and a bolt, of an engine part. Thus, the gasket can be properly positioned and immovably placed on the engine part. The gasket is not accidentally disengaged nor falls from the engine part.
The gasket is basically formed of first and second metal plates piled and connected together. The first plate includes at least one first hole formed at a portion corresponding to the engaging projection of the engine part, and at least one first engaging portion extending into the first hole.
The second plate is situated above the first plate. The second plate includes at least one second hole formed at a portion corresponding to the first hole, and at least one second engaging portion extending into the second hole.
When the first and second plates are urged against the engine part, the first and second engaging portions deform to allow the engaging projection to enter into the first and second holes, and engage the engaging projection. The first and second engaging portions are arranged vertically and independently engage the engaging projection to thereby prevent the gasket from easily disengaging from the engaging projection.
Namely, the first and second engaging portions are vertically piled or spaced from one another and are independently formed. Thus, the first and second engaging portions act independently against the engaging projection. When a lateral or vertical force is applied to the gasket, at least one of the engaging portions engages the engaging projection to thereby prevent the gasket from disengaging from the engine part.
Especially, in case the first and second plates are formed of different plates in thickness, hardness or shape, the engaging force of the engaging projections becomes different. Thus, the engaging portions surely hold the engaging projection.
In case two engaging projections situated away from each other are formed on the engine part, the gasket can be placed in a proper position on the engine part. The position of the gasket is set by the engaging projections.
Preferably, the first engaging portion is arranged angularly differently to the second engaging portion with respect to central axes of the first and second holes. Namely, the first and second engaging portions do not pile or laminate together. As a result, the first engaging portion is not affected by the second plate situated above the first plate when the gasket is properly positioned on the engine part.
The first and second plates may be connected together in a conventional method, such as welding or grommet partly covering the first and second plates. Therefore, the first and second plates do not disengage from the engine part when installed. In the gasket of the invention, one or more plate may be installed under the first plate, above the second plate or between the first and second plates to form a metal laminate gasket with three or more plates.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a part of a first embodiment of the invention for constituting a cylinder head gasket;
FIG. 2 is an enlarged perspective view of a dowel hole of the gasket of the invention;
FIG. 3 is a section view taken along a line 3--3 in FIG. 2 for showing the gasket installed on a cylinder block;
FIG. 4 is a plan view of a part of a second embodiment of the invention for constituting a manifold gasket;
FIG. 5 is an enlarged plan view of a bolt hole of the manifold gasket shown in FIG. 4; and
FIG. 6 is a section view taken along a line 6--6 in FIG. 5 for showing the manifold gasket installed on a manifold.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1-3, a first embodiment A of a metal laminate gasket of the invention is shown. The gasket A is a cylinder head gasket and is provided with a plurality of cylinder bores Hc, water holes Hw, oil holes Ho, bolt holes Hb, and positioning or dowel holes Hd, as in the conventional gasket. Since the present invention is directed to the structure of the dowel holes Hd, other structure and sealing mechanisms are not explained. Any structure and sealing mechanisms may be used.
As shown in FIG. 3, the gasket A of the invention is designed to be installed on a cylinder block J with a dowel K. The dowel K has a cylindrical form and slightly projects upwardly from an upper surface of the cylinder block J. A bolt (not shown) passes through a hole of the dowel K to connect a cylinder head (not shown) to the cylinder block J.
The gasket A comprises an upper plate A10, a middle plate A11, and a lower plate A12, which extend substantially throughout the entire area of the engine. The upper plate A10 includes a hole A10a having a diameter slightly larger than the diameter of the dowel K.
The middle plate A11 is situated under the upper plate A10 and includes a hole A11a defined by four engaging or pointed portions A11b and four non-engaging or recessed portions A11c. The distance between the pointed portions A11b facing against each other is smaller than the diameter of the dowel K. The distance between the recessed portions A11c facing against each other is greater than the diameter of the dowel K. Namely, the pointed portions A11b project into a hole for the dowel K. Thus, when the middle plate A11 is pushed over the dowel K, the pointed portions A11b are slightly bent upwardly and engage the dowel K.
The lower plate A12 is situated under the middle plate A11 and includes a hole A12a defined by four engaging or pointed portions A12b and four non-engaging or recessed portions A12c. Similar to the middle plate A11, the distance between the pointed portions A12b facing against each other is smaller than the diameter of the dowel K, while the distance between the recessed portions A12c facing against each other is greater than the diameter of the dowel K. Namely, the pointed portions A12b project into a hole for the dowel K.
The middle and lower plates A11, A12 are arranged such that the pointed portions A12b of the lower plate A12 are located under the recessed portions A11c of the middle plate A11. Namely, the pointed portions A11b, A12b are angularly shifted relative to the center of the dowel hole. Thus, when the gasket A is pushed over the dowel K, the pointed portions A12b are slightly bent upwardly to be located in the recessed portions A11c and engage the dowel K, while the pointed portions A11b are slightly bent upwardly to be located in the hole A10a of the upper plate A10 and engage the dowel K.
When the plates A10, A11, A12 are assembled, the plates A10, A11, A12 are connected together by spot welding (not shown). In case a grommet or a cover member for holding the upper and lower plates is used, the plates need not be connected together by the spot welding.
When the gasket A is installed on the cylinder block J, the gasket A is placed above the cylinder block J so that the dowel K aligns the dowel hole Hd formed of holes A10a, A11a, A12a. Then, the gasket A is strongly pushed against the cylinder block J. As a result, the pointed portions A11b, A12b are bent upwardly to allow the dowel K to enter into the hole Hd.
Since the middle plate A11 has the recessed portions A11c larger than the dowel K, when the pointed portions A12b are bent, the pointed portions A12b are urged to partly locate inside the recessed portions A11c. Also, the pointed portions A11b are slightly bent and located in the hole A10a of the upper plate A10. The pointed portions A11b do not project beyond the upper surface of the upper plate A10.
In the gasket A, the pointed portions A11b, A12b are vertically piled or spaced from each other, and are formed on the different plates. Thus, the pointed portions A11b, A12b act separately to the dowel K, so that when the gasket A is engaged with the dowel K, the gasket A is not accidentally disengaged from the cylinder block J. Especially, in case the plates A11, A12 are formed of different plates in thickness or hardness, the engaging forces of the pointed portions A11b, A12b relative to the dowel K become different. Thus, the gasket can be securely fixed to the dowel.
Generally, the two dowels are formed on the cylinder block J. When the dowels K enter into the dowel holes Hd, the gasket A does not move and is properly positioned on the cylinder block J.
FIGS. 4-6 show a second embodiment B of the gasket of the invention. The gasket B is a manifold gasket to be attached to a cylinder head L with bolts M. The gasket B is formed of a plurality of units B' for sealing around the respective holes for a manifold.
Each unit B' includes a hole Hm and bolt holes Hb1, Hb2, and is formed of an upper plate B10, a middle plate B11 and a lower plate B12, which are connected together by the spot welding S. The lower plate B12 of one unit B' is integrally connected to the adjacent lower plate B12 of another unit B' to thereby form one integral gasket B formed of several units B'. One example of the manifold gasket is disclosed in U.S. Pat. No. 4,728,110.
The upper plate B10 includes a hole B10a defined by four engaging or pointed portions B10b and four non-engaging or recessed portions B10c. The distance between the pointed portions B10b facing against each other is smaller than the diameter of the bolt M. The distance between the recessed portions B10c facing against each other is greater than the diameter of the bolt M.
The middle plate B11 is situated under the upper plate B10 and includes a hole B11a defined by four engaging or pointed portions B11b and four non-engaging or recessed portions B11c. Similar to the upper plate B10, the distance between the pointed portions B11b facing against each other is smaller than the diameter of the bolt M, while the distance between the recessed portions B11c facing against each other is greater than the diameter of the bolt M.
The lower plate B12 is located under the middle plate B11, and includes a hole B12a slightly larger than the bolt M. The holes B10a, B11a, B12a constitute the bolt hole Hb1. The bolt hole Hb2 is made of simple holes formed in the respective plates.
The upper and middle plates B10, B11 are arranged such that the pointed portions B11b of the middle plate B11 are located under the recessed portions B10c of the upper plate B10. Namely, the pointed portions B10b, B11b are angularly shifted relative to the bolt hole Hb1. Thus, when the gasket B is pushed over the bolt M, the pointed portions B10b, B11b are slightly bent upwardly, and engage the bolt M. The pointed portions B10b slightly project upwardly, while the pointed portions B11b are located inside the recessed portions B10c. The gasket B does not accidentally disengage from the cylinder head L.
When the manifold is placed on the cylinder head L and the bolt M is tightened, the pointed portions B10b projecting upwardly are bent and are substantially flattened. In this respect, an additional plate may be provided on the upper plate so that the pointed portions B10b may be located in a hole of the additional plate without projecting outwardly.
In the metal laminate gasket of the present invention, the plates are provided with holes defined by pointed and recessed portions vertically spaced from each other. When the gasket is pushed over the dowel or bolt, the pointed portions are bent to securely engage the gasket to the engine part. Since the pointed portions independently act relative to the dowel or bolt, even if the engine part is transferred in an assembly line, the gasket does not accidentally disengage from the engine part.
While the invention has been explained with reference to the specific embodiments of the invention, the explanation is illustrative, and the invention is limited only by the appended claims.
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A metal laminate gasket of the invention is engaged with an engaging projection of an engine part for immovably locating the gasket on the engine part. The gasket is basically formed of first and second metal plates laminating together. The first plate includes at least one first hole and at least one first engaging portion extending into the first hole. The second plate is situated above and connected to the first plate. The second plate includes at least one second hole and at least one second engaging portion extending into the second hole. When the gasket is urged against the engine part, the vertically spaced first and second engaging portions deform and engage the engaging projection to thereby prevent the gasket from easily disengaging from the engaging projection.
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BACKGROUND OF THE INVENTION
The invention pertains to an electrode with a plate-shaped electrode carrier for use in an electrolysis cell with a corrosion-resistant support, a spring element, a positioning element, or a flow guide element between the carrier and the cell wall, especially to an electrode of a system for the electroplating of traveling strip material, the system being provided with an electrode carrier which has a core of material with good electrical conductivity and a jacket of valve metal surrounding the core, the core being connected electrically and in a rigidly mechanical manner to external, activated electrode components.
An anode assembly with a plate-shaped anode of valve metal with an active surface for electrolytic processes is known from U.S. Pat. No. 5,135,633. This assembly is especially suitable for the deposition of metal from a metal ion-containing solution onto a substrate, which is connected to a valve metal current conductor. The current is supplied to the electrolysis cell from the outside by way of metals with good electrical conductivity such as copper, aluminum, or steel; the current is conducted to the plate-shaped anodes byway of a carrier, to which the anodes are attached. The carrier is immersed in the electrolyte and is jacketed with valve metal.
Electrodes and anode assemblies of this type are used, for example, in systems for the electroplating of strip, in which the traveling metal strip is connected as the cathode, for example, and a coating of zinc or nickel is applied. A strip coating system and a steel strip coating system such as this are known from U.S. Pat. Nos. 4,634,504 and 4,642,173.
The existing electroplating systems for strip suffer from a problem with the lateral or rear support of the electrode carrier with respect to the inside wall of the housing, the carrier being made of a core of metal with good electrical conductivity and a jacket of valve metal. For example, an electrolyte-resistant system component such as a flow guide plate, a spacer, or a spring element can strike the valve metal jacket and wear it down to such an extent that there is the danger of intrusion by the electrolyte, which can then cause damage to the core of the electrode by corrosion.
SUMMARY OF THE INVENTION
In electrode assemblies such as that described in U.S. Pat. No. 5,135,633, the invention protects the attached jacketing of valve metal from the type of mechanical damage which can be caused by, for example, the fixed and/or spring-mounted support elements or flow guide elements in the electroplating tank. For example, in existing electroplating systems, the inside surface of the cell is provided with a spring-like valve metal plate, which serves to support the anode and to guide the flow of electrolyte and which rests directly on the valve metal jacketing of the electrode.
The invention provides an electrode carrier for an electrode assembly in which the support means, the spring elements, the positioning elements, or the flow guide elements extending from the cell wall touch the valve metal jacketing around the electrode carrier in such a way that, even in the event that the fixed and/or spring-mounted support means or guide plates are made of hard alloy materials, they will be unable to cause any damage to the valve metal jacketing around the electrode carrier.
It is especially advantageous that the invention makes it possible to handle large, heavy electrode carriers in a flexible manner. The use of thermoplastic materials for the plastic components helps to damp vibrations in the electrolyte and thus helps to reduce the wear to which the thinner components such as the valve metal jacketing are subjected. In a preferred embodiment of the invention, fastening elements are designed as part of the elements used to mount the active electrode components, and the plastic bodies are attached to the side of the jacketing of the electrode carrier facing away from the electrode components.
A key advantage of this design is to be seen in that the mounting elements or threaded fasteners which are required in any case to mount the active electrode components serve additionally to hold the plastic bodies in place, so that, in practice, the overall cost for materials and labor is increased only slightly. In addition, it has also been found advantageous that the plastic bodies are easy to remove, if it should become necessary to reactivate the electrode in question.
In a further advantageous embodiment, the threaded mounting elements are provided with recesses, in which fastening elements for the plastic bodies engage; it turns out to be an advantage here that the plastic bodies can also be installed on the electrode carriers of already existing electroplating systems. It is therefore easy to convert such systems so that they can be operated under reduced-wear conditions.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows the rear surface of an electrode carrier jacketed with valve metal, to which a plastic body has been attached. The associated parts of the electrode on the front, which cannot be seen here, are used as anodes in a steel strip coating system;
FIG. 2A shows a longitudinal section through part of an electrode carrier together with the plastic body and its fastening means as well as the activated electrode parts attached to the opposite side;
FIG. 2B is a partial plan view of a plastic body with a double row of holes;
FIG. 2C is an enlarged end section along line AB of FIG. 2B;
FIG. 2D is a partial plan view of a plastic body with a single row of holes;
FIG. 2E is an enlarged end section along line CD of FIG. 2D;
FIG. 3 shows a cross section through part of an electrolysis cell together with a section of the wall of the cell container; with a portion of the electrode, connected as an anode; and with a section of the steel strip passing through container, this strip being connected as a cathode; and
FIG. 4 shows, in cross section, an exploded diagram of the various components required for the fastening of the plastic strip in their relationships to one another.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
According to FIG. 1, electrode 1 consists of a plate-shaped electrode carrier 2, which is made up of three carrier plates 3; holders 4 on both sides with side brackets 7, 8a, by means of which carrier plates 3 are held by their two side edges; and a current feed 8b. The electrode also has active electrode components, which are not visible in the figure; mounting elements 5 for the active components, these elements being on the side of electrode carrier 2 facing away from the components; and a plastic body 6, held in place by mounting elements 5 and fastening elements 9, this body being designed in the form of a plastic strip. Electrode carrier 2, i.e., carrier plates 3, consists of a base electrode frame of material with good electrical conductivity and a jacket of valve metal, preferably of titanium sheet, which protects the enclosed metal with good electrical conductivity, such as steel, from corrosion. Inside the valve metal sheathing, a shield gas such as argon or nitrogen is introduced at a slight positive pressure with respect to the out- side atmosphere. The horizontal arms of the two side brackets 7, 8a of holder 4 make it possible to hang the carrier inside the container of the electrochemical cell, and a pressurized gas connection is provided so that the space inside the jacketing of carrier plates 3 can be filled with the shield gas. In a preferred embodiment, the current is supplied through hollow conductors, so that a channel for the supply of coolant is provided. The brackets are made of glass fiber-reinforced plastic.
In the back of mounting elements 5 for the active electrode parts, a recess is provided, inside which there is a thread, which allows plastic body 6, designed as a strip, to be fastened in place. The actual fastening of plastic bodies 6 is accomplished by means of fastening screws or elements 9, which are inserted through slots 10 in the plastic body, these slots being large enough to accommodate both the changes in dimensions caused by thermal expansion and production tolerances, as explained in greater detail below on the basis of FIG. 2a.
According to FIG. 2A, carrier plate 3 of the electrode carrier consists of a base frame 11 of mechanically stable material with good electrical conductivity such as steel and a jacket applied thereon, consisting of a valve metal plate 12, to project the material of the base frame from corrosion by the electrolyte. The basic structure of an electrode assembly such as this is described in U.S. Pat. No. 5,136,633. A contact bushing 14 of valve metal, which has an inside thread 15, is welded to active electrode component 13, shown here schematically, which can thus be fastened by means of an Allen screw 16 to the electrode carrier. A threaded bushing 17 with an internal thread 18 is welded to the head of Allen screw 16. Fastening screw 9, which has the shape of a T in profile, engages in inside thread 18; this screw passes through an opening 10 in plastic body 6 designed as a plastic strip. Two recesses 19 are provided in the head of fastening screw 9 to make it easier to turn and to keep it from turning when making adjustments.
The two lateral flanks 22, 23 of plastic body 6, shown in cross-sectional profile, rest on area 34 of sheath 12 of valve metal, this area being either flat or arched as a result of internal pressure, whereas fastening element 9 engages in internal thread 18 of threaded bushing 17 welded to Allen head screw 16, with the result that wide head 21 of fastening element 9 presses the flange-like recess 25 of plastic body 6, which extends all the way to the center of opening 10, against sheath 12 of electrode carrier 2. The actual fastening of the plastic body is accomplished by using recesses 19 to turn and thus tighten the fastening element, which is designed as a threaded fastener. After the fastening operation, fastening screw 9 itself is then blocked or locked by means of a stud screw 35, which consists of valve metal and which can be turned coaxially with respect to the fastening screw. As a result, additional security is provided against the self-loosening of fastening element 9. On the basis of the cross section according to FIG. 2a, it can be seen that, after plastic body 6 has been attached, no corrosion-susceptible parts of base frame 11 are exposed to the outer electrolyte area.
The top view and the cross section according to FIGS. 2B-2E show sections of plastic bodies, one with a double row of attachment holes 10 and one with a single row of holes, which, to allow the body to slide in response to thermal expansion, are designed as slots. FIGS. 2C and 2E show the respective cross sections of the plastic strips on an enlarged scale. The design variant with a double row of attachment holes is especially suitable for plastic bodies of large format.
FIG. 3 is a schematic diagram in cross section of an electrolysis cell for galvanizing traveling strip material together with the electrode, also shown in cross section, as known from, for example, U.S. Pat. No. 4,634,504. According to FIG. 3, the back of electrode I and thus plastic body 6 are facing wall 28 of the cell for electrolysis operation, only a portion of which is shown; to maintain the proper distance between the electrode and the cell wall and to regulate the flow of electrolyte, a spring element or flow guide element 31 is provided, which extends over the entire width of the electrode and which consists of a corrosion-resistant valve metal alloy, preferably a hard titanium alloy; the spring or flow guide element also serves as a supporting or positioning element. Spring element or circulation guide element 31, which is subjected to vibrational stresses during the strip coating process, is attached to container wall 29 and rests against plastic body 6 on the rear surface of electrode 1. On the side of the electrode facing away from plastic body 6, active electrode components 13 and continuous strip 32 can be seen, the strip being connected to function as a cathode. The electrolyte is supplied in the direction opposite that in which continuous strip 32 is traveling, as indicated by arrow 33. The electrochemical system is therefore formed by active electrode components 13, which are connected as anodes, and by strip 32, which functions as the cathode. The gap with the electrolytic function extends over the distance between strip 32 and the outside surface of active electrode components 13. Steel, aluminum, copper, and their combination with jacketing 12 of titanium produced by explosive plating or by rolling techniques have proven to be especially good materials for base frame 11 of the electrode. The sheathing or jacketing is made of titanium sheet with a thickness in the range of 0.5-2 mm; the activated electrode parts and the associated fastening elements consist of titanium. Polyethylene (PE) and polypropylene (PP) have proven to be especially good materials for the plastic body.
FIG. 4 is a schematic diagram which shows a partial, exploded view of the system of components for fastening plastic body 6 and active electrode components parts 13; active electrode component 13 is welded in this case to a T-shaped flange 14, which has an internal thread 15, so that an Allen screw serving as fastening element 16 can be screwed into it. A threaded bushing 17 with an internal thread 18 is welded to the head of Allen screw 16. Fastening screw 9, which has a T-shaped profile, can be screwed into the bushing. Plastic body 6 is mounted between the plate-like flange of head 21 of fastening screw 9 and sheathing 12 of the electrode carrier; the flange of the fastening screw rests on a flange-like recess 25 in plastic body 6. To lock the components in place, a stud screw 35 is provided for fastening element 9. During the assembly procedure, this stud screw is turned in internal thread 24 inside the fastening element and thus pressed against the head surface of the Allen screw. As a result, advantage is taken of the locknut effect to lock fastening element 9 permanently in place. The locknut effect is based here on the distorting force acting on thread 24 in the reverse direction. When the head end of the stud screw is tightened against the inside surface or head 26 of Allen screw 16, distorting force is exerted on thread 24 by virtue of the torque present in the assembled state.
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An electrode for an electrochemical cell used in strip coating systems for continuous metal sheets has a plate-shaped electrode carrier, to which activated electrode components are connected mechanically in a detachable manner. The electrode carrier contains a metal core of material with good electrical conductivity, which, with the exception of the points where the activated electrode parts are connected, is surrounded by a jacketing of valve metal; on the side of the electrode carrier facing the cell wall, a corrosion- resistant plastic body in attached, against which the support means, the spring elements, the positioning elements, or the flow guide elements extending from the cell wall rest, these supports or elements thus being unable to cause any damage to the valve-metal jacketing of the electrode carrier.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 15/180,823, filed on Jun. 13, 2016; which claims priority to U.S. Provisional Application No. 62/216,038 filed Sep. 9, 2015; the disclosures of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The invention generally relates to a mixture of halophosphite conformational isomers, methods of making the mixture, hydroformylation catalysts containing the mixture, and hydroformylation processes using the catalysts.
BACKGROUND OF THE INVENTION
[0003] The hydroformylation reaction, also known as the oxo reaction, is used extensively in commercial processes for preparing aldehydes by reacting one mole of an olefin with one mole each of hydrogen and carbon monoxide. The most extensive use of the reaction is in the preparation of normal- and isobutyraldehyde from propylene.
[0004] The ratio of the amount of the normal-aldehyde product to the amount of the iso-aldehyde product typically is referred to as the normal to iso (N:I or N/I) or the normal to branched (N:B or N/B) ratio.
[0005] In the case of propylene, the normal- and iso-butyraldehydes obtained from propylene are, in turn, converted into many commercially valuable chemical products, such as, for example, n-butanol, 2-ethyl-hexanol, n-butyric acid, iso-butanol, neo-pentyl glycol, 2,2,4-trimethyl-1,3-pentanediol, and the mono-isobutyrate and di-isobutyrate esters of 2,2,4-trimethyl-1,3-pentanediol. The hydroformylation of higher α-olefins (such as 1-octene, 1-hexene, and 1-tetradecene) yields aldehyde products that are useful feedstocks for preparing detergent alcohols and plasticizer alcohols.
[0006] U.S. Pat. No. 5,840,647 and U.S. Pat. No. 6,130,358 introduced a new concept in ligand design with the disclosure of halogen substituents on the phosphorus atom of trivalent phosphorus ligands. These halogenated phosphorus ligands are readily prepared, possess high activity and good stability, and permit a wide N/I range of products to be prepared by simply varying the process parameters.
[0007] Many of the halophosphite ligand compositions contain the phosphorus atom in a macrocyclic ring structure. Macrocyclic rings introduce the possibility of many different structural and conformational isomers of the phosphorus ligands. The presence of a plurality of isomeric forms of the phosphorus ligand can be problematic, because each of the different isomers can form complexes with the transition metal catalyst, and the reactivity and selectivity of the catalyst can vary greatly depending on which isomeric form of the phosphorus ligand is attached to the transition metal atom. Frequently, using mixed isomeric forms of the phosphorus ligand results in a complex catalyst composition, which makes it difficult to predict and control the activity and selectivity of the catalyst.
[0008] Thus, it is desirable to be capable of creating a catalyst composition from a mixture of phosphorus ligand isomers that behaves in a manner as if it were a single isomer of the phosphorus ligand. In addition or alternatively, it is desirable to have a process by which a single isomer can be isolated from a mixture of isomers.
[0009] The present invention addresses these desires as well as others, which will become apparent from the following description and the appended claims.
SUMMARY OF THE INVENTION
[0010] The invention is as set forth in the appended claims.
[0011] Briefly, in one aspect, the present invention provides a composition comprising conformational isomers A and B:
[0000]
[0000] The lone pair of electrons on the phosphorus atom in isomer A is in a pseudo-equatorial orientation. The lone pair of electrons on the phosphorus atom in isomer B is in a pseudo-axial orientation. X is fluorine or chlorine. R is a divalent group having the formula 1:
[0000]
[0000] R 1 , R 2 , R 3 , R 4 , and R 5 are each independently hydrogen or a hydrocarbyl group containing 1 to 40 carbon atoms. R 6 and R 7 are each independently hydrogen or a hydrocarbyl group containing 1 to 10 carbon atoms with the proviso that at least one of R 6 and R 7 contains at least one carbon atom. The composition has a B:A molar ratio of greater than 1:1.
[0012] In another aspect, the present invention provides a method for separating conformational isomers. The method comprises:
(a) dissolving a feed mixture of the halophosphite conformational isomers A and B in a solvent to form a reactant solution; (b) contacting the reactant solution with an alcohol in the presence of an acid catalyst at conditions effective to form a product mixture having a greater B:A molar ratio than the feed mixture; and (c) quenching the product mixture with water.
[0016] In yet another aspect, the present invention provides a catalyst composition comprising a transition metal (M) selected from Group VIIIB and rhenium, and a mixture of the halophosphite conformational isomers A and B. The molar ratio of B:A is such that the isomer B forms a complex with the transition metal. The molar ratio of A:M is 5 or less.
[0017] In yet another aspect, the present invention provides a catalyst solution, which comprises the catalyst composition according to the invention and a hydroformylation solvent.
[0018] In yet another aspect, the present invention provides a process for preparing an aldehyde. The process comprises contacting an olefin, hydrogen, and carbon monoxide with a catalyst solution according to the invention at conditions effective to form an aldehyde.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a graph of the effect of the molar ratio of B/A on the N/I product ratio and the catalyst activity based on the data from Example 4.
[0020] FIG. 2 is a graph of the effect of the Rh loading on the N/I product ratio and the catalyst activity based on the data from Example 6.
DETAILED DESCRIPTION OF THE INVENTION
[0021] We have surprisingly discovered that the chemical reactivity of the “A” and “B” isomers of the cyclic fluorophosphite, Ethanox 398™, is indeed different, if the process conditions to which the material is subjected are less than the temperature needed to rapidly equilibrate the isomers. In the case of the Ethanox 398™ molecule, the “A” isomer will selectively bind to transition metals preferentially to the “B” isomer.
[0022] In this regard, solutions of rhodium dicarbonyl acetonylacetonate were prepared with mixtures of isomers, and when examined by NMR, the spectra indicated that the “A” isomer was preferentially bonded to the transition metal. Furthermore, in the specific case of Ethanox 398™ and rhodium, the “A” isomer formed a bis-ligated complex prior to the “B” isomer forming a mono-ligated complex.
[0023] We have also surprisingly discovered that if the differences between the reactivity of the “A” and “B” isomers are sufficiently great, then a mixture of the isomers will behave as if it were a single isomer. This selectivity in reactivity occurs if the ratio of the “A” and “B” isomers are maintained at a specific minimum ratio. Thus, it is possible to utilize a mixture of isomers to prepare a catalyst composition in which only one of the isomeric forms reacts to create transition metal complexes. As a result, the catalyst composition expresses the chemistry of only one of the isomeric forms of the phosphorus ligand. Such control of the chemistry allows for the use of mixed isomer samples to prepare a catalyst that behaves like it contains only a single isomer. The single isomer selectivity can be achieved without having to go through the difficulty of purifying out the pure isomers.
[0024] We have further surprisingly discovered that if the “B” isomer is used in a hydroformylation catalyst mixture that contains no “A” isomer or very small amounts of the “A” isomer, then the behavior of the catalyst is substantially changed when used in the hydroformylation reaction. Therefore, it is advantageous to carefully monitor the molar ratio of the “A” and “B” isomers in order to maintain the desired catalyst behavior. It is also advantageous to carefully monitor the “A” isomer and rhodium molar ratios as well as the ratio of “A” and “B” isomers. We have unexpectedly found that a “B” to “A” isomer ratio of 90:1 or greater can produce the effect of the “B” isomer alone. We have also unexpectedly found that if the “A” isomer to rhodium molar ratio is greater than 2.0, then the “A” isomer can dominate the chemistry of the catalyst. Blends of isomers with a “B” to “A” ratio of less than 90:1, but greater than 20:1, can still allow the “B” isomer to influence the chemistry of the catalyst; but a catalyst mixture with a “B” to “A” ratio of less than 20:1 tends to behave almost as if it were the “A” isomer alone provided that the “A” isomer to rhodium molar ratio is less than 2.0.
[0025] Thus, in one aspect, the present invention provides a composition comprising conformational isomers A and B:
[0000]
[0000] wherein
the lone pair of electrons on the phosphorus atom in isomer A is in a pseudo-equatorial orientation; the lone pair of electrons on the phosphorus atom in isomer B is in a pseudo-axial orientation; X is fluorine or chlorine; R is a divalent group having the formula 1:
[0000]
R 1 , R 2 , R 3 , R 4 , and R 5 are each independently hydrogen or a hydrocarbyl group containing 1 to 40 carbon atoms; and
R 6 and R 7 are each independently hydrogen or a hydrocarbyl group containing 1 to 10 carbon atoms with the proviso that at least one of R 6 and R 7 contains at least one carbon atom, and
wherein the composition has a B:A molar ratio of greater than 1:1.
[0032] The compounds contemplated in the present invention may be represented by the structure of formula 2:
[0000]
[0000] wherein R 1 to R 7 and X are as defined above.
[0033] In one embodiment, the molar ratio of B:A in the composition is 20 or greater. In another embodiment, the molar ratio of B:A in the composition is 30 or greater. In other embodiments, the molar ratio of B:A in the composition may be 40 or greater, 50 or greater, 60 or greater, 70 or greater, 80 or greater, 90 or greater, or 100 or greater. The upper limit of the molar ratio of B:A is not critical, and may be any practical value, for example, 1000 or less, 500 or less, 250 or less, 200 or less, or 150 or less.
[0034] In a preferred embodiment, R is a 2,2′-ethylidene bis(4,6-di-tert-butylphenyl) group.
[0035] In another preferred embodiment, X is fluorine.
[0036] When R is a 2,2′-ethylidene bis(4,6-di-tert-butylphenyl) group and X is fluorine, the compound is known as Ethanox 398™ in the trade. The structure of Ethanox 398™ and those of its A and B isomers are shown below.
[0000]
[0037] Ethanox 398™ and other compounds having the structure of formula 2 are generally commercially available. They may also be prepared according to the procedures described in U.S. Pat. No. 4,912,155. Such compounds are generally available in a B:A molar ratio of approximately 1:1 or less.
[0038] Compositions containing more B than A may be made according to a method of the invention. The method utilizes the differences in the reactivity of the two isomers in an acid catalyzed hydrolysis reaction.
[0039] Thus, in another aspect, the invention provides a method for separating conformational isomers. The method includes the steps of:
(a) dissolving a feed mixture of the halophosphite conformational isomers A and B in a solvent to form a reactant solution; (b) contacting the reactant solution with an alcohol in the presence of an acid catalyst at conditions effective to form a product mixture having a greater B:A molar ratio than the feed mixture; and (c) quenching the product mixture with water.
[0043] In one embodiment, the method further comprises the steps of:
(d) cooling the product mixture to a sub-ambient temperature (e.g., 10° C. or less, 5° C. or less, 0° C. or less, −5° C. or less, or −10° C. or less) to precipitate the product; and (e) isolating the product by filtration.
[0046] The typical B:A molar ratio in the feed mixture can range from 1:1 to 0.7:1.
[0047] Steps (a)-(c) or (a)-(e) may be repeated until a product with the desired B:A molar ratio is obtained.
[0048] In one embodiment, the molar ratio of B:A in the product mixture is greater than 30:1. In other embodiments, the molar ratio of B:A in the product mixture is greater than 50:1, greater than 75:1, greater than 100:1, greater than 125:1, greater than 150:1, greater than 175:1, or greater than 200:1.
[0049] The solvent for dissolving the feed mixture is not particularly limiting. It may be any organic solvent capable of dissolving the isomers at ambient conditions or at elevated temperatures. Examples of such solvents include aromatic hydrocarbons, alcohols, and mixtures of both. The alcohols may be the same as those used to react with the isomer A. Examples of aromatic hydrocarbons include benzene, toluene, and xylene. Examples of alcohols include ethanol and 2-propanol. In one embodiment, the solvent comprises toluene. In another embodiment, the solvent comprises an ethanol or 2-propanol. In yet another embodiment, the solvent comprises both toluene and ethanol or 2-propanol.
[0050] The acid catalyst for use in the method of the invention is also not particularly limiting. It may be any acid capable of facilitating a hydrolysis reaction between the alcohol and the isomer A. Examples of suitable acid catalysts include sulfonic acids, such as p-toluenesulfonic acid, methanesulfonic acid, and benzenesulfonic acid.
[0051] In a typical method of the invention, the mixed isomers of the fluorophosphite are combined in a substantially dry toluene/alcohol mixture and then a strong acid, such as a sulfonic acid, is added to the reaction mixture. The mixture is heated for a specified period of time, quenched with water, cooled to sub-ambient temperatures to precipitate the product, and then the product is isolated by filtration.
[0052] The mixture of isomers A and B according to the invention is particularly useful as ligands for transition metals. The transition metal complexes are particularly useful as catalysts for hydroformylation reactions.
[0053] Thus, in yet another aspect, the present invention provides a catalyst composition comprising (a) a transition metal (M) selected from Group VIIIB and rhenium and (b) the mixture of halophosphite conformational isomers A and B. The molar ratio of B:A in the catalyst composition is such that the isomer B forms a complex with the transition metal. Moreover, the molar ratio of A:M is 5 or less.
[0054] As noted above, the molar ratio of B:A may be 20 or greater, 30 or greater, 40 or greater, or 90 or greater.
[0055] In one embodiment, the molar ratio of A:M is 4 or less. In another embodiment, the molar ratio of A:M is 3 or less. In yet another embodiment, the molar ratio of A:M is 2 or less.
[0056] Preferably, X in the isomers A and B in the catalyst composition is fluorine. Preferably, R in the isomers A and B in the catalyst composition is a 2,2′-ethylidene bis(4,6-di-tert-butylphenyl) group. In one embodiment, X in the isomers A and B in the catalyst composition is fluorine, and R is a 2,2′-ethylidene bis(4,6-di-tert-butylphenyl) group.
[0057] Preferably, the transition metal (M) in the catalyst comprises rhodium.
[0058] Rhodium compounds that may be used as a source of rhodium for the active catalyst include rhodium (II) or rhodium (III) salts of carboxylic acids, examples of which include di-rhodium tetraacetate dihydrate, rhodium(II) acetate, rhodium(II) isobutyrate, rhodium(II) 2-ethylhexanoate, rhodium(II) benzoate, and rhodium(II) octanoate. Also, rhodium carbonyl species such as Rh 4 (CO) 12 , Rh 6 (CO) 16 , and rhodium(I) acetylacetonate dicarbonyl may be suitable rhodium feeds. Additionally, rhodium organophosphine complexes such as tris(triphenylphosphine) rhodium carbonyl hydride may be used when the phosphine moieties of the complex fed are easily displaced by the phosphite ligands of the present invention. Other rhodium sources include rhodium salts of strong mineral acids such as chlorides, bromides, nitrates, sulfates, phosphates, and the like.
[0059] Optionally, the catalyst composition according to the invention contains a hydroformylation solvent, although the reactant olefin and/or the product aldehyde may be used as the solvent.
[0060] The hydroformylation solvent may be selected from a wide variety of compounds, mixture of compounds, or materials that are liquid at the pressure at which the process is being operated. The main criterion for the solvent is that it dissolves the catalyst and the olefin substrate, and does not act as a poison to the catalyst. Such compounds and materials include various alkanes, cycloalkanes, alkenes, cycloalkenes, carbocyclic aromatic compounds, alcohols, esters, ketones, acetals, ethers and water. Specific examples of such solvents include alkane and cycloalkanes, such as dodecane, decalin, octane, iso-octane mixtures, cyclohexane, cyclooctane, cyclododecane, methylcyclohexane; aromatic hydrocarbons, such as benzene, toluene, xylene isomers, tetralin, cumene, alkyl-substituted aromatic compounds, such as the isomers of diisopropylbenzene, triisopropylbenzene and tert-butylbenzene; alkenes and cycloalkenes, such as 1,7-octadiene, dicyclopentadiene, 1,5-cyclooctadiene, octene-1, octene-2, 4-vinylcyclohexene, cyclohexene, 1,5,9-cyclododecatriene, 1-pentene; crude hydrocarbon mixtures, such as naphtha, mineral oils, and kerosene; high-boiling esters, such as 2,2,4-trimethyl-1,3-pentanediol diisobutyrate. The aldehyde product of the hydroformylation process also may be used. In practice, the preferred solvent is the higher boiling by-products that are naturally formed during the hydroformylation reaction and the subsequent steps, e.g., distillations, that are typically used for aldehyde product isolation.
[0061] Preferred solvents for the production of volatile aldehydes (e.g., propionaldehyde and the butyraldehydes) are those that are sufficiently high boiling to remain, for the most part, in a gas sparged reactor. Solvents and solvent combinations that are preferred for use in the production of less volatile and non-volatile aldehyde products include 1-methyl-2-pyrrolidinone, dimethyl-formamide, perfluorinated solvents (such as perfluoro-kerosene), sulfolane, water, and high-boiling hydrocarbon liquids as well as combinations of these solvents.
[0062] The concentration of the rhodium and ligand in the hydroformylation solvent or reaction mixture is not critical for the successful operation of the invention. A gram mole ligand:gram atom rhodium ratio of at least 1:1 normally is maintained in the reaction mixture. In order to obtain the desired selectivity of the catalyst, the molar ratio of the isomer with the axial lone pair of electrons and the isomer with the equatorial lone pair of electrons should be carefully monitored as well as the molar ratio of the isomer with the equatorial lone pair of electrons and rhodium.
[0063] As noted previously, it has been surprisingly found that an axial (B) to equatorial (A) isomer ratio of 90:1 or greater can yield the effect of the axial lone pair of electrons isomer (B) alone. It has also been surprisingly found that if the molar ratio of the isomer with the equatorial lone pair of electrons (A) to rhodium (M) is greater than 2.0, then the equatorial isomer (A) dominates the chemistry of the catalyst. Blends of isomers with an axial to equatorial (B:A) ratio of less than 90:1, but greater than 20:1, can still allow the axial isomer (B) to influence the chemistry of the catalyst, but a catalyst mixture with an axial to equatorial molar (B:A) ratio of less than 20:1 behaves almost as if it were the equatorial isomer alone.
[0064] The absolute concentration of rhodium in the reaction mixture or solution may vary from 1 mg/liter up to 5000 mg/liter or more. When the process is operated within the practical conditions of this invention, the concentration of rhodium in the reaction solution normally is in the range of about 20 to 300 mg/liter. Concentrations of rhodium lower than this range generally do not yield acceptable reaction rates with most olefin reactants and/or may require reactor operating temperatures that are so high as to be detrimental to catalyst stability. Higher rhodium concentrations are not preferred, because of the high cost of rhodium.
[0065] No special or unusual techniques are required for preparing the catalyst systems and solutions of the present invention, although it is preferred, to obtain a catalyst of high activity, that all manipulations of the rhodium and the phosphorus ligand components be carried out under an inert atmosphere, e.g., nitrogen, argon and the like. The desired quantities of a suitable rhodium compound and ligand are charged to the reactor in a suitable solvent. The sequence in which the various catalyst components or reactants are charged to the reactor is not critical.
[0066] The catalyst compositions and solutions of the invention are particularly suitable for preparing aldehydes.
[0067] Thus, in yet another aspect, the invention provides a process for preparing an aldehyde. The process comprises contacting an olefin, hydrogen, and carbon monoxide with the catalyst solution according to the invention at conditions effective to form an aldehyde.
[0068] The olefin used as the starting material is not particularly limiting and may be linear or cyclic olefins. Specifically, the olefin can be ethylene, propylene, butene, pentene, hexene, octene, styrene, non-conjugated dienes (such as 1,5-hexadiene), and blends of these olefins. Furthermore, the olefin may be substituted with functional groups so long as they do not interfere with the hydroformylation reaction. Suitable substituents on the olefin include any functional group that does not interfere with the hydroformylation reaction and includes groups such as carboxylic acids and derivatives thereof such as esters and amides, alcohols, nitriles, and ethers. Examples of substituted olefins include esters such as methyl acrylate or methyl oleate, alcohols such as allyl alcohol and 1-hydroxy-2,7-octadiene, and nitriles such as acrylonitrile.
[0069] The cyclic olefins that may be used in the hydroformylation process of the present invention may be cycloalkenes, e.g., cyclohexene, 1,5-cyclooctadiene, and cyclodecatriene, and from various vinyl-substituted cycloalkanes, cycloalkenes, heterocyclic, and aromatic compounds. Examples of such cyclic olefins include 4-vinylcyclohexene, 1,3-cyclohexadiene, 4-cyclohexene-carboxylic acid, methyl 4-cyclohexene-carboxylic acid, 1,4-cyclooctadiene, and 1,5,9-cyclododecatriene. The preferred olefin reactants include mono α-olefins of 2 to 10 carbon atoms, especially propylene. It has been found that cyclic olefins are sometimes less reactive than α-olefins, but that the lower reactivity can be overcome by adjusting process variables, such as the reaction temperature or the ligand to rhodium ratio.
[0070] Mixtures of olefins can also be used in the practice of this invention. The mixtures may be of the same carbon number, such as mixtures of n-octenes, or it may represent refinery distillation cuts, which typically contain a mixture of olefins over a range of several carbon numbers.
[0071] The reaction conditions used are not critical for the operation of the process, and conventional hydroformylation conditions normally can be used. The process involves contacting an olefin with hydrogen and carbon monoxide in the presence of the catalyst system described hereinabove. While the process may be carried out at temperatures in the range of about 20° to 200° C., the preferred hydroformylation reaction temperatures are from 50° to 135° C., with the most favored reaction temperatures ranging from 75° to 125° C. Higher reactor temperatures are not favored, because of increased rates of catalyst decomposition, while lower reactor temperatures can result in relatively slow reaction rates. The total reaction pressure may range from about ambient or atmospheric up to 70 bars absolute (about 1000 psig), preferably from about 8 to 28 bars absolute (about 100 to 400 psig).
[0072] The hydrogen:carbon monoxide mole ratio in the reactor likewise may vary considerably ranging from 10:1 to 1:10, and the sum of the absolute partial pressures of hydrogen and carbon monoxide may range from 0.3 to 36 bars absolute. The partial pressures of the ratio of the hydrogen to carbon monoxide in the feed is selected according to the linear:branched isomer ratio desired. Generally, the partial pressure of hydrogen and carbon monoxide in the reactor is maintained within the range of about 1.4 to 13.8 bars absolute (about 20 to 200 psia) for each gas. The partial pressure of carbon monoxide in the reactor is maintained within the range of about 1.4 to 13.8 bars absolute (about 20 to 200 psia) and is varied independently of the hydrogen partial pressure. The molar ratio of hydrogen to carbon monoxide can be varied widely within these partial pressure ranges for the hydrogen and carbon monoxide. The ratios of the hydrogen to carbon monoxide and the partial pressure of each in the synthesis gas (syngas—carbon monoxide and hydrogen) can be readily changed by the addition of either hydrogen or carbon monoxide to the syngas stream.
[0073] The amount of olefin present in the reaction mixture also is not critical. For example, relatively high-boiling olefins, such as 1-octene, may function both as the olefin reactant and the process solvent. In the hydroformylation of a gaseous olefin feedstock, such as propylene, the partial pressures in the vapor space in the reactor typically are in the range of about 0.07 to 35 bars absolute. In practice, the rate of reaction is favored by high concentrations of olefin in the reactor. In the hydroformylation of propylene, the partial pressure of propylene preferably is typically greater than 1.4 bars, e.g., from about 1.4 to 10 bars absolute. In the case of ethylene hydroformylation, the preferred partial pressure of ethylene in the reactor is greater than 0.14 bars absolute.
[0074] Any of the known hydroformylation reactor designs or configurations may be used in carrying out the process provided by the present invention. Thus, a gas-sparged, vapor take-off reactor design as disclosed in the examples set forth herein may be used. In this mode of operation, the catalyst, which is dissolved in a high boiling organic solvent under pressure, does not leave the reaction zone with the aldehyde product taken overhead by the unreacted gases. The overhead gases then are chilled in a vapor/liquid separator to condense the aldehyde product and the gases can be recycled to the reactor. The liquid product is let down to atmospheric pressure for separation and purification by conventional technique. The process may also be practiced in a batchwise manner by contacting the olefin, hydrogen, and carbon monoxide with the present catalyst in an autoclave.
[0075] A reactor design where catalyst and feedstock are pumped into a reactor and allowed to overflow with product aldehyde, i.e., liquid overflow reactor design, is also suitable. For example, high boiling aldehyde products, such as nonyl aldehydes, may be prepared in a continuous manner with the aldehyde product being removed from the reactor zone as a liquid in combination with the catalyst. The aldehyde product may be separated from the catalyst by conventional means, such as by distillation or extraction, and the catalyst then recycled back to the reactor. Water soluble aldehyde products can be separated from the catalyst by extraction techniques. A trickle-bed reactor design also is suitable for this process. It will be apparent to those skilled in the art that other reactor schemes may be used with this invention.
[0076] For continuously operating reactors, it may be desirable to add supplementary amounts of the phosphorus ligand over time to replace those materials lost by oxidation or other processes. This can be done by dissolving the ligand into a solvent and pumping it into the reactor as needed. The solvents that may be used include compounds that are found in the process, such as the reactant olefin, the product aldehyde, condensation products derived from the aldehyde, as well as other esters and alcohols that can be readily formed from the product aldehyde. Examples of such solvents include propionaldehyde, butyraldehyde, isobutyraldehyde, 2-ethylhexanal, 2-ethylhexanol, n-butanol, isobutanol, isobutyl isobutyrate, isobutyl acetate, butyl butyrate, propyl propionate, butyl propionate, butyl acetate, 2,2,4-trimethylpentane-1,3-diol diisobutyrate, and n-butyl 2-ethylhexanoate. Ketones, such as cyclohexanone, methyl isobutyl ketone, methyl ethyl ketone, diisopropylketone, and 2-octanone may also be used as well as trimeric aldehyde ester-alcohols, such as Texanol™ ester alcohol.
[0077] In one embodiment, the hydroformylation process according to the invention produces an aldehyde with an N/I molar ratio of 1 to 5. In another embodiment, the N/I molar ratio ranges from 1 to 4. In yet another embodiment, the N/I molar ratio ranges from 1 to 3 or from 1 to 2.
[0078] The present invention includes and expressly contemplates any and all combinations of embodiments, features, characteristics, parameters, and/or ranges disclosed herein. That is, the invention may be defined by any combination of embodiments, features, characteristics, parameters, and/or ranges mentioned herein.
[0079] As used herein, the indefinite articles “a” and “an” mean one or more, unless the context clearly suggests otherwise. Similarly, the singular form of nouns includes their plural form, and vice versa, unless the context clearly suggests otherwise.
[0080] While attempts have been made to be precise, the numerical values and ranges described herein should be considered to be approximations (even when not qualified by the term “about”). These values and ranges may vary from their stated numbers depending upon the desired properties sought to be obtained by the present invention as well as the variations resulting from the standard deviation found in the measuring techniques. Moreover, the ranges described herein are intended and specifically contemplated to include all sub-ranges and values within the stated ranges. For example, a range of 50 to 100 is intended to describe and include all values within the range including sub-ranges such as 60 to 90 and 70 to 80.
[0081] The content of all documents cited herein, including patents as well as non-patent literature, is hereby incorporated by reference in their entirety. To the extent that any incorporated subject matter contradicts with any disclosure herein, the disclosure herein shall take precedence over the incorporated content.
[0082] This invention can be further illustrated by the following examples of preferred embodiments thereof, although it will be understood that these examples are included merely for purposes of illustration and are not intended to limit the scope of the invention.
Examples
Example 1—Separation of Isomer B of Ethanox 398™
[0083] One kilogram of Ethanox 398™ with an A-to-B isomer molar ratio of 1.35:1 was dissolved into 1 liter of toluene and 2 liters isopropyl alcohol. The mixture was stirred and heated to 80° C. p-Toluenesulfonic acid (25 grams) was dissolved into 100 milliliters of isopropyl alcohol and then was slowly added to the hot toluene/isopropyl alcohol solution. The mixture was then stirred for one hour at 80° C. The progress of the reaction was monitored by gas chromatography and when the analysis showed a B/A molar ratio higher than 30, water (60 milliliters) was added to the hot solution. The reaction mixture was stirred overnight and allowed to cool to ambient temperature. The mixture was then chilled to −10° C. to finish the precipitation of the product. The solids were isolated by filtration, rinsed with 100 milliliters of isopropanol, and dried under N 2 for 24 hours to give the crude product. The crude product was normally 600-700 grams.
[0084] The crude product was typically combined into a double batch for the final purification. Two of the crude batches were combined with 1 liter of toluene and 2 liters isopropyl alcohol and heated to 80° C. p-Toluenesulfonic acid (10 grams) was dissolved into 100 milliliters of isopropyl alcohol and then was slowly added to the hot toluene/isopropyl alcohol solution. The mixture was then stirred for one hour at 80° C. The progress of the reaction was monitored by gas chromatography and when the analysis showed B/A molar ratio higher than 200, water (40 milliliters) was added to the hot solution. The reaction mixture was allowed to cool overnight and was then chilled to 0° C. to finish the precipitation of the product. The solids were isolated by filtration, rinsed with 100 milliliters of isopropanol, and dried under N 2 for 24 hours to give the final product. The typical yield for a double batch was 900 to 1100 grams of product with a B/A isomer molar ratio of >200 and a product purity of 90 wt % or higher.
Example 2—NMR Studies with “A” and “B” Isomers of Ethanox 398™
[0085] A solution of rhodium dicarbonyl acetonylacetonate containing 1.0 molar equivalent of rhodium and 2.0 molar equivalents of the “B” isomer of Ethanox 398™ was prepared in deutero chloroform. Phosphorus NMR showed the presence of mono-ligated rhodium species as a doublet of doublets with absorptions at 132, 134, 139 and 141 ppm as well as the free ligand as a doublet with absorptions at 129 and 137 ppm. Integration of the peaks showed that the ratio of the areas of the free ligand peaks to the complexed ligand peaks was 1.36. This is indicative that the ligand was forming predominantly a mono-ligated complex of rhodium, even with 2.0 equivalents of the “B” isomer.
[0086] Adding 1.0 equivalents of the “A” isomer to the mixture caused the peaks from the complexed “B” isomer to disappear and the appearance of a series of complex absorptions at 109 to 114 ppm and 117 to 121 ppm, which represent the “A” isomer complexed to the rhodium. The new absorptions appeared to be mixtures of mono-ligated and bis-ligated rhodium species. The uncomplexed “B” isomer was still present, but no uncomplexed or free “A” isomer was observed.
[0087] Adding a second molar equivalent of the “A” isomer caused the mono-ligated rhodium-“A” species to disappear and enhanced the signals from the bis-ligated rhodium-“A” species. A small amount of the non-complexed “A” ligand was also observed as a broad doublet with absorptions at 104 and 112 ppm.
[0088] These studies show that the “A” isomer will preferentially bind the rhodium atom and that the “A” isomer will rapidly displace the “B” isomer from rhodium complexes, even at very low concentrations.
Hydroformylation Process Set-Up
[0089] Propylene was reacted with hydrogen and carbon monoxide in a vapor take-off reactor made of a vertically arranged stainless steel pipe having a 2.5 cm inside diameter and a length of 1.2 meters to produce butyraldehydes. The reactor was encased in an external jacket that was connected to a hot oil machine. The reactor had a filter element located in the side near the bottom of the reactor for the inlet of gaseous reactants. The reactor contained a thermocouple, which was arranged axially with the reactor in its center for accurate measurement of the temperature of the hydroformylation reaction mixture. The bottom of the reactor had a high-pressure tubing connection that was connected to a cross. One of the connections to the cross permitted the addition of non-gaseous reactants (such as higher boiling alkenes or make-up solvents), another led to the high-pressure connection of a differential pressure (D/P) cell that was used to measure catalyst level in the reactor, and the bottom connection was used for draining the catalyst solution at the end of the run.
[0090] In the hydroformylation of propylene in a vapor take-off mode of operation, the hydroformylation reaction mixture or solution containing the catalyst was sparged under pressure with the incoming reactants of propylene, hydrogen, and carbon monoxide as well as any inert feed, such as nitrogen. As butyraldehyde was formed in the catalyst solution, it and unreacted reactant gases were removed as a vapor from the top of the reactor by a side-port. The removed vapor was chilled in a high-pressure separator where the butyraldehyde product was condensed along with some of the unreacted propylene. The uncondensed gases were let down to atmospheric pressure via the pressure control valve. These gases passed through a series of dry-ice traps where any other aldehyde product was collected. The product from the high-pressure separator was combined with that of the traps, and was subsequently weighed and analyzed by standard gas/liquid phase chromatography (GC/LC) techniques for the net weight and normal/iso ratio of the butyraldehyde product. Activity was calculated as kilograms of butyraldehydes produced per gram of rhodium per hour.
[0091] The gaseous feeds were introduced into the reactor via twin cylinder manifolds and high-pressure regulators. The hydrogen passed through a mass flow controller and then through a commercially available “Deoxo” (registered trademark of Engelhard Inc.) catalyst bed to remove any oxygen contamination. The carbon monoxide passed through an iron carbonyl removal bed (as disclosed in U.S. Pat. No. 4,608,239), a similar “Deoxo” bed heated to 125° C., and then a mass flow controller.
[0092] Nitrogen can be added to the feed mixture as an inert gas. Nitrogen, when added, was metered in and then mixed with the hydrogen feed prior to the hydrogen Deoxo bed. Propylene was fed to the reactor from feed tanks that were pressurized with hydrogen and was controlled using a liquid mass flow meter. All gases and propylene were passed through a preheater to ensure complete vaporization of the liquid propylene prior to entering the reactor.
Example 3—Hydroformylation of Propylene with Varying A and B Ratios—Effect of Isomer Ratios on Reaction Products
[0093] A catalyst solution was prepared under nitrogen using a charge of 7.7 milligrams of rhodium (0.075 millimole, as rhodium 2-ethylhexanoate), various amounts of the ligands as indicated in Table 1, and 190 mL of dioctylphthalate. The mixture was stirred under nitrogen (and heated, if necessary) until a homogeneous solution was obtained.
[0094] The mixture was charged to the reactor in a manner described previously, and the reactor was sealed. The reactor pressure control was set at 17.9 bar (260 psig), and the external oil jacket on the reactor was heated to 95° C. Hydrogen, carbon monoxide, nitrogen, and propylene vapors were fed through the frit at the base of the reactor, and the reactor was allowed to build pressure. The hydrogen and carbon monoxide (H 2 /CO ratio was set to be 1:1 or other desired ratio) were fed to the reactor at a rate of 6.8 liters/min, and the nitrogen feed was set at 1.0 liter/min. The propylene was metered as a liquid and fed at a rate of 1.89 liters/min (212 grams/hour). The temperature of the external oil was modified to maintain an internal reactor temperature of 95° C. The unit was usually operated for 3 to 5 hours, and hourly samples were taken. The hourly samples were analyzed as described above using a standard GC method. The last two to three samples of the run were used to determine the N/I ratio and catalyst activity.
[0095] The results of the bench unit runs are summarized in Table 1.
[0000]
TABLE 1
Ligand B
Molar
Ligand A
Molar
Molar
Run
Amount
Ratio of
Amount
Ratio of
Ratio of
Catalyst
No.
(mmole)
B to Rh
(mmole)
A to Rh
B to A
Activity*
N/I Ratio
1
3.375
45
0
0
6.92
1.25
2
3.413
45.5
0.0375
0.5
91
9.16
1.38
3
3.450
46
0.075
1
46
11.1
1.53
4
3.488
46.5
0.113
1.5
31
12.3
1.54
5
3.525
47
0.150
2
23.5
13.9
1.56
6
3.563
47.5
0.188
2.5
19
14.2
1.64
7
3.750
50
0.375
5
10
14.9
1.81
8
0.515
6.8
0.375
5
1.4
10.5
1.71
9
0.034
0.45
0.375
5
0.091
13.4
1.69
*Catalyst activity is expressed as pounds of butyraldehyde formed per gram-Rh-hour (lbs. HBu/gr-Rh-hr).
[0096] Runs 1 through 7 show the effect of increasing the amount of the “A” isomer in the catalyst mixture. The catalyst activity increased along with the Nil ratio as the presence of the “A” isomer increased. The data show that as the molar ratio of the “B” isomer to the “A” isomer fell below about 90:1, the “A” isomer began to influence the chemistry as reflected in the Nil ratio. As the molar ratio of the “B” isomer to the “A” isomer fell below about 20, the “A” isomer dominated the chemistry as the chemical results became indistinguishable from Run 9, which contained an excess of the “A” isomer.
[0097] Run 8 was made with a mixture of isomers in which the ratio of the “B” isomer to the “A” isomer was at 1.4. Based on the results of the previously discussed NMR studies and the isomer mixture of Run 8, it is expected that the rhodium atom would only form ligand complexes with the “A” isomer. The Runs 1 through 5 show the influence of increasing amounts of the “A” isomer and runs 6 through 8 show the results from a catalyst composition that is dominated by the “A” isomer.
[0098] Run 9 was made with a ligand mixture enriched in the “A” isomer at an “A” to “B” isomer ratio of 11:1. The chemistry and the properties of the catalyst in this run were dominated by the “A” isomer. This is reflected in the higher catalyst activity and normal-to-iso ratio.
Example 4—Hydroformylation of Propylene with Fixed Amounts of Rh and B, and Varying Amounts of A
[0099] The procedure of Example 3 was repeated with the amounts of Rh, A, and B listed in Table 2 below. The results of each run are also reported in Table 2.
[0000]
TABLE 2
Run No.
10
11
12
13
14
15
16
Ligand B
2.35
2.35
2.35
2.35
2.35
2.35
2.35
Amount
(mmole)
Ligand A
1.40
1.10
0.80
0.58
0.35
0.10
0.05
Amount
(mmole)
Rh Amount
5.00
5.00
5.00
5.00
5.00
5.00
5.00
(mg)
Molar Ratio of
77.18
71.00
64.83
60.30
55.57
50.42
49.39
Total Ligand/Rh
Molar Ratio of
28.81
22.64
16.46
11.94
76.20
2.06
1.03
A/Rh
Molar Ratio of
48.36
48.36
48.36
48.36
48.36
48.36
48.36
B/Rh
Molar Ratio of
1.68
2.14
2.94
4.05
6.71
23.50
47.00
B/A
Product N/I
3.93
3.69
3.29
2.93
2.48
1.61
1.62
Ratio
Catalyst Activity
10.88
13.66
21.42
29.46
30.34
34.9
32.02
(lbs. HBu/gr-
Rh-hour)
[0100] FIG. 1 graphically shows the effect of the molar ratio of B/A on the N/I product ratio and the catalyst activity based on the data from Table 2.
Example 5—Hydroformylation of Propylene with Fixed Amounts of Rh and A, and Varying Amounts of B
[0101] The procedure of Example 3 was repeated with the amounts of Rh, A, and B listed in Table 3 below. The results of each run are also reported in Table 3.
[0000]
TABLE 3
Run No.
17
18
19
20
21
22
Ligand B
0.37
0.36
0.20
1.00
2.00
0.70
Amount
(mmole)
Ligand A
0.76
0.77
0.76
0.76
0.76
0.76
Amount
(mmole)
Rh Amount
5.00
5.00
5.00
5.00
5.00
5.00
(mg)
Molar Ratio of
23.26
23.26
19.76
36.22
56.80
30.05
Total Ligand/Rh
Molar Ratio of
15.64
15.85
15.64
15.64
15.64
15.64
A/Rh
Molar Ratio of
7.61
7.41
4.12
20.58
41.16
14.41
B/Rh
Molar Ratio of
0.49
0.47
0.26
1.32
2.63
0.92
B/A
Product N/I
3.53
3.73
3.16
3.34
3.21
3.33
Ratio
Catalyst Activity
17.77
14.68
21.5
19.12
27.21
22.84
(lbs. HBu/gr-
Rh-hr)
Example 6—Hydroformylation of Propylene with Fixed Amounts of A and B, and Varying Amounts of Rh
[0102] The procedure of Example 3 was repeated with the amounts of Rh, A, and B listed in Table 4 below. The results of each run are also reported in Table 4.
[0000]
TABLE 4
Run No.
23
24
25
26
Ligand B
4.1
4.1
4.1
4.1
Amount
(mmole)
Ligand A
0.21
0.21
0.21
0.21
Amount
(mmole)
Rh Amount
0.0565
0.028
0.019
0.014
(mmole)
Molar Ratio of
76.28
153.93
226.84
307.86
Total Ligand/Rh
Molar Ratio of
3.72
7.50
11.05
15.00
A/Rh
Molar Ratio of
72.57
146.43
215.79
292.86
B/Rh
Molar Ratio of
19.52
19.52
19.52
19.52
B/A
Product N/I
1.9
2.11
2.12
2.5
Ratio
Catalyst Activity
37.43
19.34
14.44
7.57
(lbs. HBu/gr-
Rh-hour)
[0103] FIG. 2 graphically shows the effect of the Rh loading on the Nil product ratio and the catalyst activity based on the data from Table 4.
[0104] The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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This invention pertains to hydroformylation catalysts containing a mixture of isomeric forms of halo-phosphorus ligands. This invention also describes a procedure for preparing isomers of certain halophosphite ligands, which contain the phosphorus atom in a macrocyclic ring.
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U.S. GOVERNMENT RIGHTS
[0001] The invention was made with U.S. Government support under Agreement No. N00421-02-3-3111 awarded by the Naval Air Systems Command. The U.S. Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0002] The invention relates to nickel-base superalloys. More particularly, the invention relates to such superalloys used in high-temperature gas turbine engine components such as turbine disks and compressor disks.
[0003] The combustion, turbine, and exhaust sections of gas turbine engines are subject to extreme heating as are latter portions of the compressor section. This heating imposes substantial material constraints on components of these sections. One area of particular importance involves blade-bearing turbine disks. The disks are subject to extreme mechanical stresses, in addition to the thermal stresses, for significant periods of time during engine operation.
[0004] Exotic materials have been developed to address the demands of turbine disk use. U.S. Pat. No. 6,521,175 discloses an advanced nickel-base superalloy for powder metallurgical manufacture of turbine disks. The disclosure of the '175 patent is incorporated by reference herein as if set forth at length. The '175 patent discloses disk alloys optimized for short-time engine cycles, with disk temperatures approaching temperatures of about 1500° F. (816° C.). Other disk alloys are disclosed in U.S. Pat. No. 5,104,614, US2004221927, EP1201777, and EP1195446.
[0005] Separately, other materials have been proposed to address the demands of turbine blade use. Blades are typically cast and some blades include complex internal features. U.S. Pat. Nos. 3,061,426, 4,209,348, 4,569,824, 4,719,080, 5,270,123, 6,355,117, and 6,706,241 disclose various blade alloys.
SUMMARY OF THE INVENTION
[0006] One aspect of the invention involves a nickel-base composition of matter having a relatively high concentration of tantalum coexisting with a relatively high concentration of one or more other components.
[0007] In various implementations, the alloy may be used to form turbine disks via powder metallurgical processes. The one or more other components may include cobalt. The one or more other components may include combinations of gamma prime (γ′) formers and/or eta (η) formers.
[0008] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an exploded partial view of a gas turbine engine turbine disk assembly.
[0010] FIG. 2 is a flowchart of a process for preparing a disk of the assembly of FIG. 1 .
[0011] FIG. 3 is a table of compositions of an inventive disk alloy and of prior art alloys.
[0012] FIG. 4 is an etchant-aided optical micrograph of a disk alloy of FIG. 3 .
[0013] FIG. 5 is an etchant-aided scanning electron micrograph (SEM) of the disk alloy of FIG. 3 .
[0014] FIG. 6 is a table of select measured properties of the disk alloy and prior art alloys of FIG. 3 .
[0015] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0016] FIG. 1 shows a gas turbine engine disk assembly 20 including a disk 22 and a plurality of blades 24 . The disk is generally annular, extending from an inboard bore or hub 26 at a central aperture to an outboard rim 28 . A relatively thin web 30 is radially between the bore 26 and rim 28 . The periphery of the rim 28 has a circumferential array of engagement features 32 (e.g., dovetail slots) for engaging complementary features 34 of the blades 24 . In other embodiments, the disk and blades may be a unitary structure (e.g., so-called “integrally bladed” rotors or disks).
[0017] The disk 22 is advantageously formed by a powder metallurgical forging process (e.g., as is disclosed in U.S. Pat. No. 6,521,175). FIG. 2 shows an exemplary process. The elemental components of the alloy are mixed (e.g., as individual components of refined purity or alloys thereof). The mixture is melted sufficiently to eliminate component segregation. The melted mixture is atomized to form droplets of molten metal. The atomized droplets are cooled to solidify into powder particles. The powder may be screened to restrict the ranges of powder particle sizes allowed. The powder is put into a container. The container of powder is consolidated in a multi-step process involving compression and heating. The resulting consolidated powder then has essentially the full density of the alloy without the chemical segregation typical of larger castings. A blank of the consolidated powder may be forged at appropriate temperatures and deformation constraints to provide a forging with the basic disk profile. The forging is then heat treated in a multi-step process involving high temperature heating followed by a rapid cooling process or quench. Preferably, the heat treatment increases the characteristic gamma (γ) grain size from an exemplary 10 μm or less to an exemplary 20-120 μm (with 30-60 μm being preferred). The quench for the heat treatment may also form strengthening precipitates (e.g., gamma prime (γ′) and eta (η) phases discussed in further detail below) of a desired distribution of sizes and desired volume percentages. Subsequent heat treatments are used to modify these distributions to produce the requisite mechanical properties of the manufactured forging. The increased grain size is associated with good high-temperature creep-resistance and decreased rate of crack growth during the service of the manufactured forging. The heat treated forging is then subject to machining of the final profile and the slots.
[0018] Whereas typical modern disk alloy compositions contain 0-3 weight percent tantalum (Ta), the inventive alloys have a higher level. This level of Ta is believed unique among disk alloys. More specifically, levels above 3% Ta combined with relatively high levels of other γ′ formers (namely, one or a combination of aluminum (Al), titanium (Ti), niobium (Nb), tungsten (W), and hafnium (Hf)) and relatively high levels of cobalt (Co) are believed unique. The Ta serves as a solid solution strengthening additive to the γ′ and to the γ. The presence of the relatively large Ta atoms reduces diffusion principally in the γ′ phase but also in the γ. This may reduce high-temperature creep. Discussed in further detail regarding the example below, a Ta level above 6% in the inventive alloys is also believed to aid in the formation of the η phase and insure that these are relatively small compared with the γ grains. Thus the η precipitate may help in precipitation hardening similar to the strengthening mechanisms obtained by the γ′ precipitate phase.
[0019] It is also worth comparing the inventive alloys to the modern blade alloys. Relatively high Ta contents are common to modern blade alloys. There may be several compositional differences between the inventive alloys and modern blade alloys. The blade alloys are typically produced by casting techniques as their high-temperature capability is enhanced by the ability to form very large polycrystalline and/or single grains (also known as single crystals). Use of such blade alloys in powder metallurgical applications is compromised by the formation of very large grain size and their requirements for high-temperature heat treatment. The resulting cooling rate would cause significant quench cracking and tearing (particularly for larger parts). Among other differences, those blade alloys have a lower cobalt (Co) concentration than the exemplary inventive alloys. Broadly, relative to high-Ta modern blade alloys, the exemplary inventive alloys have been customized for utilization in disk manufacture through the adjustment of several other elements, including one or more of Al, Co, Cr, Hf, Mo, Nb, Ti, and W. Nevertheless, possible use of the inventive alloys for blades, vanes, and other non-disk components can't be excluded.
[0020] Accordingly, the possibility exists for optimizing a high-Ta disk alloy having improved high temperature properties (e.g., for use at temperatures of 1200-1500° F. (649-816° C.) or greater). It is noted that wherever both metric and English units are given the metric is a conversion from the English (e.g., an English measurement) and should not be regarded as indicating a false degree of precision.
EXAMPLE
[0021] Table I of FIG. 3 below shows a specification for one exemplary alloy or group of alloys. The nominal composition and nominal limits were derived based upon sensitivities to elemental changes (e.g., derived from phase diagrams). The table also shows a measured composition of a test sample. The table also shows nominal compositions of the prior art alloys NF3 and ME16 (discussed, e.g., in U.S. Pat. No. 6,521,175 and EP1195446, respectively). Except where noted, all contents are by weight and specifically in weight percent.
[0022] The most basic η form is Ni 3 Ti. It has generally been believed that, in modern disk and blade alloys, η forms when the Al to Ti weight ratio is less than or equal to one. In the exemplary alloy, this ratio is greater than one. From compositional analysis of the η phase, it appears that Ta significantly contributes to the formation of the η phase as Ni 3 (Ti, Ta). A different correlation (reflecting more than Al and Ti) may therefore be more appropriate. Utilizing standard partitioning coefficients one can estimate the total mole fraction (by way of atomic percentages) of the elements that substitute for atomic sites normally occupied by Al. These elements include Hf, Mo, Nb, Ta, Ti, V, W and, to a smaller extent, Cr. These elements act as solid solution strengtheners to the γ′ phase. When the γ′ phase has too many of these additional atoms, other phases are apt to form, such as η when there is too much Ti. It is therefore instructive to address the ratio of Al to the sum of these other elements as a predictive assessment for η formation. For example, it appears that η will form when the molar ratio of Al atoms to the sum of the other atoms that partition to the Al site in γ′ is less than or equal to about 0.79-0.81. This is particularly significant in concert with the high levels of Ta. Nominally, for NF3 this ratio is 0.84 and the Al to Ti weight percent ratio is 1.0. For test samples of NF3 these were observed as 0.82 and 0.968, respectively. The η phase would be predicted in NF3 by the conventional wisdom Al to Ti ratio but has not been observed. ME16 has similar nominal values of 0.85 and 0.98, respectively, and also does not exhibit the η phase as would be predicted by the Al to Ti ratio.
[0023] The η formation and quality thereof are believed particularly sensitive to the Ti and Ta contents. If the above-identified ratio of Al to its substitutes is satisfied, there may be a further approximate predictor for the formation of η. It is estimated that η will form if the Al content is less than or equal to about 3.5%, the Ta content is greater than or equal to about 6.35%, the Co content is greater than or equal to about 16%, the Ti content is greater than or equal to about 2.25%, and, perhaps most significantly, the sum of Ti and Ta contents is greater than or equal to about 8.0%.
[0024] In addition to substituting for Ti as an η-former, the Ta has a particular effect on controlling the size of the η precipitates. A ratio of Ta to Ti contents of at least about three may be effective to control η precipitate size for advantageous mechanical properties.
[0025] FIGS. 4 and 5 show microstructure of the sample composition reflecting atomization to powder of about 74 μm (0.0029 inch) and smaller size, followed by compaction, forging, and heat treatment at 1182° C. (2160° F.) for two hours and a 0.93-1.39° C./s (56-83° C./minute (100-150° F./minute)) quench. FIG. 4 shows η precipitates 100 as appearing light colored within a γ matrix 102 . An approximate grain size is 30 μm. FIG. 5 shows the matrix 102 as including much smaller γ′ precipitates 104 in a γ matrix 106 . These micrographs show a substantially uniform distribution of the η phase. The η phase is no larger than the γ grain size so that it may behave as a strengthening phase without the detrimental influence on cyclic behavior that would occur if the η phase were significantly larger.
[0026] FIG. 5 shows the uniformity of the γ′ precipitates. These precipitates and their distribution contribute to precipitation strengthening. Control of precipitate size (coarsening) and spacing may be used to control the degree and character of precipitate strengthening. Additionally, along the η interface is a highly ordered/aligned region 108 of smaller γ′ precipitates. These regions 108 may provide further impediments to dislocation motion. The impediment is a substantial component of strengthening against time-dependent deformation, such as creep. The uniformity of the distribution and very fine size of the γ′ in the region 108 indicates this is formed well below the momentary temperatures found during quenching.
[0027] Alloys with a high γ′ content have been generally regarded as difficult to weld. This difficulty is due to the sudden cooling from the welding (temporary melting) of the alloy. The sudden cooling in high γ′ alloys causes large internal stresses to build up in the alloy leading to cracking.
[0028] The one particular η precipitate enlarged in FIG. 5 has an included carbide precipitate 120 . The carbide is believed primarily a titanium and/or tantalum carbide which is formed during the solidification of the powder particles and is a natural by-product of the presence of carbon. The carbon, however, serves to strengthen grain boundaries and avoid brittleness. Such carbide particles are extremely low in volume fraction, extremely stable because of their high melting points and believed not to substantially affect properties of the alloy.
[0029] As noted above, it is possible that additional strengthening is provided by the presence of the η phase at a size that is small enough to contribute to precipitate phase strengthening while not large enough to be detrimental. If the η phase were to extend across two (or more) grains, then the dislocations from deformation of both grains would be more than additive and therefore significantly detrimental, (particularly in a cyclic environment). Exemplary η precipitates are approximately 2-14 μm long in a field of 0.2 μm cooling γ′ and an average grain diameter (for the γ) of 30-45 μm. This size is approximately the size of large γ′ precipitates as found in conventional powder metallurgy alloys such as IN100 and ME16. Testing to date has indicated no detrimental results (e.g., no loss of notch ductility and rupture life).
[0030] Table II of FIG. 6 shows select mechanical properties of the exemplary alloy and prior art alloys. All three alloys were heat treated to a grain size of nominal ASTM 6.5 (a diameter of about 37.8 μm (0.0015 inch)). All data were taken from similarly processed subscale material (i.e., heat treated above the γ′ solvus to produce the same grain size and cooled at the same rate). The data show a most notable improvement in quench crack resistance for the inventive alloys. It is believed that the very fine distribution of γ′ in the region 108 around the η precipitate (which γ′ precipitates do not form until very low temperatures are reached during the quench cycle) are participating in the improved resistance to quench cracking. A lack of this γ′ around the η might encourage the redistribution of the stresses during the quench cycle to ultimately cause cracking.
[0031] From Table II it can be seen that, for equivalent grain sizes, the sample composition has significant improvements at 816° C. (1500° F.) in time dependent (creep and rupture) capability and yield and ultimate tensile strengths. At 732° C. (1350° F.) the sample composition has slightly lower yield strength than NF3 but still significantly better than ME16. Further gains in these properties might be achieved with further composition and processing refinements.
[0032] A test has been devised to estimate relative resistance to quench cracking and results at 1093° C. (2000° F.) are also given in Table II. This test accounts for an ability to withstand both the stresses and strains (deformation) expected with a quench cycle. The test is dependent only on the grain size and the composition of the alloy and is independent of cooling rate and any subsequent processing schedule. The sample composition showed remarkable improvements over the two baseline compositions at 1093° C. (2000° F.)
[0033] Alternative alloys with lower Ta contents and/or a lack of η precipitates may still have some advantageous high temperature properties. For example, lower Ta contents in the 3-6% range or, more narrowly the 4-6% range are possible. For substantially η-free alloys, the sum of Ti and Ta contents would be approximately 5-9%. Other contents could be similar to those of the exemplary specification (thus likely having a slightly higher Ni content). As with the higher Ta alloys, such alloys may also be distinguished by high Co and high combined Co and Cr contents. Exemplary combined Co and Cr contents are at least 26.0% for the lower Ta alloys and may be similar or broader (e.g., 20.0% or 22.0%) for the higher Ta alloys.
[0034] One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the operational requirements of any particular engine will influence the manufacture of its components. As noted above, the principles may be applied to the manufacture of other components such as impellers, shaft members (e.g., shaft hub structures), and the like. Accordingly, other embodiments are within the scope of the following claims.
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A composition of matter comprises, in combination, in weight percent: a largest content of nickel; at least 16.0 percent cobalt; and at least 3.0 percent tantalum. The composition may be used in power metallurgical processes to form turbine engine turbine disks.
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FIELD OF THE INVENTION
The present invention relates to the field of computer systems and methods, and more particularly without limitation to the field of computer security.
This application claims priority to copending Europe utility application entitled, “A Computer Security Method And Computer System” having serial no. EP 05300198.8, filed Mar. 18, 2005, which is entirely incorporated herein by reference.
BACKGROUND AND PRIOR ART
Over the last two decades, the functionality and convenience of computers has improved steadily. An ever growing number of interconnected computers and mobile devices are used to perform important tasks in many areas of society and in the daily lives of a growing number of people. This development, however beneficial, brings with it new vulnerabilities and concerns for security. A central problem is to allow a user to establish trust in the integrity of a computer system, or more particularly, in the integrity of a software application used for an important or sensitive purpose.
The integrity of a computer system depends not only on the integrity of the data in the non-volatile memory such as ROM or disks but also on the integrity of the runtime image in volatile memory such as RAM. The integrity of the runtime image can be corrupted due to intentional or non-intentional modifications of this image even if the static integrity of the executables before loading is guaranteed. Relevant vulnerabilities include loading of unauthorized code, buffer overflow, insufficient input validation, or, on Microsoft Windows platforms, security attacks based on a technique known as “DLL injection” where a remote process can write to the address space of a running application. Even with genuine code such as some system tools the runtime image of an application can be modified in an unauthorized manner. Since modifications can occur at any time, it is impossible to ensure a dynamic integrity of the runtime image of a software application with a single authentication before execution.
One prior art method for “secure software registration and integrity assessment in a computer system” is described in U.S. Pat. No. 5,944,821. A loader compares hash values of software applications before execution to previously prepared hash values in secure storage. Since no integrity checks during execution are performed, a dynamic integrity of the runtime image cannot be achieved.
The 2003 Microsoft Professional Developers Conference release of Microsoft Corporation's Next-Generation Secure Computing Base technologies for the Microsoft Windows family of operating systems is described in a white paper available at the Microsoft Developer Network library (http://msdn.microsoft.com/library/en-us/dnsecure/html/nca_considerations.asp). The computing environment is divided into two separate and distinct operating modes. Users can perform routine tasks in Standard mode using their existing applications, services, and devices. For their high-security tasks, those same users can run trusted, authenticated Nexus computing agents that execute in a separate and protected operating environment called Nexus mode. While Nexus mode protects Nexus computing agents from any harmful programs that may be running in Standard mode, within Nexus mode a Nexus security kernel uses standard virtual memory protections to isolate itself from Nexus computing agents and to isolate Nexus Computing agents from one another.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a computer security method comprising loading a software application from a non-volatile memory in a volatile memory of a computer system by a secure loader, performing a first authentication of the software application, starting execution of the software application after its first authentication, and performing a second authentication of the software application during its execution.
Embodiments of the present invention are particularly advantageous as they enables to ensure not only the integrity of data stored in non-volatile memory but also the integrity of the runtime environment in volatile memory.
For example, the invention can help a user of a computer system ensure the integrity of software applications running on his or her platform. In another possible scenario the user can be prevented from executing an application in a way he or she is not explicitly authorized for, as is a common requirement in digital rights management.
In accordance with an embodiment of the invention the second authentication is performed repeatedly during the execution of the software application, for example at constant or variable time intervals. This has the advantage that unauthorized changes in the runtime environment occurring during the execution of the software application are detected after the passing of the current time interval. Such unauthorized changes may for example be caused by buffer overflow or insufficient input validation. A shorter time interval will lead to faster detection, and therefore higher security. Additionally or alternatively repeating the second authentication whenever new code sections are loaded into volatile memory or released from it by the software application has the advantage that unauthorized changes in the runtime environment at such events, for example caused by dynamically loaded unauthorized code, are detected before such code can be executed.
In accordance with an embodiment of the invention a digital certificate accompanies the software application, preferably in the form of a separate file on disk, for example in XML format, digitally signed by an authority trusted by the platform owner. The certificate is loaded and the software application authenticated using the information from the certificate.
In accordance with an embodiment of the invention the digital certificate lists hash values of code sections allowed to be loaded by the application; an assumption is that all pieces of code the application loads should be declared in the application's certificate. Each hash value itself is digitally signed by an authority trusted by the platform owner.
In accordance with an embodiment of the invention the second authentication of the software application is performed by authenticating a snapshot of the current image of the software application in volatile memory. The current image of the software application is read from the volatile memory. For each code section, the current hash value is then calculated from the image. The authentication is successful if each of the calculated hash value matches one of the hash values listed in the certificate. Either at regular intervals, or at any time a new code section is loaded or unloaded dynamically the application process is suspended, a new snapshot taken and authenticated.
In accordance with an embodiment of the invention the authentication method is adapted to take into account any genuine modifications that under some operating systems are applied to the runtime image of a code section after or during loading it in the volatile memory. This is achieved by reverse transforming the code of a code section after reading it from the volatile memory and before calculating its current hash value.
In accordance with an embodiment of the invention the genuine modifications are fix-ups of code that is not independent of its position in the volatile memory. For example, dynamically linked libraries on Microsoft Windows platforms often contain code that is not position-independent and has to be modified if the library is loaded at an address other than its preferred address.
In accordance with an embodiment of the invention the certificate comprises authorization rules limiting the right of the user to execute the software application in a way he or she is not explicitly authorized for. For example, the execution of the software application can be bound to a specific machine or a specific user; it is possible to limit the number of allowed executions, allow only parts of the application to be used on a particular platform, or execution during a given timeframe. An authorization rule may also allow dynamic loading of code sections from a library or executable signed by a specified, trusted software provider. The signature can be attached to the library or executable file in a special section.
In accordance with an embodiment of the invention the computer system comprises a cryptographic unit that directly controls loading and execution of the software application, which has to be separated into a first and a second part. The cryptographic unit provides cryptographic capabilities, secure storage, and authentication capabilities. The following protocol by which the cryptographic unit starts the software application requires that the cryptographic unit and the first part of the software application share a secret key and are able to independently calculate a keyed-hash message authentication code with it.
First, the cryptographic unit creates a token specifying a timeout and comprising information necessary for establishing a secure communication channel. The cryptographic unit inserts the token into a software verification function it stores, and calculates the keyed hash from the resulting bytes using the secret key shared with the first part of the software application. The cryptographic unit then provides the software verification function and its keyed hash to the first part of the software application. The first part of the software application verifies the keyed hash to authenticate the received software verification function and passes control to it. The software verification function then provides back the token to the cryptographic unit, before the token's timeout expires. The software verification function then passes control to the second part of the software application and provides the token to it. The second part of the software application then uses the token to establish a secure communication channel with the cryptographic unit.
In accordance with an embodiment of the invention, the second part of the software application comprises an encrypted section. After having sent the token back to the cryptographic unit, the software verification function requests the decryption of the encrypted section from the cryptographic unit.
In accordance with an embodiment of the invention the described protocol for starting the software application by the cryptographic unit is preceded by further steps to establish trust between the first part of the software application and the cryptographic unit. The first part of the software application begins by providing a request for a session identifier to the cryptographic unit. Then, the cryptographic unit creates the session identifier, preferably a random number, and returns it. The first part of the software application then prepares a request for communication comprising the session identifier and the process identifier of its own process. It calculates a keyed hash of the request for communication using the secret key shared with the cryptographic unit and provides both the request and the keyed hash to the cryptographic unit. The cryptographic unit then verifies the keyed hash.
In accordance with an embodiment of the invention the computer system comprises a secure loader. The secure loader, which is responsible for performing the second authentication of the software application, is itself implemented as another software application, its loading and execution preferably controlled directly by the cryptographic unit as described. The secure loader is started by loading it from the non-volatile memory in the volatile memory, performing a first authentication of the secure loader, starting execution of the secure loader after its first authentication, and performing a second authentication of the secure loader during its execution.
In accordance with an embodiment of the invention the computer system is a trusted platform in the sense of the Trusted Computing Group specification. The secure loader is loaded as part of a secure boot process, where the cryptographic unit provides a root of trust for the platform. The secure loader can be seen as a measurement agent on the trusted platform, which measures the dynamic integrity of the running applications. Preferably standard capabilities of the trusted platform are reused for establishing the shared secret between the cryptographic unit and the secure loader, and also for replacing some of the steps in the described protocol that establish trust between the first part of the software application and the cryptographic unit.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following preferred embodiments of the invention will be described in greater detail by way of example only making reference to the drawings in which:
FIG. 1 is a block diagram of a first embodiment of a computer system of the invention,
FIG. 2 is a flowchart illustrating a preferred mode of operation of the computer system of FIG. 1 for user authentication,
FIG. 3 is an object relationship diagram illustrating a preferred protocol for starting a software application,
FIG. 4 is a juxtaposition of a preferred executable file format of a software application and its runtime image in volatile memory.
DETAILED DESCRIPTION
FIG. 1 shows a computer system 104 comprising a non-volatile memory 101 , a volatile memory 102 , a cryptographic unit 116 and a processor 146 . The non-volatile memory 101 , for example a hard disk, stores several files, including a software application 100 and a digital certificate 106 belonging to the software application 100 . The digital certificate 106 contains information about the code authorized to be loaded by the software application, in the form of hash values 108 of the code sections 110 of the software application. It can furthermore contain authorization rules 114 governing the execution of the application or allowing dynamic loading of additional code libraries 115 signed by a specific software provider whom the platform owner trusts.
In operation, the processor 146 can execute various program functions. In particular, it can execute a loader function 128 for loading executable code such as the code sections 110 of software application 100 from the non-volatile memory 101 into the volatile memory 102 . It furthermore can execute a first authenticator 130 that performs a first authentication of the software application 100 . This first authentication includes verifying the integrity of both the code sections 110 to load and of the certificate 108 . Using the hashing component 136 hash values of the code sections 110 are calculated and compared to the certified hash values 108 stored in the certificate 106 . The first authenticator 130 checks any authorization rules 114 found in the certificate as for example requirements to execute the software application on a specific platform, or in a specific time frame.
After a successful first authentication the processor 146 can execute program instructions 132 for starting execution of the software application 100 . During the execution of the software application 100 , a second authenticator 134 monitors and checks the integrity of the runtime image either at regular intervals or whenever it detects a change in the runtime image, for example when one of the code libraries 115 is dynamically loaded or unloaded.
The computer system 104 preferably comprises a cryptographic unit 116 having an identifier creator 144 for creating session identifiers, a token creator 138 for creating security tokens, a software verification function 118 , a hashing component 140 that is independent of the hashing component 136 of the processor 146 , and program instructions 142 of its own. Depending on the nature of the computer system 104 the cryptographic unit 116 can be implemented in different ways. On a trusted platform in the sense of the Trusted Computing Group specification the cryptographic unit can be considered as an extension to the Trusted Platform Module, a simple hardware module that serves as a root of trust for the platform. On non-trusted platforms, it can be implemented in the form of a cryptographic expansion card, or even purely as software.
The cryptographic unit 116 can directly control the loading and execution of the software application 100 , under the provision that the software application 100 be divided into a first 120 and a second 122 part, where the first part can be launched as a conventional software application, and the second part may comprise a code section that is encrypted in a way that requires the services of the cryptographic unit for decryption before it can be executed. By requiring these services, the software application 100 is forced to submit itself under the control of the cryptographic unit. To allow the software application 100 and the cryptographic unit 116 to authenticate to each other, they are instructed to share a secret key kept both in the cryptographic unit and by the software application.
In operation, when the processor 146 starts to execute software application 100 , a new process is created that loads the code sections 110 of the first part 120 of the software application. The first part of the software application initiates communication with the cryptographic unit by requesting a session identifier. The identifier creator 144 of the cryptographic unit generates a random number and returns it as session identifier to the first part of the software application. The session identifier will remain valid until the software application terminates and serves to protect against replay attacks, where a potential attacker records genuine messages and replays them at a later time. Using the hashing component 136 of the first part of the software application and the secret key shared by the first part of the software application and the cryptographic unit, the first part of the software application then calculates the keyed hash of the request for communication and provides both the request for communication and the keyed hash calculated from it to the cryptographic unit 116 . Using its own internal hashing component 140 , which employs the same hashing algorithm as the hashing component 136 of the first part of the software application, and the secret key shared with the first part of the software application, the cryptographic unit independently calculates the keyed hash of the request for communication received from the first part of the software application and verifies that the first part of the software application knows the secret key by establishing the identity of the result with the keyed hash supplied by the first part of the software application.
Having in this way authenticated the first part 120 of the software application 100 , the cryptographic unit 116 by means of the token creator 138 next creates a token, being essentially a string of bytes that wraps a timeout specification and further information needed by the software application 100 to establish a secure communication channel with the cryptographic unit. The cryptographic unit then executes program instructions 142 to insert the token into a template of a software verification function 118 that is stored by the cryptographic unit. Using its own internal hashing component 140 and the secret key it shares with the first part of the software function, the cryptographic unit then calculates a keyed hash of the bytes of the software verification function including the token. The cryptographic unit then executes further program instructions 142 for sending both the bytes of the software verification function and the keyed hash calculated from it to the first part of the software application.
Having received the software verification function 118 and the keyed hash that the cryptographic 116 unit calculated from it, the first part 120 of the software application 100 verifies the keyed hash by calculating itself a keyed hash of the software verification function using its own hashing component 136 and the secret key it shares with the cryptographic unit If the results are equal, the first part of the software application has authenticated the cryptographic unit, by having established that the cryptographic unit knows the shared secret. The first part of the software application then inserts the software verification function including the token into its own memory space, and instructs it with the name of the second part of the software application that needs to be loaded and potentially decrypted before loading. Finally, it yields control of execution to the software verification function.
Having gained control, the software verification function 118 , which is located in the volatile memory 102 spaces of the first part of the software application, returns a copy of the token contained within it to the cryptographic unit 116 . As a security measure, the returning of the token has to complete within the timeout specified in the token. The software verification function then takes a snapshot of the code sections 110 of the first part 120 of the software application 100 and sends it for authentication to the cryptographic unit along with a digital signature that is part of the executable file of the first part 120 of the software application. The format of the executable file including the digital signature, which is an encrypted hash value, is explained in FIG. 4 .
After the cryptographic unit 116 has the digital signature of the first part 120 of the software application 100 , the software verification function 118 sends to the cryptographic unit the bytes of the second part 122 of the software application along with a digital signature that is part of the executable file of the second part of the software application. The cryptographic unit verifies the digital signature of the second part of the software application. If the second part of the software application comprises encrypted code sections the cryptographic unit decrypts these code sections. The cryptographic unit returns the code of the second part of the software application to the software verification function, which loads it into the volatile memory 102 space of the software application. The software verification function then passes control to the second part of the software application. The second part of the software application uses the information contained in the token to establish a secure communication channel with the cryptographic unit.
If the computer system 104 is a trusted platform in the Trusted Computing Group specification, the cryptographic unit provides a root of trust that extends to the software application 100 because the software application 100 is authenticated and therefore trusted by the cryptographic unit. In a similar way, if the cryptographic unit is implemented as a cryptographic expansion card or in software only, a user of the computer system 104 , who has confidence in the cryptographic unit, can have confidence in the operation of the software application 100 , too.
In principle, any software application can, in the way described for the software application 100 , be authenticated by the cryptographic unit 116 , provided that it can be built in the same format as described for the software application 100 . In particular, it is possible to create a software application that, while itself being authenticated by the cryptographic unit in the way described for the software application 100 , is able to authenticate further software applications. The computer system 104 comprises such a software application, called a secure loader 126 .
The secure loader 126 is started as described above for software application 100 . Preferably the secure loader is loaded and executed under direct control of the cryptographic unit 116 , in the same way as described for the software application 100 . The secure loader 126 can then in turn securely load, dynamically authenticate, and authorize other software applications.
If the computer system 104 is a trusted platform in the sense of the Trusted Computing Group specification, the secure loader 126 is preferably loaded as part of a secure boot process. The cryptographic unit 116 provides a root of trust that extends to the secure loader, which is authenticated by the cryptographic unit, and via the secure loader to other software applications loaded and authenticated by the secure loader. On a trusted platform where the root of trust is implemented as a low-cost, low-performance hardware module the secure loader is of particular advantage. Because the secure loader is executed by the main processor 146 of the computer system the hardware requirements for the cryptographic unit 126 can be kept modest.
The secure loader 126 can be implemented as a part of the operating system of the Computer system 104 , such as an extension of the standard operating system loader.
FIG. 2 shows a flowchart illustrating a computer security method, which comprises steps of secure loading, dynamic authentication, and authorization of a software application. In Step 200 , the software application is loaded from the non-volatile memory in the volatile memory. In Step 202 , the first authentication of the software application is performed. In Step 204 , the execution of the software application is started. In Step 206 , the second authentication of the software application is performed.
On a computer system comprising a secure loader, the method is performed twice. First it is performed with respect to the secure loader, preferably under control of a cryptographic unit of the computer system, and preferably as part of a secure boot process on a trusted platform in the sense of the Trusted Computing Group specification, where the cryptographic unit serves as a root of trust of the system. In Step 200 , the secure loader is loaded from the non-volatile memory in the volatile memory. In Step 202 , the first authentication of the secure loader is performed, In Step 204 , the execution of the secure loader is started. In Step 206 , the second authentication of the secure loader is performed. As a result, on a trusted platform, trust extends from the cryptographic unit as root of trust to the secure loader.
Second, the method is performed by the secure loader with respect to another, securely loaded software application. In Step 200 , the secure loader loads the securely loaded software application from the non-volatile memory in the volatile memory. In Step 202 , the secure loader performs the first authentication of the securely loaded software application. In Step 204 , the secure loader starts the execution of the securely loaded software application. In Step 206 , the secure loader performs the second authentication of the securely loaded software application. As a result, on a trusted platform, trust extends from the cryptographic unit as root of trust to the secure loader, and via the secure loader to the securely loaded software application.
FIG. 3 shows an object-relationship diagram illustrating a protocol by which the cryptographic unit starts the software application, which in order to be directly controlled by the cryptographic unit needs to be separated into a first and second part. After the start of the execution of the first part of the software application it requests ( 300 ) a session identifier from the cryptographic unit. The cryptographic unit creates ( 302 ) the session identifier and provides ( 304 ) it back to the first part of the software application. The first part of the software application then prepares ( 306 ) a request for communication intended for the cryptographic unit. To prove the authenticity of the request to the cryptographic unit, the first part of the software application calculates ( 308 ) and attaches a message-authentication code using a secret key that is known also to the cryptographic unit. The message authentication code preferably is a keyed hash based on a cryptographic hash function such as MD5 or SHA-1 and the secret key, calculated according to the method described by H. Krawczyk, M. Bellare, and R. Canetti in “HMAC: Keyed-Hashing for Message Authentication,” Internet Engineering Task Force, Request for Comments (RFC) 2104, February 1997. The first part of the software application provides ( 310 ) the request for communication and its keyed hash to the cryptographic unit, which verifies ( 312 ) the keyed hash, creates ( 314 ) a token comprising a timeout and information for establishing a secure communication channel with the cryptographic unit, inserts ( 316 ) the token into the software verification function it stores, and calculates ( 318 ) a keyed hash of the resulting bytes using the same secret key. The cryptographic unit then provides ( 320 ) the software verification function including the inserted token and its keyed hash to the first part of the software application, which verifies ( 322 ) the keyed hash and passes control to the software verification function, which now resides within the software application's memory space in the volatile memory.
The software verification function immediately provides back ( 326 ) the token to the cryptographic unit. This has to occur within the limit set by the timeout, which should be as short as possible for maximum security. The software verification function then requests ( 328 ) the cryptographic unit to decrypt any encrypted code sections of the second part of the software verification function. The cryptographic unit fulfils ( 330 ) the request and provides ( 331 ) the decrypted code to the software verification function, which passes ( 332 ) execution control and the token to the second part of the software application. The second part of the software application then uses this information to establish a secure communication channel with the cryptographic unit.
FIG. 4 shows a juxtaposition of a possible format of an executable file of the software application 100 suitable for being securely loaded with a corresponding runtime image 432 in volatile memory. The depicted format of the executable file is based on the standard executable format of Microsoft Windows executables but the principle considerations are equally valid on other platforms. At the beginning of the executable file 100 are located standard headers and sections 400 as can be found also in executable files of the standard executable format. During loading of the software application these standard headers and sections are copied into volatile memory, where their image 420 forms the head end of the software application's runtime image 432 in volatile memory. The standard headers and sections 400 are followed by non-encrypted code sections 110 , as can be found in the same way in executable files of the standard executable format. The non-encrypted code sections are copied to corresponding sections 422 of the software application's runtime image in volatile memory, possibly subject to post-processing depending on the location of the code in volatile memory.
A part of the code of the software application 100 is located in encrypted code sections 124 that can be sandwiched by sections of non-encrypted code. Such sections are not part of the standard executable format. During the loading of the software application 100 the encrypted code sections are decrypted before being added as further, decrypted, code sections 424 to the runtime image, subject to post-processing depending on the location of the decrypted code in volatile memory. Following the non-encrypted 110 and encrypted 124 code sections in the executable file 100 are further standard sections 406 as are found also in executable files of the standard executable format. These sections are copied during loading to form the tail end of the software application's runtime image, resulting in a runtime image 432 in volatile memory that is of the same format as a runtime image of a standard executable file.
The executable file further comprises a code encryption key 408 that was used for the encryption 402 of the code of the encrypted code section 124 . This key 408 is either supplied by the software creator or by the platform owner, possibly during installation of the software application 100 . The key 408 itself is subject to asymmetric encryption 410 using a public key of a public-private key pair, the private key of which is stored in the cryptographic unit 116 . If the computer system 104 is a trusted platform in the sense of the Trusted Computing Group specification the public key used could be part of an identity credential of the platform. The executable file further comprises pointers to the offset of the start 412 and the end 414 of the encrypted code section 124 serving to identify which part of the executable file has to be decrypted. Note that an executable file structured as depicted 100 could contain further encrypted code sections, each encrypted with different encryption keys stored in the file 100 .
The final section 416 of the depicted executable file 100 contains as digital signature a hash valve calculated from the rest of the executable file 100 . The hash value is subject to encryption 418 with the private key of the software creator or the platform owner. If the private key of the platform owner is used and the computer system 104 is a trusted platform in the sense of the Trusted Computing Group specification, the execution of the software application 100 could be bound to a specific platform identity.
LIST OF REFERENCE NUMERALS
100 Software application
101 Non-volatile memory
102 Volatile memory
104 Computer system
106 Certificate
108 Hash value
110 Code section
114 Authorization rule
115 Library
116 Cryptographic unit
118 Software verification function
120 First part of the software application
122 Second part of the software application
126 Secure loader
128 Loader
130 First authenticator
132 Program instructions
134 Second authenticator
136 Hashing component
138 Token creator
140 Hashing component
142 Program instructions
144 Identifier creator
146 Processor
200 Loading into volatile memory
202 First authentication
204 Start of execution
206 Second authentication
300 Request for session identifier
302 Creation of session identifier
304 Provision of session identifier
306 Preparation of request for communication
308 Calculation of keyed hash of request for communication
310 Provision of request for communication
312 Verification of keyed hash
314 Creation of token
316 Insertion of token into software verification function
318 Calculation of keyed hash of software verification function
320 Provision of software verification function
322 Verification of keyed hash
324 Passing of control to software verification function
326 Provision of token
328 Provision of request to decrypt
330 Decryption
331 Provision of decrypted second part of software application
332 Passing control to second part of software application
334 Establishing of secure channel
400 Standard headers and sections
402 Encryption by code encryption key
406 Other standard sections
408 Code encryption key
410 Encryption by public key of cryptographic unit
412 Offset of encrypted code start
414 Offset of encrypted code end
416 File hash
418 Encryption by private key of platform owner or software creator
420 Runtime image of standard headers and sections
422 Runtime image of non-encrypted code
424 Runtime image of encrypted code
430 Runtime image of other standard sections
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A method for secure loading, integrity checking of the runtime image and control over the runtime execution of applications which ensures that a software application loads only code it was authorized to load, and that the software application is monitored for unauthorized modifications of the runtime image. The method proposed can be used as a basis for further enforcing of authorization rules during the execution of an application, e.g. for Digital Rights Management.
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BACKGROUND OF THE INVENTION
The invention is relative to an oscillatory standing floor.
U.S. Pat. No. 1,640,326 teaches an oscillatory standing floor with an upper part which can move relative to the lower part positioned on the ground or like supporting surface, which upper part and lower part are connected to one another by springs.
DE-U-85 31 386 teaches the suspending of an upper part of a frame on a lower part for receiving a single foot of a chair, armchair, couch or bed via cable rope pendulums of different stages connected functionally in series and with different natural resonant frequencies.
DE patent 31 37 757 teaches an resilient spring floor for gymnasiums which consists of a sub-floor resting on carrier elements and distributing the pressure, on which sub-floor a floor covering is placed. These carrier elements are designed to be permanently resilient and comprise a carrier body which surrounds a hollow space which reduces its vertical clearance upon vertical loading. The lower part of a stop extends into the hollow space which stop can be adjusted in height from the outside, is guided in the carrier element and can be locked opposite the latter at the desired height. This known resilient floor allows a vertical motion but not a horizontal one.
Furthermore, DE-AS 23 19 667 teaches an oscillating dancing surface with at least one plate resiliently supported on a fixed sub-floor, with at least one oscillation generator acting on the plate. An electromechanical converter is fastened to the bottom of the plate as oscillation generator which converter transforms the supplied electric tone frequency output modulated with dancing music into mechanical oscillations. Even this oscillating dancing surface executes only vertical movements. The surface is secured from lateral shifting by its mounting in so-called troughs of steel sheeting or plastic. A layer of plastic or rubber is located between the plates and the sub-construction in order to avoid resonance noises during operation. No horizontal movements are possible with this known oscillating surface nor is the surface excited in natural frequency or oscillations.
Finally, DE patent 0,259,325 teaches a pendulum in which each of its two ends is provided with a clamping head and which comprises distributed over the length of the pendulum with the exception of a short zone in the end areas of the pendulum a plurality of bulging, toroid relatively rigid bodies with only a slight mutual distance from each other arranged like beads. There is no discussion in this patent of the oscillating mounting of a standing floor.
For many people who must carry out their professional activity while standing, e.g. surgeons, dentists or speakers, the long time spent standing in a more or less rigid posture or in positions given by the course of the activity constitutes a considerable strain. There is an urgent desire for a dynamically mounted standing floor.
In addition, there is also a desire in the area of therapy for a dynamically mounted standing floor.
The invention has the problem of creating a reliably functioning standing floor which can oscillate in a horizontal plane.
SUMMARY OF THE INVENTION
It has been noted that people who work on an oscillatory standing floor are considerably less stressed and have a lesser tendency to become tired or develop back pains, obviously due to of the dynamic components of the standing floor. It is of course extremely important that the dynamic component of the standing floor is properly dimensioned. If the dynamic component is too small the desired dynamic properties obviously occur only to a slight extent; on the other hand, if the dynamic component is too great the user has the feeling of standing on a "swaying floor". The dynamic component must therefore be selected in such a manner that the ability to work is not negatively influenced in any way.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in the following with reference made to the drawings.
FIG. 1 shows a standing floor suspended within a carrier frame on pendulums.
FIG. 2 shows a standing floor on the bottom of which support arches are arranged which are suspended for their part via pendulums on the carrier frame arranged below the standing floor.
FIG. 3 shows a variant of the embodiment of FIG. 2 with a multistage pendulum system.
FIG. 4 shows a detailed view of FIG. 3 in which even a certain oblique position of the pendulum can be set if needed.
FIG. 5 shows a standing floor in which the oscillating mounting takes place via a sphere within two associated cup-shaped receiving shells.
FIG. 6 shows a detailed view of the mounting according to FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
The standing floor can be mounted in various ways so that it can oscillate. FIG. 1 shows a carrier frame 10 with at least three essentially curved bracket-shaped carrier brackets 11 which hold horizontally standing floor 13 via pendulums 12 in such a manner that it can oscillate essentially in a horizontal plane and is thus capable of lateral movements. Naturally, slight vertical motion components also result during the oscillating or swinging motion.
The fact is significant that pendulums 12 do on the one hand make an oscillating motion possible but on the other hand also assure a certain damping, since the motion of deflection must obviously not exceed a certain extent. Otherwise, the user of the standing floor would lose a feeling of safety when standing thereon. Pendulums according to EP patent 0,259,325 have proven to be especially advantageous.
A plurality of relatively rigid bead-like bodies 15 are advantageously arranged in a series over the length of pendulum 12 which are arranged with only a slight interval from each other like beads over almost the entire length of the pendulum. Looping movements of pendulum 12 during transport or in the case of similar actions are reliably avoided by these bead-like bodies with only a slight interval from each other. The diameter of the relatively rigid bead-like bodies arranged like beads can increase from the end areas of pendulum 12 toward the middle. A relatively short zone in the vicinity of the clamping heads remains free of bead-like bodies 15 in order to assure a trouble-free suspension on the clamping heads and therewith an unobjectionable functioning of the pendulum. The intermediate spaces between individual bead-like bodies 15 arranged like beads can be largely filled up with an elastic material which also surrounds, if necessary, said bodies. The behavior of pendulum 12 can be influenced by the strength or thickness of the elastic covering applied. A reinforcement of this layer elevates the damping properties. A pendulum 12 corresponding exactly to the particular requirements can be created by a plurality of graduations, which pendulum then only has to be selected and suspended. Further details can be seen from EP patent 0,259,325.
FIG. 2 shows a similar design of a standing floor 13 in which, however, receiving supports 14 are arranged on its underside essentially axially symmetric to carrier support 11. These receiving supports 14 engage the lower end of pendulum 12. This construction brings it about that a surface is created in the plane of standing floor 13 which surface is free of interfering hindrances such as those posed e.g. by carrier supports 11 in FIG. 1.
FIG. 3 shows a standing floor 13 which agrees largely with FIG. 2; however, it comprises a multistage pendulum suspension. Several pendulums 12a are suspended on carrier supports 11 of carrier frame 10 on which pendulums intermediate plane 20 is held which for its part carries a further pendulum 12b via carrier structure 16 which pendulum 12b holds support arm 14 of standing floor 13. According to FIG. 4 a first carrier element 11a supported on the floor has essentially the shape of a U resting on its side and carries carrier arch 11b suspended in its upper shank which arch carries for its part at least three pendulums 12a which for their part hold an essentially bell-shaped intermediate carrier 16. Cup-shaped intermediate carrier 16a is supported on this bell-shaped intermediate carrier 16 via at least one pendulum 12b which carrier 16a carries another cup-shaped element 16b via at least three pendulums 12c of a third stage. This element 16b also forms, among other things, the upper plane of the entire body via a carrier body designed essentially in the shape of a reclining U. Standing floor 13 is arranged on this upper plane either directly or under interpositioning of yet additional elements.
In such an instance the total behavior of standing floor 13 is determined by differing behavior of the particular cable or rope pendulums, e.g. different lengths, different damping, etc. The action of one or the other groups of pendulums can be cut out by known blocking mechanisms. The user then has the choice of the behavior of the one or of the other pendulum group.
There is also the possibility, as FIG. 4 shows, of varying receiving points 21 for pendulums 12 in a radial direction. The effects resulting from such a measure are described in detail in EP patent 0,386,202. A shifting of the receiving points for pendulums 12 can adjust the latter in such a manner that they form a trapezoid open at the top or tapering upward. Thus, there is a continuous possibility of adjusting the arrangement formed by pendulums 12 and the bridges and therewith a continuous influencing of the oscillatory behavior. The user has the possibility therewith of adapting the oscillatory behavior to his particular desires and requirements in a correspondingly continuous manner. In the case of a parallel setting of pendulums 12 a normal oscillatory behavior results, and, an oscillatory behavior deviating from the normal case will occur as a function of the deviation from the parallel position of pendulums 12 in the one direction or the other.
FIG. 5 shows another variant in which the oscillating motion is brought about by two spherical cups 18a, 18b with a large radius of curvature arranged in a mirror-inverted manner relative to one another between which sphere or ball 17 is located. The surfaces of spherical cups 18a, 18b are preferably hardened and likewise for the surface of sphere 17. A casing 22 sealing the inner area with sphere 17 in a dust-proof manner is provided between upper spherical cup 18a and lower spherical cup 18b which casing consists of elastic material and at the same time exerts a certain damping action of the lateral oscillating motions. Casing 22 is provided in its end areas with an inner bead or which fits into corresponding groove 24 of the outer circumference of spherical cups 18a, 18b and is fixed in this position via clamping ring 23 in such a manner that only a slight rotation of casing 22, conditioned by the elasticity, is possible but no lasting relative motion between the bead and spherical cups 18a, 18b.
In the case of any lateral deflections upper spherical cup 18a shifts relative to lower spherical cup 18b with the participation of sphere 17. As a result thereof, sphere 17 is shifted out of the low position in spherical cup 18b into a higher position and then oscillates into the low position again and then past the low position into a high position on the other side. This results in the lateral oscillatory motions. For the rest, that which has already been said for the exemplary embodiments according to FIGS. 1 to 4 is valid.
The described standing floor is also suitable for therapeutic treatments of an "unstable" knee or of an "unstable" ankle joint.
In addition, the standing floor has proven to be therapeutically effective for
Constitutional or local hypermobilities in the postural system,
Functional deviations of the spinal column at any age,
Idiopathic scolioses,
So-called juvenile hunchbacks,
Scoliosizations of the spinal column, especially in children and adolescents,
So-called postural weaknesses,
Projecting shoulder-blades [scapilae],
Disturbances of the plantar arches, especially in children,
Incomplete, limp paralyses in the postural system,
Polyneuropathies in which disturbances of the proprioceptive afference predominate (not suitable if there are relevant disturbances of the rising pathways in the spinal marrow),
Disturbances of proprioceptive afference, organically or functionally conditioned.
If the standing floor is used like this in therapy, it is additionally provided with a support railing in order to give a patient a better grip.
The operation is basically assured by at least three pendulums 12 in one embodiment and three pairs of spherical cups 18a, 18b in the second embodiment. However, more such elements can be provided as needed. The pairs of spherical cups 18a, 8b can be operated functionally in series. To this end, e.g. several stages are arranged in a superposed manner from which each individual one can be put out of operation as needed. This means as a result that the individual pairs of spherical cups 18a, 18b of the one stage or of the other stage can be cut out by blocking mechanisms so that the one or the other stage alone or also several stages together can enter into operation. Since the oscillating behavior, especially the frequency, depends on the shaping of the particular spherical cups 18a, 18b, it is possible to achieve in this manner that a blocking of the one stage or of the other stage permits only quite specific given frequencies to act. The user can thus select the optimum natural frequencies corresponding to one's particular individual requirements, within a certain framework.
It is contemplated that the surface of standing floor 13, 13a may be rectangular, square, round or also some other shape.
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An oscillatory floor surface for standing thereupon. The surface is supported at at least three points each having two circular cups mounted above one another. Each has a spherical depression in confrontation to define a space. A ball is in the space. The cups being affixed to each other by an elastic annular casing. The casing being held to each of the cups by a band.
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TECHNICAL FIELD
[0001] This invention relates to a heat-insulating, sound insulating, high tensile strength and non-toxic emitting fireproof panel and its manufacturing method.
BACKGROUND OF THE INVENTION
[0002] In normal renovations or room partitions, the intended partition is first created by forming a frame using angle block, which then later is attached on by wooden boards, using rivet gun or super glue.
[0003] For fireproof compartments, this is done by attaching fireproof panels to a partition frame created by light steel plates.
[0004] However, the above-mentioned materials posed some flaws, which need to be rectified:
1) Wooden board: Using such materials will be detrimental to the environment. In addition, the production cost will be higher as wood-made materials are expensive. If replacing it with composite board found in the market, such material is flammable and subjected to decay by worms and corrosion by tides. 2) Fire-resistance board: Fireproof panels can be made of either soft or hard materials. Soft materials (such as asbestos) require plywood as external cover, which is inconvenient in construction and increase the cost considerably. Hard materials (such as Gypsum board) is brittle, hence such material is used as part of the assembly unit. This is not suitable for industrial use as a lot of different components are need before the fire-resistance board can be set up. 3) Metal plate: Its surface corrodes easily due to oxidation, hence lytic agent needed to remove the rust. This has a detrimental effect to the environment. Secondly, plywood materials (such as foaming materials or fiberglass) need to be fill in, before the plate achieve sound proof effects, and this also increase the production costs.
[0009] Hence, after much analysis and research, the inventor had come up with a design concept, which can rectify the above-mentioned problems. This involves using polyester filament as the substrate, with cement filling into the exterior and inner fiber gaps of the polyester filament. After drying, the material will have high structural strength and tenacity, as well as sound and heat insulation properties. Hems can be added to the material during manufacturing, so as to provide convenience during assembly and processing work. Hence it is suitable as outdoor and indoor building material.
SUMMARY OF INVENTION
[0010] The main aim of this invention is to showcase a new fireproof panel that is of high structural strength, tenacity, having sound and heat insulation properties, and also its manufacturing method.
[0011] Another aim of this invention is to offer a fireproof panel that has hem, thus providing convenience in assembly and processing work.
[0012] To meet the aim, this invention is implemented in the following manner: the fireproof panel is arranged in a stromatolithic structure, with more than one layer in it. The fireproof panel uses polyester filament as the substrate, with cement filling into the exterior and inner fiber gaps of the polyester filament. Such material has the characteristics of high structural strength and tenacity, as well as sound and heat insulation properties.
[0013] This mineral filler of 40% cement, 5% soil powder, 5% adhesives, and is mixed with 50% water. In addition, the side of the panel has hem, so it can be used in assembly work.
[0014] The steps to manufacture this material are as follows:
Pick-up process: Polyester filament is made into a fiber structure, and undergoes hardening treatment to form the substrate. Feed-in process: Filling up the exterior and inner fiber gaps with mineral filler and heat-dry partially. Cutting progress: Cut out the shape and measurement of the block needed; Molding process: Place the block into a mould, adding pressure for a certain time, so that its shape will be fixed. Drying process: After removing from the mould, heat-dry the plate totally, and the fire-proof material is produced.
BRIEF DESCRIPTION OF DRAWINGS
[0020] The invention will be more clearly understood after referring to the following detailed description read in conjunction with the drawings wherein:
[0021] FIG. 1 is the schematic diagram showing the formation of the panel structure.
[0022] FIG. 2 is the implementation diagram showing the embodiment of the panel structure.
[0023] FIG. 3 is the flowchart of the manufacturing process.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] The inventions will be further explained in detail using drawings and concrete embodiments, in order for the honorable examiner to understand the aims, characteristics and uses of this invention:
[0025] Please refer to FIGS. 1 and 2 . The former is the map of the formation of the panel structure, whereas the latter is the embodiment of the panel structure. As shown from the drawing, the fireproof material 1 , is arranged in a stromatolithic structure, with more than one layer on it. The fireproof material 1 , uses polyester filament as its substrate 11 , and the exterior and inner fiber gap of the substrate 11 is totally fill-up with mineral filler 12 . This results in the high structure strength, as well as the sound and heat insulating properties of the material.
[0026] To achieve the best result, the ratio of polyester filament substrate 11 to the mineral filler 12 should be 1:1 or close to 1:1.
[0027] The mineral filler 12 consist of 40% cement, 5% soil powder as well as 5% adhesive that is made up of agar-agar powder, and thoroughly mixed with 50% water.
[0028] Also, the fireproof material 1 of this invention can be used as a single piece, or attached together to form multi-layers. When use as a single piece, hem 13 must be included at its side extension. (This should be created during the manufacturing process) The hem 13 at the sides will enable the material to undergo assembly work. When used as a stack, attach the smooth surface of the fireproof material 1 with the fireproof material 1 with hem 13 to create a single structure. (Pressure added to the stack during manufacturing to fuse it)
[0029] Paint or other decorative coat can be applied to the surface of the fireproof material in order to beautify it. Alternatively, designs, as well as prints and embossments can also be produce on the surface.
[0030] As previously mentioned, be it smooth surface or with hem 13 , the quality of the fireproof material 1 is the same. Hence the effect is very good when they are attached together. In addition, as the substrate 11 is made up of polyester filament, this can increase the tenacity of the structure. Furthermore, as the mineral filler 12 of the exterior and inner fiber gap is cement, this gives a surface quality that similar to normal cement. Not only does it have high structural strength, it is non-toxic and has good heat and sound insulating properties, which makes it useful for painting or pasting wall paper. It also overcomes the problems faced by commonly used partition materials.
[0031] Please refer to FIG. 3 . This is the manufacturing flow-chart of the invention. According to the chart, the manufacturing method of the fireproof panel 1 of this invention, consist of the following process:
Pick-up process A, the extraction of the polyester filament; Processing process B, processing the polyester filament into fabric structure; Hardening process C, treat the polyester filament under the temperature of 200° C., roll until it forms a hardened substrate; Feed-in process D: Soak the substrate with exterior and inner fiber gaps with the mineral filler consisting of 40% cement, 5% soil powder, 5% adhesive made with agar-agar powder and 50% water; Drying process E: Heat-dry the substrate partially (about 50% dry). This will form the bottom first layer. Make sure that the surface of the processing machinery is clean. Stacking process F: Follow processes A to E to manufacture the second layer. (More layers can be added if required) Stack the new layers on top of the first layer; Drying process G: Heat-dry the stacked panel under the temperature of 200° C. Make sure that the mineral fill-in material on the surface of the panel is partially dry; Cutting process H: Use the cutter to slice out the measurement and shape of the stacked block required; Molding process I: Add clapboard between the inter-linings of the block, and place it in the mould. Apply pressure to the cast for 1 day (about 24 hours); De-molding process J: The final shape of the fireproof panel is formed after removing the mould; Drying process K: Heat dry the panel completely under the temperature of 200° C. The fireproof panel manufacturing process is complete after that; Trimming process L: Trim and even out the edge of the fireproof panel (trim the edge); Surface processing process M: Paint or other decorative coat can be applied to the surface of the fireproof material in order to beautify it. Alternatively, designs, as well as prints and embossments can also be produce on the surface.
[0045] The fireproof panel that I produced is the above-mentioned manufacturing flowchart is mainly pertaining to a single layer structure. The aforesaid flowchart represents the production of multiple layers of individual fireproof panels 1 by an automatic machine. If there is a need to produce multiple layers, processes E and I can be omitted after producing the second layer of the panel. After the molding and processing processes, the pre-made layers can be stacked together into a single structure to form the fireproof panel.
[0046] Of course, the surface design of the mould can be altered to produce fireproof material 1 with hem 13 , so as to meet the need of producing a single layer or multi-layer fireproof panels.
[0047] From the above-mentioned, this invention and its manufacturing method can provide a sound and heat insulating, high strength and non-toxic fireproof panel. This can rectified the different flaws of the clapboard commonly found in the market. It is more suitable to be used for indoor partitions and decorations. Hence, it is brand new, improved and has uses in the industry.
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This present invention relates to a fireproof material and its manufacturing method, which comprising a material pick-up process, a feed-in process, a cutting process, molding process and drying process. The present invention fireproof material, which uses polyester filament as substrate and the hiatus of exterior substrate and inner fiber completely are infilled with mineral filler, has several advantages such as high structure strength, heat-insulating and sound-insulating.
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[0001] The present invention depends from Australian Provisional Patent Application No. PQ 3027, filed 23 Sep. 1999 in the Commonwealth of Australia, full Paris Convention priority is hereby earnestly solicited and reserved.
FIELD OF THE INVENTION
[0002] The present invention relates to an intraluminal device for use in the treatment of aneurysmal or stenotic disease.
BACKGROUND OF THE INVENTION
[0003] It is known to use intraluminal grafts and stents of various designs for the treatment of aneurysms such as aortic aneurysms and occlusive diseases affecting the vasculature or other vessels comprising, inter alia, the hepatobiliary and genito-urinary tracts (which are all hereinafter “vessels”). It is known to form such an intraluminal device of a sleeve in which is disposed a plurality of self-expanding wire stents (see Balko A. et al (1986) Transfemoral Placement of Intraluminal Polyurethane Prosthesis for Abdominal Aortic Aneurysms, 40 Journal of Surgical Research 40, 305-309; Mirich D. et al. (1989) Percutaneously Placed Endovascular Grafts for Aortic Aneurysms: Feasibility Study 170(3) Radiology 170(3), 1033-1037).
[0004] In the past, such devices have commonly been used in the treatment of aneurysms, see, for example. U.S. Pat. Nos. 5,782,904, 5,968,068, 5,976,192, 6,013,092, and U.S. application Ser. No. 09/203,998 all subject to assignment to the entity owning all rights in the instant subject matter. However, it has been recognized that it is within the ambit of some such devices that they also be used to treat stenotic lesions. Whatever the purpose for which an intraluminal device is being used, it has the capacity to be inserted percutaneously through a distal (or proximal) and connecting vessel to that in which the device is to be used. For example, the device may be inserted through the femoral artery in a catheter, where the device is intended to be used in the treatment of a lesion within the aorta. Upon release of the device from the catheter it may expand to a desirable size, and may extend above and below the lesion thereby bridging that lesion. This method of inserting the device into the body of a patient is applicable where the invention is used in the treatment of aneurysmal disease or stenotic disease.
[0005] Further, where the device is used in the treatment of an aneurysm which extends from a single vessel into one or more divergent vessels, a bifurcated or “trouser graft” is required as described in, for example, Australian Application No 74862/96, and U.S. application Ser. Nos. 09/204,699, 09/392,655, 09/478,352, and 09/478,413 each of which is expressly incorporated herein by reference and subject to assignment to a common entity.
[0006] There may be a number of problems associated with such known intraluminal devices which may include rupture of the intraluminal graft due to general wear or damage upon insertion into the vessel. While thicker and more durable grafts may be designed to overcome this problem, such grafts in turn require a larger sized catheter for delivery into the affected vessel. The limitation in this regard is the size of the artery in which the catheter is being inserted. For example in the situation where a graft is inserted to bridge an aneurysm in the thoracic aorta, the catheter bearing the graft must be inserted through one of the femoral arteries, moved through the femoral artery, into the common iliac artery and eventually into the aorta. If the catheter is too large in diameter, it is not suitable for insertion into the femoral artery of a patient.
[0007] Further, in so-called “trouser grafts”, the graft may have a tendency to “kink” in an area of the graft immediately above the area of bifurcation. Whilst kinking in this region may be overcome by adding further reinforcing wires integral the material of the graft in this region, this may increase the diameter of the graft and thus a larger size of catheter may be required to introduce the graft into the vessel.
[0008] The present invention is directed to an alternative form of intraluminal device which in preferred forms may overcome the above problems and in fact has been revised and novel enhanced iterations advanced to the market for the first time post-1999. Likewise further embodiments are yet to be released.
SUMMARY OF THE INVENTION
[0009] In a first aspect, the present invention consists in an intraluminal device comprising a first tubular graft body and at least a second tubular graft body, each tubular graft body having a length and a first and at least second end wherein when the intraluminal device is disposed within a vessel of a patient, a majority of the length of the second tubular graft body overlaps with a majority of the length of the first tubular graft body.
[0010] In yet another aspect, the invention consists in a method for positioning a first and at least a second tubular graft segment, cuff, or body in a vessel of a patient's body, the method including the steps of introducing a catheter into the vessel in the body, causing the first tubular graft member to be moved through the catheter until it extends into the vessel from the proximal end of the catheter, urging the first tubular graft body into contact with the wall of the vessel; causing the second tubular graft member to be moved through the catheter until a substantial length of the second tubular graft body overlaps a substantial length of the first tubular graft body and urging the second tubular graft body into contact with the first tubular graft body.
[0011] In an embodiment of this further aspect for example, the first tubular graft body is moved through the catheter on an inflatable balloon until it extends into the vessel from the proximal end of the catheter. The balloon is then inflated to cause the first tubular graft body to be urged into contact with the wall of the vessel and subsequently deflated and withdrawn from the vessel. The second tubular graft body is then moved through the catheter on an inflatable balloon until a substantial length of the second tubular graft body overlaps a substantial length of the second tubular graft body and the balloon inflated such that the second tubular graft body is urged into contact with the first tubular graft body. The balloon is then deflated and the catheter withdrawn from the vessel. Alternatively, the first tubular graft body is moved through the catheter until it extends into the vessel. A balloon may then be passed through the catheter until it extends from the proximal end of the catheter internal the first tubular graft body whereupon the balloon is inflated to cause the first tubular graft body to be urged into contact with the wall of the vessel. The second tubular graft body may be similarly introduced into the vessel.
[0012] In yet another embodiment, in place of a balloon, the first and the second tubular graft bodies may be self expandable such that when the tubular graft body extends from the proximal end of the catheter it takes on an expanded configuration such that it is caused to contact the vessel wall.
[0013] In examples based on at least one embodiment, the first and the second tubular graft bodies have an equal cross sectional area or a different cross sectional area before insertion into the vessel of a patient. When in situ, however, typically the maximum cross sectional area of the first tubular graft is greater than the maximum cross sectional area of the second tubular graft body. Accordingly, the first tubular graft body is inserted into the vessel of a patient and the second tubular graft body inserted internal the first tubular graft body such that a substantial portion of the second tubular graft body overlaps with a substantial portion of the first tubular graft body. Alternatively, the maximum cross sectional area of the first tubular graft body may be less than the maximum cross sectional area of the second tubular graft body such that upon placement of the first tubular graft body within the vessel of a patient, the second tubular graft body is introduced such that the second tubular graft body is placed external to the first tubular graft body.
[0014] In one illustrated embodiment, the entire length of the second tubular graft body is overlapped with a length of the first tubular graft body.
[0015] In a further illustrated embodiment the entire length of the first tubular graft body is overlapped with a length of the second tubular graft body.
[0016] In yet a further illustrated embodiment, the first and second tubular graft bodies are of the same length and the entire length of the second tubular graft body is overlapped with the entire length of the first tubular graft body.
[0017] Prototypes of related iterations have been used and tested. According to yet a still further embodiment, the area of overlap of the two tubular graft bodies is greater than 50% of the length of the tubular graft bodies. More preferably, the area of overlap is greater than 75-80% and more preferably still between 80 and 100%.
[0018] In a still further embodiment, a portion of the second tubular graft body does not overlap with the first tubular graft body, said non-overlapping portion extending longitudinally from the first tubular graft member into the lumen of the vessel in which the device is disposed.
[0019] In one tested and working embodiment, the first and at least second tubular graft bodies are circumferentially reinforced along their length by a plurality of separate, spaced apart, malleable wires. Each of the wires can have a generally closed sinusoidal shape.
[0020] In still a further embodiment, the first and second tubular graft bodies are longitudinally reinforced along their length by a longitudinally reinforcing malleable wire. The longitudinally reinforcing wire may be positioned between two circumferentially reinforcing wires. Several longitudinally reinforcing wires may be positioned along the length of both the first and the second tubular graft bodies. Each wire may be generally straight in shape or may have a zig-zag or sinusoidal shape. The presence of a longitudinally reinforcing wire has the advantage of reinforcing the tubular graft bodies such that neither tubular graft body is forced into a compressed state along its longitudinal axis.
[0021] In a still further embodiment, one of the tubular graft bodies (for example, the first) may be longitudinally reinforced, said tubular graft body having no circumferential reinforcement. In this embodiment the other (for example, the second) tubular graft body is circumferentially reinforced, said other tubular graft body having no longitudinal reinforcement.
[0022] In another alternate embodiment, the first and at least second tubular graft bodies are circumferentially reinforced along their length by one continuous wire, the wire taking on a spiral configuration along the length of both the first and at least second tubular graft bodies. Likewise. helices in the configuration of the wire are within the scope of the instant techniques.
[0023] In another embodiment, the first and at least second tubular graft bodies are circumferentially reinforced along their length by a series of wires or one continuous wires woven into the material of the tubular graft bodies such that the wires are not exposed at either the outer or the inner surface of the tubular graft bodies. Such an enclosed wireform arrangement is particularly useful in one embodiment of the invention wherein the tubular graft body is inserted into the vessel of a patient and caused to expand within the vessel of the patient by way of an inflatable balloon. In a further embodiment wherein the tubular graft body is adapted to self expand without the need for a balloon it is not required that the wires be entirely enclosed and indeed it is preferred that at least a portion of the wires are positioned on either the outside or the inside surfaces of the tubular graft bodies. Like wise, it is known to artisans that, for example, any techniques in the commonly owned or assigned patents and patent applications such as interweaving of wireforms having predetermined or pre-ordained spatial orientations made of, for example, Elgiloy® wireforms with Dacron® grafts (available from Baxter Vascular Systems Division, Irvine, Calif.) or a PTFE (Baxter Healthcare Corporation, Laguna Hills, Calif.) and Nitinol™ (Memry Metal, California) are equally applicable and work well within human patients.
[0024] In a further embodiment, both tubular graft bodies are either balloon expandable or self expandable. Alternatively, one of the tubular graft bodies may be balloon expandable and the other tubular graft body self expandable. Preferably, when in situ within the vessel of a patient the outer tubular graft body (for example, the first tubular graft body) which is in contact with the vessel wall is of the self expandable type and the inner tubular graft body (for example the second tubular graft body) is of the balloon expandable type.
[0025] In a still further embodiment, at least a portion of the length of one tubular graft body may be adapted to be balloon expandable and the remaining length of the same tubular graft body adapted to be self expandable. In a particularly preferred embodiment, the first end of the tubular graft body is self expandable and the remainder of the tubular graft body is balloon expandable. This embodiment is of particular significance when it is understood that misplacing of a balloon internal the tubular graft body such that the balloon extends past the first end of the tubular graft body may cause inflation of the vessel wall itself and may potentially result in rupture of the vessel wall. With the first end of the tubular graft body adapted such that it is self expandable, the balloon need not be inserted as far towards the first end thereby reducing the risk of over extension of the balloon and subsequent damage of the vessel wall.
[0026] In a further embodiment, the first and at least second tubular graft bodies are reinforced along their length by a series of separate spaced apart stents. Alternatively in another embodiment, at least some of the stents may be interconnected or all of the stents may be interconnected to form one continuous stent.
[0027] In still a further embodiment, the first tubular graft body includes at least one first engagement member which is connected to or integral with a wall of the first tubular graft body at a position intermediate the ends of the first tubular graft body.
[0028] In yet a further embodiment, the at least one first engagement member is adapted to extend externally of the wall of the first tubular graft body. When disposed in a vessel, the engagement member preferably abuts the surrounding vessel wall thereby securing the first tubular graft body within the vessel.
[0029] In another embodiment, the at least one first engagement member comprises the ends of the malleable wires which are joined together to form a tail means. Each tail means is preferably on the outside of the graft body and positioned to lie along its radially outer surface. The ends may be joined by welding, by being twisted together or in any other suitable manner. The ends of adjacent wires preferably project in generally opposite directions along the first tubular graft body and when the first tubular graft body is inserted into a vessel those wires that engage the vessel wall will assist in preventing dislodgement of the first tubular graft body within the vessel.
[0030] In a further embodiment, several of the tails of the malleable wires may be on or adjacent an inside wall of the first tubular graft body such that upon insertion of the second tubular graft body internal the first tubular graft body, the tails engage with the wall of the second tubular graft body thereby securing the second tubular graft body in place. Frictional, mechanical, and frustoconical means for engaging are further used with the overlapping aspects of the present invention.
[0031] In another embodiment, the at least one first engagement member comprises a hook-like member adapted to project from at least the first end of the first tubular graft body, when disposed in a vessel, the hook-like member preferably engages the wall of the vessel in which the first tubular graft body is disposed thereby preventing dislodgement of the first tubular graft body within the vessel. Alternatively, the first tubular graft body includes a stent or a series of spaced apart stents which form a framework to which may be attached an endoluminal graft. Expansion of the stent or stents will cause the first tubular graft body to expand and press against the wall of a vessel into which it has been placed thereby securing the first tubular graft body in that vessel.
[0032] In yet a further embodiment, the first tubular graft body includes at least one second engagement member positioned intermediate the two ends of the first tubular graft body, the at least one second engagement member is adapted to project into the lumen of the first tubular graft body such that it engages the wall of the second tubular graft body.
[0033] In one embodiment, the at least one second engagement member preferably includes a ring-like member adapted to project into the lumen of the first tubular graft body from the inner surface of the first tubular graft body.
[0034] In a further embodiment, the ring-like member is continuous or discontinuous in configuration.
[0035] Alternatively, in a further embodiment, the second engagement member could include hook-like members circumferentially disposed around the inner surface of the first tubular graft body. In another form, the tails formed from the ends of the separate, spaced apart malleable wires could be adapted to project into the lumen of the first tubular graft body such that they engage with the second tubular graft body, thereby securing the second tubular graft body within the lumen of the first tubular graft body.
[0036] In one embodiment, the first tubular body comprises a simple tubular sheath adapted to be disposed in a vessel such that it engages with and is attached to the wall of the vessel.
[0037] In a further embodiment, the at least second tubular graft is preferably formed of a more durable and thick material than that of the first tubular graft body, for example Dacron® or polytetrafluoroethylene (PTFE).
[0038] In yet a further embodiment, the surfaces of both the first and the second tubular graft bodies are coated with a material from the group comprising biocompatible glues, adhesives, or the like engineered cellular matrices for joining surfaces. The biocompatible glue or the like adhesion means enhances attachment of the first tubular graft body to a vessel wall thereby further preventing dislodgement of the intraluminal device within the vessel and further enhancing attachment of the second tubular graft body to the first tubular graft body.
[0039] In another embodiment, the surfaces of both the first and second tubular graft bodies may be coated with fibrins or some other material to stimulate fibrin or cellular ingrowth into the device from the surrounding tissue. Such ingrowth further secures the intraluminal device within the vessel wall. An example of a material which increases tissue ingrowth into the tubular graft bodies is polyurethane. Alternatively, a polyurethane/polycarbonate composite may be used to enhance cellular ingrowth.
[0040] In a further embodiment, the first and at least one second tubular graft bodies include a collar member attached to the first end. In addition, a further collar member may be attached to the at least one second end of the tubular graft bodies.
[0041] In another embodiment, the collar member is not attached to the tubular graft bodies but is inserted separately from the tubular graft bodies.
[0042] The surface of the collar member may be coated with fibrins or some other material such as polyurethane or polyurethane/polycarbonate composite and adapted to stimulate cellular ingrowth into the device from the surrounding tissue.
[0043] In a further embodiment, the first tubular graft body is circumferentially reinforced by a series of separate, spaced apart malleable wires along only a portion of its length.
[0044] In alternately, yet still another embodiment, the second tubular graft body is circumferentially reinforced by a series of separate, spaced apart malleable wires along only a portion of its length, see for example U.S. application Ser. No. 09/163,831 which has been expressly incorporated by reference herein.
[0045] In a further embodiment, when the device of the invention is in situ within the vessel of a patient, the portion of the first tubular graft body that is not reinforced overlaps with the portion of the second tubular graft body that is reinforced and the portion of the second tubular graft body that is not reinforced overlaps with the portion of the first tubular graft body that is reinforced. In this case, the entire length of the device will be reinforced.
[0046] In yet a further embodiment, when the device is in situ within a vessel of a patient, only a superior portion of the first tubular graft body distal its own entry point is circumferentially reinforced by the wires and only an inferior portion of the second tubular graft body proximal its entry point is reinforced by the wires such that the overlapping of first and second tubular graft bodies causes the entire length of the device to be circumferentially reinforced. The circumferential reinforcement of each tubular graft body is not, however, limited to circumferential reinforcement of the superior or inferior portions of each tubular graft body and is simply adapted such that in situ, a length of the device that is not reinforced by the separate spaced apart malleable wires located on the first tubular graft body is reinforced by separate, spaced apart, malleable wires located on the second tubular graft body.
[0047] The intraluminal device according to this invention may be used to treat aneurysmal or occlusive disease. In addition to treating aortic aneurysms they are particularly suitable for treating aneurysms of the femoral artery, the popliteal artery, the thoracic segment of the aorta, the visceral arteries such as the renal and mesenteric arteries, the iliac and subclavian artery.
[0048] It is sometimes the case that the aneurysm extends to or slightly beyond an arterial bifurcation. In such a case, the second tubular graft body is adapted such that it is bifurcated at its downstream end, a so-called “trouser graft”. A supplemental graft, or cuff-means may then be introduced through each of the subsidiary arteries and overlapped with the respective lumenae of the bifurcated part of the second tubular graft body. For instance, in the case of an aneurysm in the aorta that extends into one or each of the iliac arteries, the second tubular graft body would be placed in the aorta through one of the iliac arteries. Supplemental grafts which dock with the bifurcated end of the primary graft would then be inserted through each of the iliac arteries. In such a case the region of graft body directly superior the bifurcated region of the second tubular graft body can have a propensity to occasionally kink. The overlapping of the first and second tubular graft bodies, therefore, increases the circumferential reinforcement in the region of the device superior the bifurcated region by increasing the number of separate, spaced apart, malleable wires or other reinforcing wires thereby reducing the likelihood of kinking in this region. In a further embodiment, the first and at least second tubular graft bodies are longitudinally reinforced in addition to or instead of being circumferentially reinforced.
[0049] In a further embodiment of the first and second aspects of the invention, the second tubular graft body is inserted into the lumen of the first tubular graft body such that a substantial length of the second tubular graft body overlaps with a substantial length of the first tubular graft body.
[0050] In still a further embodiment of the second aspect of the invention, the second tubular graft body is of the “trouser graft” type such that the bifurcated portion is positioned such that it extends longitudinally from the first tubular graft body into the surrounding vessel, for example, the aorta and wherein a supplemental graft may be introduced though each of the subsidiary arteries and overlapped with the respective lumenae of the bifurcated portion of the second tubular graft body.
[0051] In another embodiment, where the intraluminal device is adapted to span an aneurysm affecting an area of artery which is bifurcated, both the tubular graft bodies are of the “trouser graft” variety. Accordingly, the tubular graft bodies comprise a main body positioned in, for example, the aorta and two leg members adapted to extend into the iliac arteries. The first leg member of the first tubular graft body may be shorter than the second leg member. In this case, the second leg member of the second tubular graft member is shorter than the first leg member of the second tubular graft member. Accordingly, the two tubular graft members may be mirror images of each other or as close to mirror images as is practicable. This has the advantage of avoiding unnecessary bulking in the leg members of the graft due to excessive overlapping of the two grafts in this area. Because the main bodies of each tubular graft body overlap with each other, however, the intraluminal device is still reinforced in the area of the device most likely to kink, that is, the area directly above the bifurcation of the tubular graft bodies.
[0052] In a further embodiment, the first tubular graft body may include only one leg member, the first tubular graft body having an aperture rather than a second leg member. In this case, the second tubular member is adapted such that it has one leg member that may be inserted through the aperture of the first tubular graft body. In place of the second leg member, the second tubular member has an aperture through which the leg member of the first tubular graft body may be inserted. This embodiment has the advantage that each tubular graft member is symmetrical in shape. Typically, with trouser grafts, the tubular graft body must be positioned in a certain orientation, such that one leg member extends into one vessel and the other leg member extends into another vessel. In the case of a graft for bridging an aneurysm spanning the bifurcation of the aorta into the iliac arteries, one of the leg members will extend towards or into the left iliac artery and the other leg member will extend towards or into the right iliac artery. Radio-opaque markers positioned on the graft are typically used to ensure the correct positioning of the graft. In the present embodiment, however, because the first tubular graft body is symmetrical in shape there is no need to use such markers to ensure correct positioning of the tubular graft body and the one leg member will extend towards or into the desired iliac artery. A second tubular graft member may then be inserted, the second tubular graft member having one leg member that extends towards or into the other iliac artery.
[0053] According to a feature of the present invention, there is provided in an endovascularly emplaced prosthesis for bridging an aneurysm, the improvement which comprises; at least a supplemental graft member positioned whereby a flow path through a treated vessel is extended.
[0054] According to another feature of the present invention, there is provided, an apparatus for intraluminal emplacement comprising; a first tubular body; and a second tubular body wherein each said tubular body further comprises a graft having a length and a first and at least a second end, whereby when the apparatus is disposed within a vessel of a patient, a predetermined length of the second graft body overlaps with a desired length of the first graph body.
[0055] According to yet still another feature of the present invention, there is provided a method of intraluminal emplacement comprising:
[0056] providing a first graft body and positioning a cuff-means for extending the first graft body within said first graft body for affixing said cuff-means whereby a lumen of said first graft body is extended.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] Hereinafter by way of example is a preferred embodiment of the present invention described with reference to the accompanying drawings, in which:
[0058] FIG. 1 is a diagrammatic partially cut-away ventral view of a patient with an aortic aneurysm which has been bridged by an intraluminal graft according to an embodiment of the present invention.
[0059] FIG. 2 is a detailed longitudinal sectional view of the intraluminal device of FIG. 1 .
[0060] FIG. 3 is a detailed elevational view of one end of an intraluminal device of an embodiment of the invention.
[0061] FIG. 4 is a detailed view of one component of one embodiment of the invention.
[0062] FIG. 5 is a detailed view of one component of a further embodiment of the invention.
[0063] FIG. 6 is a side elevational view of a device of the present invention showing the spatial arrangement between the components of the device, according to an embodiment of the present invention.
[0064] FIG. 7 is a detailed view of one component of a further embodiment of the invention.
[0065] FIG. 8 is a side elevational view of one embodiment of the invention.
[0066] FIG. 9 is a side elevational view of one component of the embodiment of the invention depicted in FIG. 8 .
[0067] FIG. 10 is a side elevational view of another component of the embodiment of the invention depicted in FIG. 8 .
[0068] FIG. 11 is a more detailed side elevational view of the embodiment of the invention as depicted in FIG. 8 .
[0069] FIG. 12 is a schematic view of a further embodiment of the invention.
[0070] FIG. 13 is a side elevational view of another embodiment of the invention.
[0071] FIG. 14 shows a supplemental cuff-means according to an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0072] An intraluminal device according to the present invention is generally shown as 10 in the drawings. The intraluminal device 10 comprises two separate components, a first graft 11 and a second graft 12 .
[0073] The device 10 is adapted for insertion transfemorally into a patient to achieve bridging and occlusion of an aneurysm 13 present in the aorta 14 . As shown in FIG. 1 , the aorta 14 bifurcates to form the common iliac arteries 15 which in turn divide into the internal 16 and external 17 iliac arteries. The external iliac artery in turn forms the femoral artery 18 . The first graft 11 is inserted inside a catheter (not shown) and introduced into one of the femoral arteries 18 in a leg of a patient. Once the catheter is located appropriately with its proximal end in the aorta 14 , the first graft 11 is ejected from the catheter and expanded using a balloon so that the first graft 11 is in intimate contact along its length and around its full periphery with the surrounding vessel. The first graft 11 then bridges the aneurysm. Alternatively, in a preferred embodiment, the first graft 11 is made from a self expandable material such that first graft 11 is in a collapsed configuration internal the catheter. Upon ejection from the catheter, the first graft takes on an expanded configuration such that the first graft 11 is in intimate contact along its length and around its full periphery with the surrounding vessel.
[0074] In one embodiment, the first graft 11 comprises a tube made from a very thin material and is used essentially as an anchor for the second more durable graft 12 . To assist in the placement of the first graft 11 in the aorta 14 , the first graft 11 is provided with engagement members 19 (see FIG. 5 ) which project from one end 21 of the first graft 11 . It is to be recognised that further engagement members may be circumferentially disposed along the entire length of the first graft 11 .
[0075] The first graft 11 and second graft 12 may be circumferentially reinforced along their lengths by a number of separate and spaced wires 22 . The wires are preferably as thin as possible and are malleable such that they may be bent to any desired shape. The wires are each woven into the fabric of the first graft 11 or second graft 12 such that alternate crests of each wire 22 are outside of the graft with the remainder of the wire 22 inside the graft. The ends of each wire 22 are located outside the first graft 11 or second graft 12 and are twisted together to form a tail 23 . The tails or alternate wires may be bent in opposite longitudinal directions along the outside of the surface of the first graft 11 . The arrangement of the tails 23 on the outside of the first graft 11 assists in the positioning of the first graft 11 in the aorta as the tails 23 have a tendency to abut against the wall of the aorta thereby securing the first graft 11 within the aorta.
[0076] In a further embodiment, the first graft 11 and the second graft 12 may be longitudinally reinforced by wire 36 . FIG. 13 depicts the longitudinal reinforcement of the first graft 11 only but it is readily envisaged that second graft 12 may be similarly reinforced. Further, wire 36 is shown as being connected to the circumferentially reinforcing wires 22 . It is to be understood that wire 36 may be connected to the material of the first graft 11 and not to the wires 22 . Wire 36 may be straight or zig-zag in shape or may be a sinusoidal shape as depicted in FIG. 13 .
[0077] Once the first graft 11 is in position, the second graft 12 is similarly introduced into the aorta 14 by way of insertion of a catheter through the femoral artery 18 of a patient. In the depicted embodiment, the second graft 12 is of the “trouser graft” type, that is, it has a main body 24 and a bifurcated portion 25 and is made from woven Dacron® The catheter is introduced into the lumen of the first graft 11 and the second graft 12 inflated by way of a balloon such that the main body 24 expands and abuts against the inner facing surface of the first graft 11 . The bifurcated portion 25 extends in a longitudinal plane from the other end 26 of the first graft 11 into the lumen of the aorta 14 .
[0078] The first graft 11 may be provided with internal rings 27 which act to overlay the wires 22 of the second graft 12 and thereby secure the second graft 12 in place within the lumen of the first graft 11 .
[0079] FIG. 8 to 10 depict a further embodiment of the invention wherein both graft 11 and 12 are “trouser grafts”. The first graft 11 has a main body 24 , a long leg 28 and a short leg 29 . The second graft 12 also has a main body 24 , a long leg 31 and a short leg 32 . When the two grafts are in situ within a vessel of a patient, as depicted in FIG. 11 , the main body 24 of each graft overlap with each other entirely whereas overlapping of the legs of the grafts is kept to a minimum to avoid unnecessary “bulking” of the graft in this area.
[0080] In another embodiment depicted in FIG. 12 , the first graft 11 has a main body 24 and one leg 33 . A second leg is absent in this embodiment, and in its place is simply an aperture 34 . A second graft 12 may be inserted internal the first graft 11 such a leg 35 of the second graft 12 extends through aperture 34 . The leg 35 of second graft 12 extending through aperture 34 is shown in phantom in FIG. 12 .
[0081] Referring now to FIG. 14 , supplemental cuff-means 38 likewise comprises a plurality of crimped stent-formed wires 22 which are each woven into the fabric of supplemental graft 38 such that alternate crests of each wire 22 are outside of graft 38 with the remainder of the wire 22 inside the graft. The ends of each wire 22 are located outside graft 38 and are twisted together to form a tail 23 . The tails or alternate wires may be bent in opposite longitudinal directions along the outside of the surface of graft 38 . The arrangement of the tails 23 on the outside of graft 38 assists in the positioning of graft 38 in the aorta as the tails 23 have a tendency to abut against the wall of the aorta thereby securing graft 38 within the aorta.
[0082] Likewise, those having a modicum of skill in the art will understand that supplemental cuff-means or graft 38 is effective for use within the (failed or leaking) grafts of other commercial entities, such as, for example, the GUIDANT/EVT brand ANCURE® DEVICE; the GORE brand EXCLUDER®; the Boston Scientific Vanguard® brand; Medtronic/AVE ANERUERX® or TALENT® brand devices in addition to those of the Cook Endovascular Graft brand ZENITH™ AAA Endovascular Graft. It is noted that specific overlapping, sizing, and the like dimensional parameters will be obvious to artisans.
[0083] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
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Supplemental intraluminal graft extension achieved by cuff-means substantially fortify and enhance endovascularly emplaced systems, particularly for bridging aneurysms. Multiple embodiments based upon overlapping of at least two segments are taught. Cuff-means likewise have applications to restore patency to, or substantially enhance, prior failing emplacements of both home-made and other commercial devices.
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BACKGROUND OF THE INVENTION
The present invention relates to a multi-cylinder engine mounted on a motorcycle.
The number of the cylinders of an internal combustion engine to be mounted on a motorcycle or the like has lately been increased with a view to increasing the upper limit r.p.m. of the engine, to thereby improve engine output power. However, if the cylinders are arranged in the longitudinal direction of the vehicle body, the wheel base of the vehicle is so prolonged as to invite an increase in body weight.
On the contrary, as shown in FIG. 1 a motorcycle which mounts thereon a series multi-cylinder internal combustion engine c having its cylinders b arranged at a right angle with respect to the longitudinal direction of the body a, as shown in FIGS. 1 to 4, has a shorter wheel base, to attain an advantage in body weight. However, the widthwise size of the engine is increased with the increase in the number of the cylinders so that the banking angle θ Ai (wherein the letter i designates the number of the cylinders) of the motorcycle is reduced to lower the turning velocity.
On the other hand, if the internal combustion engine is arranged at an upper portion of the body so as to increase the banking angle θ Ai , the center of gravity is shifted upwardly to invite a deterioration in slaloming performance.
Further, some motorcycles having a multi-cylinder engine mounted thereon have a construction wherein respective cylinders are equipped with independent carburetors. In this construction, the mounting directions of the respective cylinders are determined exclusively by physical restrictions, e.g., the body structure and the engine mounting positions.
On the other hand, since the carburetor itself is remarkably sensitive to dynamic pressure, vacuum, temperature and the air flow rate, the characteristics of the engine are highly influenced by these parameters. In a multi-cylinder engine having its respective cylinders equipped with independent carburetors, therefore, the carburetors are desirably arranged identically to one another as much as possible.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a multi-cylinder engine capable of preventing body weight increase.
Another object of the invention is to provide such an engine capable of providing a relatively large lateral body inclination angle during curving travel, yet providing the center of gravity of the resultant motorcycle at a low position.
Still another object of the invention is to provide a space for positioning carburetors for each of the cylinders of the engine, yet minimizing the longitudinal length of the frame of the motorcycle.
These and other objects of the invention will be attained by the downward and frontward extension of at least one cylinder of the multi-cylinder engine. Remaining cylinder(s) of the engine extend upwardly and frontwardly, and the lower and upper cylinders define an obtuse angle in a vertical plane. The lower cylinder is disposed at a position offset from the lateral sides defined by the upper cylinder(s).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation showing a motorcycle having a conventional three-cylinder internal combustion engine mounted thereon;
FIG. 2 is a front elevation of the same;
FIGS. 3 and 4 are front elevations of motorcycles on which four- and two-cylinder internal combustion engines are mounted, respectively;
FIG. 5 is a side elevation showing a motorcycle on which one embodiment of the multicylinder internal combustion engine according to the present invention is mounted;
FIG. 6 is a front elevation of the same;
FIG. 7 is an enlarged side elevation showing an essential portion of the same;
FIG. 8 is a front elevation showing only the engine portion, as viewed from the front of the vehicular body of FIG. 1;
FIG. 9 is a front elevation showing the engine portion with the carburetor cover attached; and
FIGS. 10 and 11 are front elevations showing other embodiments, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A V-type three-cylinder internal combustion engine will be described in the following as one embodiment of the present invention with reference to FIGS. 5 to 7. In FIG. 5, reference numerals 1, 2 and 3 indicate a steering head, an upper frame and a lower frame, respectively. The frames 2 and 3 are formed into the so-called "double cradle" frame structure, composed of two such tubes, respectively, symmetrically attached to the steering head 1, but the present device is not limited to such a construction. In the space defined by said double cradle frame, there are disposed a multi-cylinder engine, e.g., a three-cylinder engine 4 and a crankcase 5, which are attached to the frame in a well-known manner. In front of the frames 2 and 3, a pair of front forks 15 are movably supported, and a front wheel 16 is rotatably supported on the forks 15. Of the respective cylinders 6, 7 and 8, the cylinders 6 and 7 are attached to the engine 4 so that they are juxtaposed to each other in an identical horizontal plane and are directed generally upward, whereas the remaining cylinder 8 is arranged so that it is positioned below the aforementioned two cylinders 6 and 7 and such that it is directed in a direction between the front portion and the lower portion (i.e., toward the ground) of the vehicular body. The detail of that arrangement is shown in FIG. 6.
Specifically, in the center of the frame 3, there is disposed a V-type three-cylinder two-cycle internal combustion engine 4 which has its cylinders arranged at a right angle with respect to the longitudinal direction of the body 1. The central cylinder 8 is directed downwardly from the front whereas the left and right cylinders 6 and 7 are directed obliquely upwardly to the front at an angle θ' larger than 90 degrees with respect to the central cylinder 8. (See FIG. 7).
To the upper portion of the central cylinder 8 and to the front portions of the left and right cylinders 6 and 7, furthermore, there are respectively attached carburetors 17 which have identical specifications.
In the embodiment shown in FIGS. 5 to 7, as has been described hereinbefore, the left and right cylinders 6 and 7 are arranged at an obtuse angle with respect to the central cylinder 8. As a result, the cylinders 6, 7 and 8 do not interfere with one another so that the total width of the engine 4 can be reduced. Moreover, since the central cylinder is disposed at a lower level, the center of gravity of the engine can be lowered.
Furthermore, the central cylinder 8 is inclined at a downwardly directed angle whereas the left and right cylinders 6 and 7 are directed at ane elevation angle θ' larger than a right angle to the front. As a result, even if the engine 4 is shifted downwardly, the bank angles θ 3 (FIG. 6), which are defined between the ground point of the wheel 16 and the largest lateral protrusion of the engine 4 in the obliquely upward direction along the transverse direction of the vehicle, are allowed to assume a large value so that turning performance and slaloming performance, which might otherwise be incompatible, can be simultaneously satisfied. In FIG. 6, the bank angles θ 3 of the present invention are compared with the like angles θ A3 resulting with the in-line three cylinder configuration of the prior art (FIG. 2).
Moreover, the left and right cylinders 6 and 7, which are disposed at higher positions, and the central cylinder 8 which is disposed at a lower position, can be positioned at optimum angles, to thereby provide a space allowing the carburetors 17 to be attached to the cylinders 6, 7 and 8 so that the intake pipes can be set at the most proper length. To be more specific, as shown in FIGS. 8 and 9, the respective carburetors, which are independently attached to the cylinders 6, 7 and 8, respectively, can all have their air intake ports 9, 10 and 11 arranged substantially forwardly of the vehicle. Incidentally, the respective exhaust pipes of the cylinders 6 and 8 are indicated at 12 and 14 in FIG. 5, with the exhaust pipe of the cylinder 7 juxtaposed with the exhaust pipe 12 (although not shown).
With the construction thus far described, the carburetors all have their air intake ports arranged in the same direction and forwardly of the body so that they are set and arranged under the same conditions of dynamic pressure, vacuum, temperature and air flow rate.
As shown in front elevation of FIG. 9, moveover, only one carburetor cover 18 for adjusting the dynamic pressure during the running operation and for protecting the carburetors against foreign obstacles is sufficient, resulting in marked advantages in design and cost.
The embodiment shown in FIGS. 5 to 9 is directed to a V-type three-cylinder engine which has its central cylinder directed downwardly. However, the present invention can also be applied to a V-type four-cylinder engine having two central cylinders directed downwardly and the two side cylinders directed upwardly at an angle larger than 90 degrees with respect to the central cylinders, as shown in FIG. 10. As a result, effects similar to those of the embodiment shown in FIGS. 5 to 9 can be provided. FIG. 10 compares the banking angles θ 4 produced via the invention with those of the four cylinder engine of the prior art (θ A4 , FIG. 3).
As has been described hereinbefore, furthermore, the present invention can be applied to a V-type two cylinder engine having its left or right cylinder downwardly inclined and its other cylinder inclined at an elevation angle larger than 90 degrees, as shown in FIG. 11, which compares the banking angle of the invention, θ 2 , with that of the prior art configuration, θ A2 , of FIG. 4.
In view of the foregoing, according to the present invention, suitable steering stability is obtainable because of optimum multicylinder engine layout. Further, such layout provides space to allow the carburetors to be connected to the cylinders in an advantageous fashion. The carburetors of the multicylinder engine are arranged so as to have their intake ports all held under substantially the same conditions, so that there can be attained advantages in that the performance characteristics of the engine can be improved and the carburetor cover can be made as a singular element.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention.
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A multi-cylinder engine mounted on a motorcycle includes at least two cylinders arranged in a V-configuration. At least one cylinder of the engine extends downwardly and frontwardly relative to the motorcycle. The remaining cylinder(s) of the engine extend upwardly and frontwardly, and the lower and upper cylinders define a obtuse angle therebetween in a vertical plane.
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BACKGROUND
Large format inkjet printers print on a variety of different substrates. Large format print substrates include, for example, paper, vinyl and textiles that may be supplied as flexible or rigid pre-cut sheets or rolls of flexible web. Currently, flexible web substrates are more common for large format printing. Some printers handle flexible web substrates up to five meters wide. Large flexible substrates may stretch or otherwise deform as they are moved through the printer, and they may shrink and expand in response to varying temperature and humidity. The irregular and sometimes unpredictable nature of these large flexible substrates may result in improper ink drop placement, thus degrading print quality. It is desirable to monitor the actual position of the substrate as it moves through the printer to allow for corrections to the placement of the ink drops on the substrate to help maintain acceptable print quality.
DRAWINGS
FIG. 1 is a block diagram illustrating one example of an inkjet printer in which implementations of the invention may be used.
FIG. 2 is a diagrammatic elevation view illustrating a roll-to-roll web printer that includes an encoder assembly according to one implementation of the invention.
FIGS. 3-5 are diagrammatic elevation views illustrating one example configuration of an encoder assembly, such as the one shown in FIG. 2 , in which the encoder assembly is located in a channel in the platen.
FIGS. 6 and 7 are section views taken along lines 6 - 6 in FIG. 3 and lines 7 - 7 in FIG. 5 , respectively.
FIGS. 8-11 are enlarged diagrammatic elevation views illustrating one example implementation of an encoder assembly such as that shown in FIGS. 3-7 in which the encoder scale moves with the print substrate and the encoder sensor is stationary.
FIGS. 12-15 are enlarged diagrammatic elevation views illustrating one example implementation of an encoder assembly such as that shown in FIGS. 3-7 in which the encoder sensor moves with the print substrate and the encoder scale is stationary.
FIG. 16 is a perspective view illustrating an example implementation in which multiple encoder scales alternate moving with the print substrate.
FIGS. 17 and 18 are diagrammatic views illustrating two operating scenarios for the implementation shown in FIG. 16 .
FIGS. 19 and 20 are perspective views illustrating another example implementation in which the encoder scale is attached to the print substrate indirectly through a linkage.
The same part numbers are used to designate the same or similar parts throughout the figures.
DESCRIPTION
Implementations of the new encoder assembly were developed to help accurately monitor the actual position of large format print substrates as they move through the printer, to allow corrections to the placement of the ink drops on the substrate for better print quality. Implementations of the new encoder assembly, however, are not limited to use with large print substrates or large format printers. In one example implementation, one of the encoder parts—either the encoder scale or the encoder sensor—is attached to the substrate. The sensor reads the markings or other indicators on the scale while advancing the substrate with the encoder part attached. The encoder part is then detached from the substrate and returned to a previous position where the process of attaching, sensing and detaching may be repeated to monitor the position of the substrate during printing. The example implementations described below should not be construed to limit the scope of the invention, which is defined in the Claims that follow the Description.
FIG. 1 is a block diagram illustrating one example of an inkjet printer 10 in which implementations of the invention may be used. Referring to FIG. 1 , inkjet printer 10 includes a printhead 12 , an ink supply 14 , a carriage 16 , a print substrate transport mechanism 18 and a controller 20 . Printhead 12 in FIG. 1 represents generally one or more printheads and the associated mechanical and electrical components for dispensing drops of ink on to a sheet or a continuous web of paper or other print substrate 22 . Printhead 12 may include one or more stationary printheads that span the width of print substrate 22 . Alternatively, printhead 12 may include one or more printheads that scans back and forth on carriage 16 across the width of substrate 22 . Printhead 12 may include, for example, thermal ink dispensing elements or piezoelectric ink dispensing elements. Other printhead configurations and ink dispensing elements are possible.
Substrate transport 18 advances print substrate 22 past printhead 12 . For a stationary printhead 12 , substrate transport 18 may advance substrate 22 continuously past printhead 12 . For a scanning printhead 12 , substrate transport 18 may advance substrate 22 incrementally past printhead 12 , stopping as each swath is printed and then advancing substrate 22 for printing the next swath. Ink chamber 24 and printhead 12 are usually housed together in an ink pen 26 , as indicated by the dashed line in FIG. 1 . Ink supply 14 supplies ink to printhead 12 through ink chamber 24 . Ink supply 14 , chamber 24 and printhead 12 may be housed together in an ink pen. Alternatively, ink supply 14 may be housed separate from ink chamber 24 and printhead 12 , as shown, in which case ink is supplied to chamber 24 through a flexible tube or other suitable conduit. Printer 10 typically will include several ink pens 26 , for example one pen for each of several colors of ink.
Controller 20 in FIG. 1 represents generally the programming, processor(s) and associated memories, and the electronic circuitry and components needed to control the operative elements of printer 10 . In a printing operation, controller 20 receives print data and, if necessary, processes that data into printer control information and image data. Controller 20 controls the movement of carriage 16 and substrate transport 18 . Controller 20 is electrically connected to printhead 12 to energize the ink dispensing elements to dispense ink drops on to substrate 22 . By coordinating the relative position of printhead 12 and substrate 22 with the location of dispensed ink drops, controller 20 produces the desired image on substrate 22 according to the print data.
FIG. 2 is a diagrammatic elevation view illustrating a roll-to-roll web printer 10 that includes an encoder assembly 28 according to one implementation of the invention. Referring to FIG. 2 , printer 10 includes, for example, a group of multiple ink pens 26 for dispensing different color inks. Ink pens 26 are mounted on a carriage 16 over a platen 30 . In the example implementation shown in FIG. 2 , substrate transport 18 in printer 10 includes a web supply roller 32 and a web take-up roller 34 . A web substrate 22 extends from supply roller 32 over platen 30 between intermediate rollers 36 and 38 to take-up roller 32 . Intermediate rollers 36 and 38 , for example, help control the direction and tension of web 22 through a print zone 40 over platen 30 . Pens 26 are scanned back and forth (into and out of the page in FIG. 2 ) on carriage 16 across the width of substrate 22 as it passes over platen 30 through print zone 40 .
FIGS. 3-5 are enlarged diagrammatic elevation views illustrating one example configuration for encoder assembly 28 in FIG. 2 . FIGS. 6 and 7 are section views taken along lines 6 - 6 in FIG. 3 and lines 7 - 7 in FIG. 4 , respectively. Referring to FIGS. 3-7 , encoder assembly 28 includes a movable encoder scale 42 and an encoder sensor 44 . As best seen in FIGS. 6 and 7 , scale 42 and sensor 44 are located in a channel 46 in platen 30 . Sensor 44 is operatively connected to a printer controller, such as controller 20 in FIG. 1 . Scale 42 carries markings or other indicators that may be sensed by sensor 44 and used by controller 20 to determine the location, velocity, acceleration or other parameters associated with substrate 22 . In operation, encoder scale 42 is attached to substrate 22 as shown in FIGS. 3 and 6 . Then, sensor 44 senses the indicators on scale 42 while advancing substrate 22 with scale 42 attached, as best seen by comparing the position of scale 42 in FIGS. 3 and 4 . Scale 42 is then detached from substrate 22 as shown in FIGS. 5 and 7 and returned to a previous position, as best seen by comparing the position of scale 42 in FIGS. 4 and 5 . The figures depict scale 42 moving up to attach to substrate 22 and moving down to detach from substrate 22 for illustrative purposes only. While scale 42 might move when attached to and detached from substrate 22 , such movement is not necessary. In some implementations, such as the implementation described below with reference to FIGS. 8-11 , neither scale 42 nor substrate 22 move during attachment and detachment.
The process of attaching, sensing, and detaching may be repeated as desired throughout a printing operation. For a printer 10 in which ink pens 26 are scanned back and forth across substrate 22 , scale 42 may be attached to substrate 22 while substrate 22 is stopped for printing a swath as ink pens 26 are scanned across substrate 22 . Scale 42 then moves forward with substrate 22 as substrate 22 is positioned for printing the next swath. Scale 42 may be released from substrate 22 and returned to a previous position while substrate 22 is stopped for printing the next swath. Depending on the length and range of travel of scale 42 , scale 42 may remain attached to substrate 22 as substrate 22 is advanced for printing multiple swaths. For a printer 10 in which substrate 22 moves continuously past a stationary printhead 12 during printing, scale 42 may be repeatedly attached to and detached from a moving substrate 22 .
Different parts of a large flexible substrate 22 may behave in different ways. For example, one part of a substrate 22 may be shrinking while another part along the same printing path may be expanding. Multiple encoder assemblies 28 may be positioned across the width of substrate 22 or positioned at other locations along the length of substrate 22 to help more accurately characterize different parts of the substrate 22 . While it is expected that scale 42 will usually be returned to the prior starting position, as shown in FIGS. 3 and 5 , scale 42 might be returned to a different starting position. Any suitable encoder technology may be used in encoder assembly 28 including, for example, an optical encoder or a magnetic encoder. Also, encoder scale 42 may include position indicators in two dimensions—across the width of substrate 22 as well as along the length of substrate 22 .
Data gathered by sensor(s) 44 may be used by controller 10 to adjust the placement of ink drops on substrate 22 or other printing parameters to improve print quality, for example by adjusting the position of substrate 22 through substrate transport 18 and/or by adjusting the ejection of ink drops through ink pens 26 . Drop placement may be adjusted for individual parts of substrate 28 using data from one or more encoder assemblies 28 to compensate for local substrate deformation and to increase local drop placement accuracy.
One example technique for attaching encoder scale 42 to substrate 22 and detaching encoder scale 42 from substrate 22 will now be described with reference to FIGS. 8-11 . Referring to FIGS. 8-11 , encoder assembly 28 includes a carrier 48 that carries encoder scale 42 . In this example implementation, carrier 48 is configured as a vacuum box operatively connected to a pump or other suitable vacuum source 50 . Scale 42 is attached to or integrated into the bottom of carrier vacuum box 48 . For example, scale 42 may be a reflective scale formed in or attached to the outer surface of the bottom of carrier 48 . The top of vacuum box 48 is positioned close to the bottom side of substrate 22 . For example, where encoder assembly 28 is positioned in a channel 46 in platen 30 , the top of vacuum box 48 may be made flush with the top of platen 30 . In the example implementation shown in FIGS. 8-11 , vacuum box 48 includes a group of openings 52 along a planar top face 54 . Each opening 52 is connected to vacuum source 50 through an interior plenum 56 .
Air is evacuated from plenum 56 , and thus from the space between box face 54 and substrate 22 , to suck together box 48 and substrate 22 as indicated by arrows 57 in FIG. 8 and attach box 48 and scale 42 to substrate 22 . Sufficient suction is applied to create enough friction between substrate 22 and box 48 to allow box 48 to move with substrate 22 . It is not necessary that one or both substrate 22 and box 48 move toward or actually contact one another. All that is required is enough suction to cause box face 54 to effectively “stick” to substrate 22 .
Sensor 44 reads scale 42 as substrate 22 is advanced through print zone 40 with carrier box 48 attached, as shown in FIG. 9 . Carrier box 48 is detached from substrate 22 by releasing the vacuum applied to openings 52 , as indicated by arrows 57 in FIG. 10 , and returned to a previous position as shown in FIG. 11 . In some applications it may be desirable to pressurize plenum 56 , and thus the space between box face 54 and substrate 22 to help maintain an air bearing between box face 54 and substrate 22 , for example by reversing a vacuum pump 50 . The air bearing allows vacuum box 48 and substrate 22 to move freely with respect of one another as box 48 is returned to a starting position as shown in FIG. 11 and as substrate 22 moves over a stationary box 48 .
In an alternative implementation shown in FIGS. 12-15 , encoder sensor 44 moves with print substrate 22 and encoder scale 42 is stationary. Referring to FIGS. 12-15 , in this implementation vacuum box carrier 48 carries encoder sensor 44 . Air is evacuated from box 48 to suck together box 48 and substrate 22 , thus attaching box 48 and sensor 42 to substrate 22 as described above with reference to FIGS. 8-11 . Sensor 44 reads scale 42 as it moves with substrate 22 along scale 42 , as shown in FIG. 13 . Carrier box 48 is detached from substrate 22 by releasing the vacuum applied to opening(s) 52 and returned to a previous position as shown in FIGS. 14 and 15 .
FIG. 16 is a perspective view illustrating an example implementation in which multiple encoder scales 42 alternate moving with print substrate 22 . FIGS. 17 and 18 are diagrammatic views illustrating two operating scenarios for the implementation shown in FIG. 16 . Referring first to FIG. 16 , encoder assembly 28 is positioned between one of the intermediate rollers 36 or 38 and platen 30 . Encoder assembly 28 includes two encoder scales 42 A and 42 B mounted to respective carrier vacuum boxes 48 A and 48 B. Each box 48 A and 48 B is mounted on a track 58 opposite one another in a direction across the width of substrate 22 .
Referring to FIG. 17 , in one operating scenario for encoder assembly 28 in FIG. 16 , each scale 42 A and 42 B is mounted on an oval track 58 that moves in only one direction around rollers 60 , 62 to carry each scale 42 A and 42 B over a single sensor 44 . Track 58 includes an advancing part 64 and a returning part 66 . In operation, scale 42 A on the advancing part 64 of track 58 is attached to and advances with substrate 22 (not shown) past encoder sensor 44 and then is released from substrate 22 . While scale 42 A is advancing with substrate 22 on advancing part 64 , scale 42 B is returning along track part 66 toward a starting position on track advancing part 64 , where it will become the advancing scale attached to substrate 22 moving past sensor 44 . Thus, one scale advances while the other scale returns.
Referring to FIG. 18 , in another operating scenario for encoder assembly 28 in FIG. 16 , each scale 42 A, 42 B is mounted on a corresponding track part 58 A and 58 B, each moving back and forth at the urging of rollers 60 , 62 to carry each scale 42 A and 42 B alternately over respective sensors 44 A and 44 B. Each track part 58 A, 58 B advances and returns a scale 42 A, 42 B. In operation, with rollers 60 and 62 turning clockwise, scale 42 A on track part 58 A is attached to and advances with substrate 22 (not shown) past encoder sensor 44 A and then is released from substrate 22 . While scale 42 A is advancing with substrate 22 on track part 58 A, scale 42 B is returning detached from substrate 22 along track part 58 B toward a starting position, where it will become the advancing scale attached to substrate 22 moving past sensor 44 B when rollers 60 and 62 are reversed to turn counter-clockwise. Thus, one scale advances while the other scale returns.
FIGS. 19 and 20 are perspective views illustrating another example implementation in which encoder scale 42 is attached to print substrate 22 through a linkage 68 . Referring to FIGS. 19 and 20 , in this implementation, a carrier 48 carrying encoder scale 42 is attached to and detached from substrate 22 through linkage 68 . Linkage 68 includes a vacuum box 70 and a connecting arm 72 connecting carrier 48 to vacuum box 70 . Vacuum box 48 is positioned close to the bottom side of substrate 22 and operatively connected to a vacuum source 50 . In operation, vacuum is applied to box 70 to suck together box 70 and substrate 22 as shown in FIG. 20 , thus attaching carrier 48 and scale 42 to substrate 22 indirectly through linkage 68 . Vacuum box 70 and scale 42 connected to box 70 moves along with the advancing substrate 22 , as best seen by comparing the position of scale 42 in FIGS. 19 and 20 , with sensor 46 sensing indicators on the moving scale 42 . Then, vacuum to box 70 may be released to detach box 70 and thus scale 42 from substrate 22 , and scale 42 returned to the previous position ( FIG. 19 ) at the urging of a pneumatic cylinder 74 or another suitable return mechanism.
As noted above, the example implementations shown in the Figures and described above do not limit the invention. Other implementations are possible. Accordingly, these and other implementations, configurations and details may be made without departing from the spirit and scope of the invention, which is defined in the following claims.
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In one implementation, an encoder assembly for a printer includes: an encoder scale having indicators thereon for determining a printing parameter; an encoder sensor for sensing indicators on the scale; and a mechanism configured to alternately attach an encoder part (either the scale or the sensor) to the substrate and detach the encoder part from the substrate. In another implementation, a method includes: attaching an encoder part to a print substrate, the encoder part being either an encoder scale or an encoder sensor; the sensor sensing indicators on the scale while advancing the substrate with the encoder part attached; and detaching the encoder part from the substrate.
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RELATED APPLICATIONS
[0001] This application is a continuation application of copending U.S. patent application Ser. No. 11/835,154 filed Aug. 7, 2007, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present application is generally related to steering tools for horizontal directional drilling and, more particularly, to a system and method using supplemental magnetic information in a steering tool type arrangement.
[0003] A boring tool is well-known as a steerable drill head that can carry sensors, transmitters and associated electronics. The boring tool is usually controlled through a drill string that is extendable from a drill rig. The drill string is most often formed of drill pipe sections, which may be referred to hereinafter as drill rods, that are selectively attachable with one another for purposes of advancing and retracting the drill string. Steering is often accomplished using a beveled face on the drill head. Advancing the drill string while rotating should result in the drill head traveling straight forward, whereas advancing the drill string with the bevel oriented at some fixed angle will result in deflecting the drill head in some direction.
[0004] One approach that has been taken by the prior art for purposes of monitoring the progress of a boring tool in the field of horizontal directional drilling, resides in what is commonly referred to as a “steering tool”. This term has come to describe an overall system which essentially predicts the position of the boring tool, as it is advanced through the ground using a drill string, such that the boring tool can be steered toward a desired target or along a planned drill path within the ground. Steering tool systems are considered as being distinct from other types of locating systems used in horizontal directional drilling at least for the reason that the position of the boring tool is monitored in a step-wise fashion as it progresses through the ground. For this reason, positional error can accumulate with increasing progress through the ground up to unacceptable levels.
[0005] Generally, in a steering tool system, pitch and yaw angles of the drill-head are measured in coordination with extension of the drill string. From this, the drill-head position coordinates are obtained by numerical integration. Nominal or measured drill rod lengths can serve as a step size during integration. While this method appears to be sound and might enable an experienced driller to use the steering tool successfully, there are a number of concerns with respect to its operation, as will be discussed immediately hereinafter.
[0006] With respect to the aforementioned positional error, it is noted that this error can be attributed, at least in part, to pitch and yaw measurement errors that accumulate during integration. This can often result in large position errors after only a few hundred feet of drilling.
[0007] Another concern arises with respect to underground disturbances of the earth's magnetic field, which can cause significant yaw measurement bias errors, potentially leading to very inaccurate position estimates.
[0008] Still another concern arises to the extent that steering effectiveness of a typical HDD drill bit depends on many factors including drill bit design, mud flow rate and soil conditions. For example, attempting to steer in wet and sandy soil with the tool in the 12 o'clock roll position might become so ineffective that measured pitch does not provide correct vertical position changes. That is, the orientation of drill head, under such drilling conditions, does not necessarily reflect the direction of its travel.
[0009] One approach in dealing with the potential inaccuracy of the steering tool system is to confirm the position of the drill head independently. For example, the drill head can be fitted with a dipole transmitter. A walk over locator can then be used to receive the dipole field and independently locate the drill head. This approach is not always practical, for example, when drilling under a river, lake or freeway. In these situations, the operator might notice position errors too late during drilling and consequently might not have an opportunity to implement a drill-path correction.
[0010] The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
SUMMARY
[0011] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
[0012] In general, a system and associated method are described in which a steering tool is movable by a drill string and steerable in a way that is intended to form an underground bore along an intended path, beginning from a starting position.
[0013] In one aspect, a sensing arrangement, forming one part of the steering tool, detects a pitch orientation and a yaw orientation of the steering tool at a series of spaced apart positions of the steering tool along the underground bore, each of which spaced apart positions is characterized by a measured extension of the drill string. At least one marker is positioned proximate to the intended path, for transmitting a rotating dipole field such that at least a portion of the intended path is exposed to the rotating dipole field. A receiver, forming another part of the steering tool, receives the rotating dipole field with the steering tool at a current one of the spaced apart positions to produce magnetic information. A processor is configured for using the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string in conjunction with the magnetic information, corresponding to the current one of the positions of the steering tool, to determine a current location of the steering tool, relative to the starting position, with a given accuracy such that using only the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string to determine the current position, without the magnetic information, would result in a reduced accuracy in the determination of the current location, as compared to the given accuracy.
[0014] In another aspect, a sensing arrangement is provided, forming one part of the steering tool, for detecting a pitch orientation and a yaw orientation of the steering tool. The steering tool is moved sequentially through a series of spaced apart positions along the underground bore. Each of the spaced apart positions is characterized by a measured extension of the drill string. At least one marker is arranged, proximate to the intended path, for transmitting a rotating dipole field such that at least a portion of the intended path is exposed to the rotating magnetic dipole. The dipole field is received using a receiver that forms another part of the steering tool, with the steering tool at a current one of the spaced apart positions on the portion of the intended path, to produce magnetic information. A processor is configured for using the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string in conjunction with the magnetic information, corresponding to the current one of the positions of the steering tool, to determine a current location of the steering tool relative to the starting position with a given accuracy such that using only the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string to determine the current location, without the magnetic information, results in a reduced accuracy in the determination of the current location, as compared to the given accuracy.
[0015] In still another aspect, a sensing arrangement is provided, forming one part of the steering tool, for detecting a pitch orientation and a yaw orientation of the steering tool. The steering tool is moved sequentially through a series of spaced apart positions to form the underground bore. Each of the spaced apart positions is characterized by a measured extension of the drill string, a detected pitch orientation and a detected yaw orientation. At least one portion of the intended path is identified along which an enhanced accuracy of a determination of the current location of the steering tool is desired. One or more markers is arranged proximate to the portion of the intended path, each of which transmits a rotating dipole field such that at least the portion of the intended path is exposed to one or more rotating dipole fields. A receiver is provided, as part of the steering tool, for generating magnetic information responsive to the rotating dipole fields. A processor is configured for operating in a first mode using the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string to determine a current location of the steering tool corresponding to any given one of the spaced apart positions with at least a given accuracy and for defaulting to a second mode using the detected pitch orientation, the detected yaw orientation, the measured extension of the drill string and the magnetic information, when the magnetic information is received, to determine the current location of the steering tool with an enhanced accuracy that is greater than the given accuracy.
[0016] In yet another aspect, a method for establishing a customized accuracy in determination of a position of the steering tool with respect to the intended path is described. A sensing arrangement, forming one part of the steering tool, detects a pitch orientation and a yaw orientation of the steering tool. The steering tool is moved sequentially through a series of spaced apart positions to form the underground bore. Each of the spaced apart positions is characterized by a measured extension of the drill string, a detected pitch orientation and a detected yaw orientation. One or more portions of the intended path are identified along which an enhanced accuracy of the determination of the current location of the steering tool is desired. One or more markers are arranged proximate to each one of the portions of the intended path where each of the markers transmits a rotating dipole field such that each one of the identified portions of the intended path is exposed to one or more rotating dipole fields. As a result of the transmission range of the rotating dipole field, more than just those portions of the intended path may be exposed to the rotating dipole field(s). A receiver is provided, as part of the steering tool, for generating magnetic information responsive to the rotating dipole fields. A processor is configured for operating in a first mode using the detected pitch orientation, the detected yaw orientation and the measured extension of the drill string to determine a current location of the steering tool corresponding to any given one of the spaced apart positions with at least a given accuracy and for operating in a second mode using the detected pitch orientation, the detected yaw orientation, the measured extension of the drill string and the magnetic information to determine the current location of the steering tool with an enhanced accuracy that is greater than the given accuracy, at least for the one or more portions of the intended path, to customize an overall position determination accuracy along the intended path.
[0017] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be illustrative rather than limiting.
[0019] FIG. 1 is a diagrammatic view, in elevation, of a system according to the present disclosure operating in a region.
[0020] FIG. 2 is a diagrammatic plan view of the system of FIG. 1 in the region.
[0021] FIG. 3 a is a block diagram which illustrates one embodiment of a steering tool that is useful in the system of FIGS. 1 and 2 .
[0022] FIG. 3 b is a diagrammatic view, in perspective, of a marker that is useful in the system of FIGS. 1 and 2 .
[0023] FIG. 3 c shows a coordinate system in which pitch and yaw are illustrated.
[0024] FIGS. 4 and 5 illustrate one embodiment of a setup technique that can be used in conjunction with the system of FIGS. 1 and 2 .
[0025] FIG. 6 is a diagrammatic view, in elevation, of a drill path along which the steering tool is disposed, shown here to illustrate one embodiment of a technique for providing an initial solution estimate for the position of the steering tool.
[0026] FIG. 7 a is a diagrammatic, further enlarged view, of a portion of FIG. 6 , shown here to illustrate further details of the initial solution estimate technique.
[0027] FIG. 7 b is a flow diagram which illustrates one possible embodiment of a technique for determining the position of the steering tool using a Kalman filter.
[0028] FIG. 8 is a plot of random distance error versus distance.
[0029] FIGS. 9 a and 9 b are plots of pitch angle and yaw angle, respectively, versus drill string length for use in a detailed simulation.
[0030] FIG. 10 a is a plot in a simulation of estimated Y (lateral) steering tool position with respect to X position, employing a basic steering tool without the use of markers.
[0031] FIG. 10 b is a plot in the simulation of estimated Z (elevational) steering tool position with respect to X position, employing a basic steering tool without the use of markers.
[0032] FIG. 10 c is a plot, for the simulation of FIGS. 10 a and 10 b, of steering tool coordinate position error versus X position, which illustrates positional errors for the X, Y and Z axes without the use of markers.
[0033] FIG. 11 a is a plot in a simulation of estimated Y (lateral) steering tool position with respect to X position, employing a steering tool in conjunction with one marker.
[0034] FIG. 11 b is a plot in the simulation of estimated Z (elevational) steering tool position with respect to X position, employing the steering tool in conjunction with one marker.
[0035] FIG. 11 c is a plot, for the simulation of FIGS. 11 a and 11 b, of steering tool coordinate position error versus X position, which illustrates positional errors for the X, Y and Z axes with the use of one marker.
[0036] FIG. 12 a is a plot in a simulation of estimated Y (lateral) steering tool position with respect to X position, employing a steering tool in conjunction with two markers.
[0037] FIG. 12 b is a plot in the simulation of estimated Z (elevational) steering tool position with respect to X position, employing the steering tool in conjunction with two markers.
[0038] FIG. 12 c is a plot, for the simulation of FIGS. 12 a and 12 b, of steering tool coordinate position error versus X position, which illustrates positional errors for the X, Y and Z axes with the use of two markers.
[0039] FIG. 13 a is a plot in a simulation of estimated Y (lateral) steering tool position with respect to X position, employing a steering tool in conjunction with three markers.
[0040] FIG. 13 b is a plot in the simulation of estimated Z (elevational) steering tool position with respect to X position, employing the steering tool in conjunction with three markers.
[0041] FIG. 13 c is a plot, for the simulation of FIGS. 13 a and 13 b, of steering tool coordinate position error versus X position, which illustrates positional errors for the X, Y and Z axes with the use of three markers.
[0042] FIGS. 14 a - c are plots of position error estimates, available through the Kalman filter analysis, versus the X axis and directly compared with position error plots show in FIG. 13 c for the drill path of FIGS. 13 a and 13 b
[0043] FIG. 15 is a diagrammatic plan view of a drilling region for a concluding portion of an intended drill path, shown here to illustrate various aspects of arranging and moving markers along the drill path.
[0044] FIG. 16 is a diagrammatic plan view of the drilling region and drill path of FIG. 16 , shown her to illustrate further aspects with respect to arranging and moving markers along the drill path.
DETAILED DESCRIPTION
[0045] The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the described embodiments will be readily apparent to those skilled in the art and the generic principles taught herein may be applied to other embodiments. Thus, the present invention is not intended to be limited to the embodiment shown, but is to be accorded the widest scope consistent with the principles and features described herein, including modifications and equivalents, as defined within the scope of the appended claims. It is noted that the drawings are not to scale and are diagrammatic in nature in a way that is thought to best illustrate features of interest. Descriptive terminology such as, for example, upper/lower, right/left, front/rear top/bottom, underside and the like has been adopted for purposes of enhancing the reader's understanding, with respect to the various views provided in the figures, and is in no way intended as being limiting.
[0046] Turning now to the figures, wherein like components are designated by like reference numbers whenever practical, attention is immediately directed to FIGS. 1 and 2 , which illustrate an advanced steering tool system that is generally indicated by the reference number 10 and produced according to the present disclosure. FIG. 1 is a diagrammatic elevation view of the system, whereas FIG. 2 is a diagrammatic plan view of the system. System 10 includes a drill rig 18 having a carriage 20 received for movement along the length of an opposing pair of rails 22 which are, in turn, mounted on a frame 24 . A conventional arrangement (not shown) is provided for moving carriage 20 along rails 22 . A steering tool 26 includes an asymmetric face 28 and is attached to a drill string 30 which is composed of a plurality of drill pipe sections 32 . An intended path 40 of the steering tool includes positions that are designated as k and k+1. The steering tool is advanced from position k to k+1 by either a full or a fraction rod length. If very short drill pipe sections are used, the distance between positions k and k+1 could be greater than a rod length. By way of example, drill pipe sections have a rod length of two feet would be considered as very short. The steering tool is shown as having already passed through points 1 and 2 , where point 1 is the location at which the steering tool enters the ground at 42 , serving as the origin of the master coordinate system. While a Cartesian coordinate system is used as the basis for the master coordinate systems employed by the various embodiments disclosed herein, it is to be understood that this terminology is used in the specification and claims for descriptive purposes and that any suitable coordinate system may be used.
[0047] An x axis 44 extends from entry point 42 to a target location T that is on the intended path of the steering tool, as seen in FIG. 1 and illustrated as a rectangle, while a y axis 46 extends to the left when facing in the forward direction along the x axis, as seen in FIG. 2 . A z axis 48 extends upward, as seen in FIG. 1 . Further descriptions will be provided at an appropriate point below with respect to establishing this coordinate system.
[0048] As the drilling operation proceeds, respective drill pipe sections, which may be referred to interchangeably as drill rods, are added to the drill string at the drill rig. For example, a most recently added drill rod 32 a is shown on the drill rig in FIG. 2 . An upper end 50 of drill rod 32 a is held by a locking arrangement (not shown) which forms part of carriage 20 such that movement of the carriage in the direction indicated by an arrow 52 causes section 32 a to move therewith, which pushes the drill string into the ground thereby advancing the boring operation. A clamping arrangement 54 is used to facilitate the addition of drill pipe sections to the drill string. The drilling operation is controlled by an operator (not shown) at a control console 60 which itself can include a telemetry section 62 connected with a telemetry antenna 64 , a display screen 66 , an input device such as a keyboard 68 , a processor 70 , and a plurality of control levers 72 which, for example, control movement of carriage 20 .
[0049] Turning now to FIG. 3 a, an electromechanical block diagram is shown, illustrating one embodiment of steering tool 26 that is configured in accordance with the present disclosure. Steering tool 26 includes a slotted non-magnetic drill tool housing 100 . A triaxial magnetic field sensing arrangement 102 is positioned in housing 100 . For this purpose, a triaxial magnetometer or coil arrangement may be used depending on considerations such as, for example, space and accuracy. A triaxial accelerometer 104 is also located in the housing. Outputs from magnetic field sensing arrangement 102 and accelerometer 104 are provided to a processing section 106 having a microprocessor at least for use in determining a pitch orientation and a yaw heading of the steering tool. A dipole antenna and associated transmitter 108 are optionally located in the steering tool which can be used, responsive to the processing section, for telemetry purposes, for transferring encoded data such as roll, pitch, magnetometer readings and accelerometer readings to above ground locations such as, for example, telemetry receiver 62 ( FIG. 1 ) of console 60 via a dipole electromagnetic field 110 and for locating determinations such as, for example, determining a distance to the steering tool. For such locating determinations, dipole electromagnetic field 110 can be used in conjunction with a walkover locator, although this is not a requirement and is not practical in some cases, as discussed above. Generally, the dipole axis of the dipole antenna is oriented coaxially with an elongation axis of the steering tool in a manner which is well-known in the art. Of course, all of these functions are readily supported by processing section 106 , which reads appropriate inputs from the magnetometer and accelerometer, performs any necessary processing and then performs the actual encoding of information that is to be transmitted.
[0050] In another embodiment, processing section 106 is configured for communication with processor 70 ( FIG. 1 ) of console 60 using a wire-in-pipe approach wherein a conductor is provided in drill string 30 for transferring information above ground as described, for example, in commonly owned U.S. Pat. No. 6,223,826 entitled AUTO-EXTENDING/RETRACTING ELECTRICALLY ISOLATED CONDUCTORS IN A SEGMENTED DRILL STRING, which is incorporated by reference in its entirety. The conductor in the drill string is in electrical communication with a line 112 that is in electrical communication with processing section 106 . It is noted that this approach may also be used to provide power to a power supply 114 from above ground, as an alternative or supplemental to the use of batteries.
[0051] Still referring to FIG. 3 a, regulated power supply 114 , which may be powered using batteries or through the aforedescribed wire-in-pipe arrangement, provides appropriate power to all of the components in the steering tool, as shown. It is noted that magnetic field sensor 102 can be used to measure the field generated by a rotating magnet as well as measuring the Earth's magnetic field. The later may be thought of as a constant, much like a DC component of an electrical signal. In this instance, the Earth's magnetic field may be used advantageously to determine a yaw heading.
[0052] Referring again to FIGS. 1 and 2 , system 10 is illustrated having three markers 140 a - c, each of which includes a rotating magnet for generating a rotating dipole field. Markers 140 a and 140 b are arranged along a line that is generally orthogonal to the X axis, while marker 140 c is offset toward drill rig 18 . A rotating dipole field can be generated either by a rotating magnet or by electromagnetic coils. Throughout this disclosure, the discussion may be framed in terms of a rotating magnet, but the described applications of magnets carry over to coils and wire loops with only minor modifications. As will be described in further detail, markers can be placed along the drill-path so that they are at least generally close to the target or other points of interest where high positioning accuracy is required, although one or two markers may provide sufficient accuracy for many drilling applications. That is, the marker signal should be receivable by the steering tool along a portion of the intended path including the target or other point(s) of interest. Aside from this consideration, the position of each marker can be arbitrary. Markers can be placed on the ground, on an elevated structure or even lowered within the ground. In each case, the marker can be at an arbitrary angular orientation. The rotation frequency (revolutions per second) of each magnet can be on the order of 1 Hz, but dipole field frequencies should be distinguishable if more than one marker/magnet is in use. A frequency difference of at least 0.5 Hz is considered to be acceptable for this purpose. Each magnet emits a rotating magnetic dipole field whose total flux is recorded by the steering tool magnetometer and subsequently converted to distance between magnet and tool. During rotation, the magnet of each marker emits a time dependent magnetic dipole field that is measured by the tri-axial magnetometer of the steering tool. As will be seen, a minimum value of the recorded total flux provides a distance between each marker and the steering tool.
[0053] Turning now to FIG. 3 b, one embodiment of marker 140 is diagrammatically illustrated. It is noted that aforedescribed markers 140 a - c may be of this design as well as any additional markers used hereinafter. In this embodiment, each marker 140 can include a drive motor 142 having an output shaft 144 which directly spins a magnet 146 having a north pole, which is visible. Motor 142 is electrically driven by a motor controller 148 to provide stable rotation of the magnet. The motor can rotate the magnet slowly, for example, at about 1 revolution per second (1 Hz), as indicated by arrow 150 , thereby emitting a rotating magnetic dipole field 152 (only partially shown). It should be appreciated that a relatively wide range of rotational speeds may employed, for example, from approximately 0.5 Hz to 600 Hz. In one embodiment, a proportional-integral-derivative (PID) controller can be used to drive motor 142 with user selectable rotational velocity. It is noted that such PIDs are commercially available. A benefit associated with using lower rotational velocity resides in a decreased influence by local magnetic objects such as, for example, rebar. If a higher rotational velocity is desired loop antennas can be used to create the rotational field. Further, the rotational velocity can be varied so that the fields from various markers are distinguishable when simultaneously rotating. A suitable power supply can be used, as will be recognized by one having ordinary skill in the art, such as for example a battery and voltage regulator, which have not been shown. It should be appreciated that there is no need for an encoder, since the specific angle of the magnet, corresponding to a particular measurement position, is not involved in making the determinations that are described below. Further, orientation sensors and a telemetry section in marker 140 are not needed. As will be seen, variation in rotation rate of magnet 146 will introduce associated positional error. Hence, a desire to increase measurement accuracy is associated with increasing the rotational stability of magnet 146 .
[0054] Still referring to FIG. 3 b, while the axis of rotation of magnet 146 is illustrated as being vertical, this is not a requirement. The axis of rotation can be horizontal or at some arbitrary tilted orientation. Moreover, positioning of the marker for field use does not require orienting the marker in any particular way. This remarkable degree of flexibility and ease of positioning these markers is one of the benefits of the system and method taught herein.
[0055] Most conventional applications of the steering tool function rely on a nominal value for drill rod length when integrating pitch and yaw to determine position. In accordance with the present disclosure, however, pitch and yaw can be measured more than once along each drill rod such that the distance between successive steering tool measurement positions can be less than the nominal length of one drill rod. This is particularly the case when the length of the drill rod is exceptionally long such as, for example, thirty feet. For this purpose, a laser distance meter, a potentiometer, an ultrasonic arrangement or some other standard distance measurement device can be mounted on the drill rig. An ultrasonic arrangement will be described immediately hereinafter.
[0056] Referring again to FIGS. 1 and 2 , a drill string measuring arrangement includes a stationary ultrasonic transmitter 202 positioned on drill frame 18 and an ultrasonic receiver 204 with an air temperature sensor 206 ( FIG. 2 ) positioned on carriage 20 . It should be noted that the positions of the ultrasonic transmitter and receiver may be interchanged with no effect on measurement capabilities. Transmitter 202 and receiver 204 are each coupled to processor 70 or a separate dedicated processor (not shown). In a manner well known in the art, transmitter 202 emits an ultrasonic wave 208 that is picked up at receiver 204 such that the distance between the receiver and the transmitter may be determined to within a fraction of an inch by processor 70 using time delay and temperature measurements. By monitoring movements of carriage 20 , in which drill string 30 is either pushed into or pulled out of the ground, and clamping arrangement 54 , processor 70 can accurately track the length of drill string 30 throughout a drilling operation. While it is convenient to perform measurements in the context of the length of the drill rods, with measurement positions corresponding to the ends of the drill rods, it should be appreciated that this is not a requirement and the ultrasonic arrangement can provide the total length of the drill string at any given moment in time. Further, the length according to the number of drill rods multiplied by nominal rod length can be correlated to the length that is determined by ultrasonic measurement.
[0057] Referring to FIG. 1 , control console 60 , in this embodiment, serves as a base station to communicate with steering tool 26 , to monitor its power supply, to receive and process steering tool data and to send commands to the steering tool, if so desired. Determined drill-path positions and estimated position errors can be displayed on display screen 66 for monitoring by the system operator. This functionality may also be extended to a remote base station configuration, for example, by using telemetry section 64 to transmit information 210 to a remote base station 212 for display on a screen 214 .
Measured Quantities
[0058] The steering method requires measurement of the following variables:
[0059] Tool pitch and yaw angles φ, β
[0060] Distances D i between N M magnets and the steering tool (i=1, . . . N M )
[0061] Magnet positions (X M i ,Y M i ,Z M i ), (i=1, . . . N M )
[0062] Initial tool position (X 1 ,Y 1 , Z 1 )
[0063] Rod length increments Δs k+1 (k=1,2,3, . . . )
[0064] Referring to FIGS. 1 and 2 , pitch and yaw are measured and magnet-to-tool distances are determined at a series of tool positions including the initial tool position. Point 1 , which is additionally denoted by the reference number 42 , designates the position of drill begin. The steering tool is currently located at a measurement position k and is intended to proceed to position k+1. These positions can correspond to the end points of a drill rod or to intermediate points along the length of each drill rod. As discussed above, intermediate points may be needed, for example, when an exceptionally long drill rod is used such as, for example, 30 feet. Higher accuracy will generally be provided through the use of relatively more measurement positions. In some cases, the drill rod length may be sufficiently short that the number of drill rods may provide a sufficiently accurate value as to the length of the drill string. The latter situation may also be characterized by drill rods having a tolerance in their average length that is reasonably close to a nominal value. In some embodiments, there may be no correspondence between the drill rod length and the measurement positions, for example, where a measurement system, such as is employed by system 10 , is capable of measuring and monitoring an overall length of the drill string. For purposes of simplicity of description, it will be assumed that the drill rod length is used in the remainder of this description to establish the measurement positions. It is noted that measurements at each measurement position may be performed on-the-fly while pushing and/or rotating the drill string; however, enhanced accuracy can be achieved by stopping movement of the steering tool at each of the measurement positions during the measurements. A rod length increment Δs k+1 is defined as the arc-length between tool measurement positions (X k ,Y k ,Z k ) and (X k+1 , Y k+1 ,Z k+1 ). The setup of this coordinate system is described immediately hereinafter.
Set-Up of Steering System
[0065] Referring to FIG. 3 c, in conjunction with FIGS. 1 and 2 , the origin and directions of the X,Y,Z-coordinate system can be specified in relation to drill begin point 1 and target T. The location where drilling begins is a convenient choice for the origin and the direction from this position to the projection of the target onto a level plane through the origin defines the X-coordinate axis. The Z-coordinate axis is positive upward and the Y-coordinate axis completes a right-handed system. If desired, a different right-handed Cartesian coordinate system or any suitable coordinate system may be used. In the present example, the formulation constrains the X-axis to be level. As noted above, yaw orientation is designated as β measured from the X axis in a level X,Y plane, whereas pitch orientation is designated as φ measured vertically from the yawed tool position in the X,Y plane as represented by a dashed line in the X,Y plane. FIG. 3 c defines pitch and yaw as Euler angles that require a particular sequence of yaw and pitch rotations in order to rotate the steering tool from a hypothetical position along the X axis into its illustrated position.
Magnet Position Measurements
[0066] The use of an Electronic Distance Measurement device (EDM) is currently the quickest and most accurate method of defining the X-coordinate axis and measuring magnet position coordinates. However, using an EDM for this purpose requires the presence of a surveyor at the HDD job site, which may sometimes be difficult to arrange. Accordingly, any suitable method may be used.
[0067] As an alternative to an EDM, a laser distance measurement device can be used. Devices of this kind are commercially available with a maximum range of about 650 feet and a distance measurement accuracy of ⅛ of an inch; the Leica Disto™ laser distance meter is an example of such a device. The device is placed at the position of drill-begin and pointed at the target to obtain the distance between these two positions. For short range measurements, the device can be handheld, but for larger distances it should be fixedly mounted to focus reliably. When an EDM, laser distance measurement device or similar device is used to determine the magnet positions, the accuracy of the device itself can be used as the magnet position error in the context of the discussions below.
[0068] Referring to FIGS. 4 and 5 , one embodiment of a setup technique is illustrated. FIG. 4 illustrates a diagrammatic plan view of steering tool 26 positioned ahead of drill begin point 1 with target T arranged along the X axis and a marker M 1 that is offset from the X axis. The target is located at coordinates X t ,Y t ,Z t . FIG. 5 illustrates a diagrammatic elevational view of steering tool 26 positioned ahead of drill begin point 1 on a surface 230 of the ground. In one embodiment, a laser distance meter (LDM) can be used having a tilt sensor so that horizontal and vertical distances X t ,Z t to the target can either be calculated or are directly provided by the LDM. The relative position (ΔX ,ΔY,ΔZ) between the target and a marker, M 1 , located near the target can also be measured using the LDM, with a measuring tape or in any other suitable manner. Marker position coordinates can be obtained by adding position increments to target coordinates, as follows:
[0000] X M1 =X t +ΔX (1)
[0000] Y M1 =ΔY (2)
[0000] Z M1 =Z t +ΔZ (3)
[0069] The foregoing procedure can be repeated for any number of markers that are arranged proximate to the target.
[0070] In another embodiment, the position of each marker can be measured directly, for example using an EDM, with no need to measure the location of the target, so long as some other position has been provided that establishes the X axis from point 1 of drill begin. For example, a marker M 2 may be arranged along the X axis. As will be further described, location accuracy along the X axis can be customized based on the arrangement of markers therealong. The need for enhanced accuracy for some portion of the path of the steering tool can be established, for example, based on the presence of a known inground obstacle 232 .
Reference Yaw Angle
[0071] Continuing to refer to FIGS. 4 and 5 , a reference yaw angle β ref is defined as the yaw angle of the steering tool, measured by the steering tool, with its elongation axis aligned with the X-direction. In the present example, the reference yaw angle is measured as a compass orientation from magnetic north, based on the Earth's magnetic field. Since steering tool yaw has previously been defined as positive for a counterclockwise rotation the particular reference yaw angle β ref shown in FIG. 4 is negative. Accordingly, in order to measure yaw accurately without interference from the magnetic influence of the drill rig, the steering tool can be placed on a level ground a sufficient distance ahead of the drill; 30 feet is usually adequate. The elongation axis of the steering tool is at least approximately on or at least parallel to the X-axis. Yaw angle β m , measured as a compass heading during steering, is subsequently replaced by β=β m −β ref .
Steering Procedure Formulation
[0072] Nomenclature
[0073] c A =pitch and yaw error covariance matrix
[0074] c e =empirical coefficient
[0075] c M =magnet position error covariance matrix
[0076] D=distance between marker and steering tool
[0077] F=continuous state equations matrix
[0078] H=observation coefficient vector
[0079] N M =number of markers
[0080] P=error covariance matrix
[0081] Q=continuous process noise covariance parameter matrix
[0082] Q k =discrete process noise covariance matrix
[0083] R=observation covariance scalar
[0084] {right arrow over (r)}=vector of magnet position measurement error
[0085] s=arc-length along drill-rod axis
[0086] ν D =distance measurement noise
[0087] ν M =magnet position measurement noise
[0088] {right arrow over (x)}=state variables vector
[0089] X,Y,Z=global coordinates
[0090] X k ,Y k ,Z k =steering tool position coordinates
[0091] z=measurement scalar
[0092] β=yaw angle
[0093] δX,δY,δZ=position state variables
[0094] δX M ,δY M ,δZ M =magnet position increments
[0095] δβ,δφ=yaw and pitch angle increments
[0096] Δs=rod length increment
[0097] φ=pitch angle
Φ k =discrete state equation transition matrix
[0099] σ=standard deviation
[0100] σ 2 =variance, square of standard deviation
Subscripts
[0101] bias=bias error
[0102] D=distance
[0103] ex=exact value
[0104] i=i-th magnet
[0105] k=k-th position on drill path
[0106] M=magnet
[0107] m=measured
[0108] ref=reference
[0109] 1 =initial tool position (drill begin at k=1)
Superscripts
[0110]
(
)
.
=
s
(
)
-
=
indicates
last
available
estimate
(
)
′
=
transpose
(
)
*
=
nominal
drill
path
x
→
^
=
state
variables
vector
estimate
Tracking Equations
[0111] The method is based on two types of equations, referred to as steering tool process equations and distance measurement equations. The former are a set of ordinary differential equations describing how tool position (X,Y,Z) changes along the drill-path as a function of measured pitch φ and yaw β and shown as equations 4.
[0000]
{
X
.
Y
.
Z
.
}
=
{
cos
φ
cos
β
cos
φsin
β
sin
φ
}
(
4
)
[0112] The over-dot indicates that derivatives of position coordinates are to be taken with respect to arc-length s along the axis of the drill rod. Pitch and yaw angles are illustrated in FIG. 3 c. Accordingly, the premise of a conventional steering tool resides in a numerical integration of equations 4 with respect to arc length s of the drill string. Unfortunately, as discussed above, this technique readily produces potentially serious positional errors in and by itself.
[0113] The aforementioned distance measurement equations are of the form:
[0000] D 2 =( X M −X ) 2 +( Y M −Y ) 2 +( Z M −Z ) 2 (5)
[0114] The distance measurement equations express distance D between the center of a rotating magnet of a marker and the center of tri-axial steering tool magnetometer 102 (see FIG. 1 ) in terms of tool position (X,Y,Z) and magnet position (X M ,Y M ,Z M ). Accordingly, N M of such equations can be written for a system, corresponding to the total number of markers.
[0115] The origin of the global X,Y,Z-coordinate system in which tool position will be tracked can be chosen to coincide with the location of drill begin (point 1 in FIGS. 1 and 2 ).
[0000] X 1 =0 Y 1 =0 Z 1 =0 (6)
[0116] Equations (4), (5) and (6) represent an initial value problem that can be solved for steering tool position coordinates.
Nonlinear Solution Procedures
[0117] The foregoing initial value problem can be solved using either a nonlinear solution procedure, such as the method of nonlinear least squares, the SIMPLEX method, or can be based on Kalman filtering. The latter will be discussed in detail beginning at an appropriate point below. Initially, however, an application of the SIMPLEX method will be described where the description is limited to the derivation of the nonlinear algebraic equations that are to be solved at each drill-path position. Details of the solver itself are well-known and considered as within the skill of one having ordinary skill in the art in view of this overall disclosure.
[0118] The present technique and other solution methods can replace the derivatives {dot over (X)},{dot over (Y)},Ż in equations (4) with finite differences that are here written as:
[0000]
X
.
=
X
k
+
1
-
X
k
Δ
s
k
+
1
(
7
)
Y
.
=
Y
k
+
1
-
Y
k
Δ
s
k
+
1
(
8
)
Z
.
=
Z
k
+
1
-
Z
k
Δ
s
k
+
1
(
9
)
[0119] Resulting algebraic equations read:
[0000] f 1 =X k+1 −X k −Δs k+1 cos φ k cos β k =0 (10)
[0000] f 2 =Y k+1 −Y k −Δs k+1 cos φ k sin β k =0 (11)
[0000] f 3 =Z k+1 −Z k −Δs k+1 sin φ k =0 (12)
[0120] The distance measurement equations (5) provide additional N M equations written as:
[0000] f 4 i =D k+1, i 2 −( X k+1 −X M i ) 2 −( Y k+1 −Y M i ) 2 −( Z k+1 −Z M i ) 2 =0 (13)
[0121] Starting with the known initial values (Equations 6) at drill begin, the coordinates of subsequent positions along the drill path can be obtained by solving the above set of nonlinear algebraic equations (10-13) for each new tool position. The coordinates of position k+1 are calculated iteratively beginning with some assumed initial solution estimate that is sufficiently close to the actual location to assure convergence to the correct position. One suitable estimate will be described immediately hereinafter.
[0122] Referring to FIGS. 6 and 7 a, the X,Z plane is illustrated with a drill path 240 formed therein and in a direction 242 using a plurality of drill rods 32 , at least some of which have been designated by reference numbers. FIG. 7 a is an enlarged view within a dashed circle 244 of FIG. 6 . An initial solution estimate is given by a point on what may be referred to as a nominal drill-path 246 that can be found by linear extrapolation of the previously predicted/last determined position to a predicted position 248 . The linear extrapolation is based on equations 4 and a given incremental movement Δs k+1 of the steering tool from a k th position where:
[0000]
{
X
k
+
1
*
Y
k
+
1
*
Z
k
+
1
*
}
=
{
X
k
Y
k
Z
k
}
+
Δ
s
k
+
1
{
cos
φ
k
cos
β
k
cos
φ
k
sin
β
k
sin
φ
k
}
(
14
)
[0123] Where predicted positions are indicated in equations 14 using an asterisk( )*. It should be appreciated that the position of the steering tool is characterized as predicted or estimated since the location is not identified in an affirmative manner such as is the case, for example, when a walk-over locater is used. The use of a steering tool differs at least for the reason that the position of the steering tool is estimated or predicted based on its previous positions. Thus, the actual position of the steering tool, for a sufficiently long drill path, can be significantly different than the position that is determined by a steering tool technique, as a result of accumulating error, if this error is not managed appropriately.
[0124] Application of the SIMPLEX method requires definition of a function that is to be minimized during the solution procedure. An example of such a function that is suitable in the present application reads:
[0000]
F
=
∑
p
=
1
3
+
N
M
f
p
2
(
15
)
[0125] As noted above, it is considered that one having ordinary skill can conclude the solution procedure under SIMPLEX in view of the foregoing.
Kalman Filter Solution
[0126] In another embodiment, a method is described for solving the tracking equations employing Kalman filtering. The filter minimizes the position error caused by measurement uncertainties in a least square sense. The filter determines position coordinates as well as position error estimates.
[0127] The three tool position coordinates (X,Y,Z) are chosen as the main system parameters. Increments (δX,δY,δZ) of these parameters are referred to as state variables. The solution method can be characterized as a predictor-corrector technique. Assuming all drill-path variables are known at a last determined position and a drill string increment is known, the current or next-determined position on the drill path can be approximated by linear extrapolation, as described above with respect to FIGS. 6 and 7 a. This is the predictor step that gives a point on nominal drill path 246 . The Kalman filter, in turn, performs a corrector step in which state variables are calculated and added to the nominal drill path.
[0128] Initial tool position coordinates (X 1 ,Y 1 ,Z 1 ) are assumed and corresponding error variances (σ X 1 2 , σ Y 1 2 , σ Z 1 2 ) are known. For example, at (X 1 ,Y 1 ,Z 1 ), which is the origin of the coordinate system, the error variances are zero. If (X 1 ,Y 1 ,Z 1 ) is not the origin, the error variances are based on the accuracy of measurement from the origin. The tracking procedure starts from this initial position and proceeds along the drill path, as follows:
[0129] As is illustrated in FIGS. 6 and 7 a , the last known drill path position (X k , Y k , Z k ) is extrapolated linearly to obtain an approximate or estimated tool position, previously introduced as nominal drill path position (X k+1 *, Y k+1 *, Z k+1 *).
[0130] The filter determines state variables (δX k+1 ,δY k+1 ,δZ k+1 ) and standard deviations of position error (σ X k+1 ,σ Y k+1 ,σ Z k+1 ).
[0131] State variables are added to the nominal drill path position to find the new tool position (X k+1 ,Y k+1 ,Z k+1 ).
[0000]
{
X
k
+
1
Y
k
+
1
Z
k
+
1
}
=
{
X
k
+
1
*
Y
k
+
1
*
Z
k
+
1
*
}
+
{
δ
X
k
+
1
δ
Y
k
+
1
δ
Z
k
+
1
}
(
16
)
Measurement Errors
[0132] The Kalman filter takes the following random measurement errors into account which must therefore be known before tracking begins.
[0133] Tool pitch and yaw angle errors σ φ ,σ β
[0134] Distance error σ D
[0135] Magnet position errors (σ X M ,σ Y M ,σ Z M )
[0136] Initial tool position errors (σ X 1 ,σ Y 1 ,σ Z 1 )
[0137] Error values are empirical and depend on the type of instrumentation used. Note that the effect of drill rod length measuring error is not part of the analysis since arc-length along the axis of the drill rod is used as an independent variable.
[0138] Knowing initial tool position errors (σ X 1 ,σ Y 1 ,σ Z 1 ), the corresponding error covariance matrix P 1 is given as:
[0000]
P
1
=
[
σ
X
1
2
0
0
0
σ
Y
1
2
0
0
0
σ
Z
1
2
]
(
17
)
[0139] Adding the latter to equations (4) to (6) completes the formulation of the initial value problem to be solved by Kalman filtering.
Linearized Tracking Equations
[0140] In addition to various measured quantities that are summarized above, the Kalman filter solution uses input of the following parameters.
[0141] Φ k discrete state equation transition matrix
[0142] Q k discrete process noise covariance matrix
[0143] z measurement scalar
[0144] H observation coefficient vector
[0145] R observation error covariance scalar
[0146] The above parameters are derived by linearizing the steering tool process equations and distance measurement equations about the nominal drill path position. The resulting two sets of linear equations are the so-called state equations and the observation equations. They are summarized below.
[0147] The state variables are defined as position increments.
[0000] {right arrow over (x)}=(δX,δY,δX)′ (18a)
[0000] {dot over ({right arrow over (x)}=(δ{dot over (X)},δ{dot over (Y)},δŻ)′ (18b)
[0148] The state equations governing state variables read
[0000] {right arrow over (x)} k+1 =Φ k {right arrow over (x)} k +Δs k+1 G k {right arrow over (u)} k (19)
[0149] Where Δs k+1 G k {right arrow over (u)} k represents pitch and yaw measurement noise. It is noted that, hereinafter, subscripts may be dropped for purposes of clarity. Accordingly:
[0000]
Φ
=
I
(
20
)
Q
=
cos
(
(
Δ
s
)
G
u
→
)
and
(
21
)
u
→
=
(
δ
φ
,
δ
β
)
′
(
22
)
G
=
[
-
sin
φcos
β
-
cos
φsin
β
-
sin
φ
sin
β
cos
φcos
β
cos
φ
0
]
(
23
)
[0150] The discrete noise covariance matrix Q k becomes:
[0000]
c
A
=
[
σ
φ
2
0
0
σ
β
2
]
(
24
)
Q
=
c
e
(
Δ
s
)
2
Gc
A
G
′
(
25
)
[0151] Note that the empirical coefficient c e has been added to equation (25) in order to account for pitch and yaw bias errors. It has unit value if pitch and yaw measurement errors are entirely random.
[0152] The observation equation of a rotating magnet reads:
[0000] z=H{right arrow over (x)}+ν D +ν M (27)
[0000] R=cov (ν D +ν M ) (28)
[0153] Where the term ν D represents distance measurement noise and the term ν M represents magnet position measurement noise. The term H will be described at an appropriate point below. The symbol z, seen in equation (27) is a difference between measured distance D and calculated distance D* from a marker to the nominal drill path position, given as:
[0000] z=D−D* (29)
[0000] D* 2 =( X*−X M ) 2 +( Y*−Y M ) 2 +( Z*−Z M ) 2 (30)
[0154] The first term H on the right hand side of equation (27) is the observation coefficient vector, written as:
[0000]
H
=
(
X
*
-
X
M
D
*
,
Y
*
-
Y
M
D
*
,
Z
*
-
Z
M
D
*
)
(
31
)
[0155] The following form of the observation covariance scalar R is used in the steering tool method:
[0000]
R
=
σ
D
2
+
Hc
M
H
′
(
32
)
c
M
=
[
σ
X
M
2
0
0
0
σ
Y
M
2
0
0
0
σ
Z
M
2
]
(
33
)
Projection of State Variables and Estimation Errors
[0156] An estimate of the state vector at the next steering tool position k+1 is denoted by {right arrow over ({circumflex over (x)} and its error covariance matrix is P − where the superscript ( ) − indicates the last available estimate. Before the filter is applied at the new tool position, set
[0000] {right arrow over ({circumflex over (x)}={0} (34)
[0157] The error covariance matrix P k is projected to the new position using
[0000] P k+1 − =Φ k P k Φ′ k +Q k (35)
Kalman Filter Loop
[0158] The filter loop is executed once for each marker, resulting in a flexible arrangement that is able to process any number of markers in use by the steering tool system.
[0159] The classical, well documented version of the filter loop is chosen as a basis for the current steering tool embodiment. It consists of three steps:
[0160] Kalman gain:
[0000] K=P − H′ ( HP − H′+R ) −1 (36)
[0161] State variables:
[0000] {right arrow over ({circumflex over (x)}={right arrow over ({circumflex over (x)} − +K ( z−H{right arrow over ({circumflex over (x)} − ) (37)
[0162] Error covariance matrix:
[0000] P= ( I−KH ) P − (38)
Position Coordinate Errors
[0163] Having completed the filter analysis at a new position, its coordinates are given by equation (16). Corresponding one-sigma position errors follow from:
[0000] σ X =√{square root over (P 11 )} (39)
[0000] σ Y =√{square root over (P 22 )} (40)
[0000] σ Z =√{square root over (P 33 )} (41)
[0164] FIG. 7 b is a flow diagram, generally indicated by the reference number 260 , which illustrates one embodiment of a Kalman filter implementation according to the descriptions above. At 262 , the nominal position of the steering tool at k+1 is determined using equation 14. At 264 , the error covariance matrix is projected to position k+1 using equation 35. The state vector is initialized at 266 . Beginning with step 270 , a loop is entered using magnetic measurements associated with one marker. The distance D* between a point on the nominal drill path and the marker is determined per equation 30. The observation coefficient vector H in turn is calculated using equation 31. Equation 32 provides the observation covariance scalar R. At 272 , the Kalman filter is executed using equations 36-38. At 274 , a determination is made as to whether magnetic information is available that is associated with another marker. If so, execution returns to step 270 . If magnetic information from all markers has been processed, step 276 establishes the final coordinates of the current position of the steering tool based on equation 16 and can associate a position error estimate with these coordinates, based on equations 39-41.
Numerical Simulations
[0165] Several numerical simulations were performed to estimate positions of the steering tool assisted by up to three rotating magnets. In all cases the steering tool was tracked, moving along a drill-path defined by:
[0000]
0
≤
X
ex
≤
300
ft
(
42
)
Y
ex
=
15
sin
(
π
300
X
ex
)
(
43
)
Z
ex
=
-
2
Y
ex
(
44
)
[0166] Note that drilling starts at the origin of the global coordinate system. The steering tool reaches a maximum depth of 30 feet and yaws to the side with a maximum lateral displacement of 15 feet before it reaches the target 300 feet out. The above coordinates are exactly known coordinates from which values for pitch, yaw and tool to magnet distances were derived.
[0167] Table 1 summarizes random and bias errors that were added to these exact values to generate “measured” data.
[0000]
TABLE 1
Errors for Generating “Measured” Simulation Data
Pitch Error
σ φ = 0.25 deg
φ bias = 0.25 deg
Yaw Error
σ β = 0.50 deg
β bias = 0.50 deg
Drill Rod Length Error
σ Δs = 0.01 ft
Distance Error
D bias = 0.02 ft
(See also, FIG. 8)
[0168] FIG. 8 sets forth random distance error σ D in feet, plotted against distance D in feet. It is noted that errors were chosen based on empirical measurements with specific pitch and yaw sensors as well as with rotating magnets. Table 2 summarizes the random errors used as input for the filter. Note that the rod length increment error is used only for generating measured data; it is not used by the filter.
[0000]
TABLE 2
Random Errors Used in Kalman Filter
Pitch Error
σ φ = 0.5 deg
Yaw Error
σ β = 1 deg
Distance Error
σ D (see FIG. 8)
Magnet Position Errors
σ X M = σ Y M = σ Z M = 0.02 ft
Initial Position Error
σ X 1 = σ Y 1 = σ Z 1 = 0
[0169] FIGS. 9 a and 9 b are plots against drill string length, in feet, which compare exact with “measured” pitch and yaw angles, respectively, used in all the simulations described below. Exact pitch and yaw values are shown by dotted lines, while measured pitch and yaw values are shown by solid lines. Increments between adjacent measurement positions along the drill-path were approximately three feet.
[0170] Estimated steering tool positions and position errors are illustrated by FIGS. 10 a - c, as an application of the basic steering tool function without the use of markers. It is noted that, in subsequent figures, an increasing number of magnets is added to the system to demonstrate the improvements that are provided through the use of markers. Illustrated position errors are shown as the differences between estimated and exact values. Since “measured” values for pitch and yaw contain bias as well as random components, lateral and vertical position errors are also biased. FIG. 10 a is a diagrammatic plan view of the estimated drill path, designated by the reference number 300 , whereas FIG. 10 b is an elevational view of the estimated drill path, designated by the reference number 302 . FIG. 10 c illustrates the X coordinate positional error as a solid line 310 , the Y coordinate positional error as a dashed line 312 and the Z coordinate positional error as a dotted line 314 . In the present example, without the use of magnets, it can be seen that there is a continuously accumulating Y coordinate error, which increases to about three feet upon reaching X=300 feet, the X axis coordinate of target T. The Z coordinate error is over one foot.
[0171] Referring collectively to FIGS. 11 a - c, simulations are now presented including the use of markers. One marker 320 is used at a location of X=300 ft, Y=−5 ft, and Z=5 ft. FIG. 11 a is a diagrammatic plan view of the estimated drill path, designated by the reference number 322 , whereas FIG. 11 b is an elevational view of the estimated drill path, designated by the reference number 324 . FIG. 11 c illustrates the X coordinate positional error as a solid line 326 , the Y coordinate positional error as a dashed line 328 , and the Z coordinate positional error as a dotted line 330 . In the present example, with the use of only one magnet near target T, it can be seen that the Y coordinate error is dramatically reduced to just over one foot upon reaching the target X coordinate at 300 feet.
[0172] Referring collectively to FIGS. 12 a - c, a second marker 340 is added at a location of X=305 ft, Y=0 ft and Z=5 ft. FIG. 12 a is a diagrammatic plan view of the estimated drill path, designated by the reference number 342 , whereas FIG. 12 b is an elevational view of the estimated drill path, designated by the reference number 344 . FIG. 12 c illustrates the X coordinate positional error as a solid line 346 , the Y coordinate positional error as a dashed line 348 , and the Z coordinate positional error as a dotted line 350 . In the present example, with the use of two magnets near target T, it can be seen that the Y coordinate error is still further reduced to a relatively small fraction of one foot upon reaching the target X coordinate at 300 feet. Moreover, the X and Z coordinate errors are likewise reduced to a small fraction of one foot upon reaching the target X coordinate at 300 feet.
[0173] Referring collectively to FIGS. 13 a - c, a third marker 360 is added at a location of X=300 ft, Y=5 ft and Z=5 ft. FIG. 13 a is a diagrammatic plan view of the estimated drill path, designated by the reference number 362 , whereas FIG. 13 b is an elevational view of the estimated drill path, designated by the reference number 364 . FIG. 12 c illustrates the X coordinate positional error as a solid line 366 , the Y coordinate positional error as a dashed line 368 , and the Z coordinate positional error as a dotted line 370 . In the present example, with the use of three magnets near target T, it can be seen that the X, Y and Z coordinate errors are reduced to a very small fraction of one foot upon reaching the target X coordinate at 300 feet. In view of the foregoing, the use of two or three markers proximate to a point of interest on the drill path (such as the target) enables a high precision guidance of the steering tool to a target at least 300 feet out from the point of drill begin, or enables high precision steering relative to some point of interest along the drill path at least 300 feet out.
[0174] It should be appreciated that, in the aforedescribed numerical simulations, errors defined as the difference between estimated and exact positions can be calculated, since exact drill-path coordinates are known. This type of error can not be calculated during actual drill-head tracking. Accordingly, a different type of error estimate is used for actual drilling. The Kalman filter analysis provides such an error estimate in the form of standard deviations of position coordinates. In this regard, FIGS. 14 a - c illustrate the two types of position errors for the drill-path of FIGS. 13 a - b with three markers placed near the target. The solid lines denote the +1 sigma position error provided by the Kalman filter analysis, whereas the dashed lines represent the corresponding −1 sigma errors. For comparison, the position errors of FIG. 13 c, defined as the difference between estimated and exact positions, are also shown in FIGS. 14 a - c. As seen, position errors expressed in terms of standard deviations vary smoothly along the drill-path since they are based on a statistical measure. In contrast, estimated positions and, hence, the errors shown as dotted lines in FIGS. 14 a - c are based on one set of partly random measurements resulting in an irregular distribution of position errors. Repeating the Kalman filter analysis with a different set of random measurements would produce different error distributions of this type. Numerical simulations were performed with c e =16.
[0175] Attention is now directed to FIGS. 15 and 16 for purposes of describing additional aspects of the present disclosure. FIG. 15 illustrates a plan view of a drilling region 400 having a concluding section of an intended drill path 402 defined therein. Further, a first inground obstacle 404 and a second inground obstacle 406 are shown in relation to intended path 402 . As can be seen, intended path 402 has been specifically designed to avoid inground obstacles 404 and 406 . Such path design can be based on any knowledge of inground features that should be avoided and can include a reliance on any suitable resource including but not limited to utility surveys, available design drawings and exploratory excavations. Moreover, inground obstacles 404 and 406 are intended to represent any type of feature within the ground that should be avoided.
[0176] Still referring to FIGS. 14 and 15 , an exemplary plurality of markers 140 a - e is distributed along intended path 402 such that markers 140 a and 140 b are in the vicinity of obstacle 404 , marker 104 c is in the vicinity of obstacle 406 , and markers 140 d and 140 e are in the vicinity of target T. It should be appreciated that orientation of the markers is arbitrary so long as the steering tool, on the intended path and proximate to some inground feature of interest, is capable of receiving at least the magnetic field that is emanated by the markers in its general vicinity. As seen above, with each marker that is added proximate to target T, there is a corresponding increase in steering tool accuracy. That is, the steering tool tracks the intended path with proportionally increasing accuracy. Placement of markers proximate to points of interest, as illustrated, likewise produces a corresponding increase in accuracy along any portion of the intended path that is exposed to the magnetic field that is emanated by that marker. In this way, an enhanced steering accuracy, of a selective degree, can be provided at any desired point or points along the intended path. Accordingly, a highly advantageous customized steering accuracy is provided along the intended path. In this regard, as discussed above, the described technique readily accommodates receiving signals from any number of markers at any given point along the intended path or receiving no marker signals for some portions of the path, such as might be the case at a point 410 midway between markers 140 c and 140 d of the present example.
[0177] Even though the present example illustrates the use of five markers, fewer markers may actually be necessary since the markers can be moved along the intended drill path responsive to the progression of the steering tool. For example, after the steering tool passes obstacle 404 , marker 140 a can be moved to the position of marker 140 c. At a suitable time, marker 140 b can be moved to the position of marker 140 d. Once the steering tool passes obstacle 406 , marker 140 a can then be moved to the illustrated position of marker 140 e. Accordingly, long drill runs can be made with as few as one or two markers.
[0178] Applicants consider that sweeping advantages are provided over the state-of-the-art with respect to steering tool systems and methods. While there are systems in the prior art that use rotating magnet signals, it should be apparent from the detailed descriptions above that providing the capability to use rotating magnet signals in the context of a steering tool system is neither trivial nor obvious. In this regard, Applicants are unaware of any prior art use of a rotating magnet signal in the context of a steering tool system and, particularly, with such flexibility and ease of use where the rotating magnet field markers can not only be arbitrarily placed, but arbitrarily oriented.
[0179] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.
|
A steering tool is movable by a drill string to form an underground bore along an intended path. A sensing arrangement of the steering tool detects its pitch and yaw orientations at a series of spaced apart positions along the bore, each position is characterized by a measured extension of the drill string. The steering tool further includes a receiver. At least one marker is positioned proximate to the intended path, for transmitting a rotating dipole field to expose a portion of the intended path to the field for reception by the receiver. The detected pitch orientation, the detected yaw orientation and the measured extension of the drill string are used in conjunction with magnetic information from the receiver to locate the steering tool. The steering tool may automatically use the magnetic information when it is available. A customized overall position determination accuracy can be provided along the intended path.
| 4
|
This is a continuation of application Ser. No. 10/035,924, filed Dec. 21, 2001, now U.S. Pat. No. 6,960,289 which is a continuation of application Ser. No. 09/618,515, filed Jul. 18, 2000, now U.S. Pat. No. 6,413,410, which is a continuation of application Ser. No. 08/981,385, filed Apr. 17, 1998, now U.S. Pat. No. 6,284,125, which is the national phase under 35 U.S.C. §371 of PCT International Application No. PCT/AU96/003 65, which has an International filing date of Jun. 19, 1996, which designated the United States of America, which was published by the International Bureau in English on Jan. 3, 1997, and which claims priority to Australian Provisional Application No. PN 3639, filed Jun. 19, 1995.
FIELD OF THE INVENTION
This invention relates to a biosensor and more particularly to an electrochemical biosensor for determining the concentration of an analyte in a carrier. The invention is particularly useful for determining the concentration of glucose in blood and is described herein with reference to that use but it should be understood that the invention is applicable to other analytic determinations.
BACKGROUND OF THE INVENTION
Electrochemical biosensors generally comprise a cell having a working electrode, a counter electrode and a reference electrode. Sometimes the function of the counter and reference electrodes are combined in a single electrode called a “counter/reference” electrode or “pseudo reference electrode”. As herein used the term “counter electrode” includes a counter/reference electrode where the context so admits.
The sample containing the analyte is brought into contact with a reagent containing an enzyme and a redox mediator in the cell. Either the mediator is reduced (receives at least one electron) while the analyte is oxidised (donates at least one electron) or visa versa. Usually it is the analyte which is oxidised and the mediator which is reduced. The invention will be herein described principally with reference to that system but it is also applicable to systems in which the analyte is reduced and the mediator oxidised.
Electrochemical glucose analysers such as those used by diabetics to monitor blood glucose levels or such as are used in clinics and hospitals are commonly based upon the use of an enzyme such as glucose oxidase dehydrogenase (GOD) and a redox mediator such as a ferricyanide or ferrocyanide. In such prior art system, the sample (e.g. blood) containing the analyte (e.g. glucose) is brought into contact with the reagents in the cell. Glucose is oxidised to gluconic acid and the glucose oxidase is thereby reduced. The mediator then re-oxidizes the glucose oxidase and is reduced in the process. The reduced mediator is then re-oxidized when it transfers electrons to the working electrode. After allowing passage of a predetermined time, sufficient to obtain an accurate estimate of the Faraday current, the concentration of glucose is estimated from the magnitude of the current or voltage signal then measured.
Prior art electrochemical cells consist of two (or three) adjacent electrodes spaced apart on one side of an insulator and adapted for connection to a measuring device. A target area on which the blood sample is placed is defined on or between the electrodes. Co-pending Application PCT/AU95/00207 describes a cell in which electrodes are: disposed on opposite sides of a porous membrane, one of the electrodes having a liquid permeable target area.
In the prior art there is a need to separate the working electrode from the counter (or counter/reference) electrode by a sufficient distance to avoid products of electrochemical reaction at one electrode from interfering with those at the other. In practice a separation of the electrodes of more than 500 μm is required to achieve acceptable accuracy.
Each batch of cells is required to have been previously calibrated and leads to inaccuracies during use because of variations within the batch, in sample composition and in ambient conditions.
It is desired to improve, the accuracy and reliability of such biosensors. Achievement of these objectives is made difficult in the case of sensors intended to determine the concentration of analytes in blood because blood contains dissolved gases, ions, colloids, complex micelles, small scale cellular debris, and living cellular components in a predominantly aqueous medium. Any of these may interfere in the determination. Existing sensors are also susceptible to influence from other interfering substances that may be present in the sample and which may be oxidised at the working electrode and mistakenly identified as the analyte of interest. Alternatively, the interfering substances may reduce the oxidised form of the redox mediator. These effects will give artificially elevated estimates of the analyte concentration. Additionally there is always some reduced redox mediator present before the analyte is added and its concentration needs to be known and subtracted from the measured value of reduced mediator to give an accurate concentration of the analyte. Moreover, oxygen in the blood may act as a redox mediator for glucose oxidase dehydrogenase (GOD) in competition with ferrocyanide. Thus high oxygen concentrations can lead to low estimates of glucose concentration. In addition the measurements are sensitive to factors such as changes in humidity, temperature, solution viscosity and haematocrit content.
OBJECT OF THE INVENTION
It is an object of the present invention to provide a method of analysis and apparatus for use in the method which avoid or ameliorate at least some of the disadvantages of the prior art. It is an object of preferred forms of the invention to provide a biosensor of improved accuracy, and/or reliability and/or speed and a method for its use.
DISCLOSURE OF THE INVENTION
According to one aspect the invention consists in a method for determining the concentration of a reduced (or oxidised) form of a redox species in an electrochemical cell of the kind comprising a working electrode and a counter electrode spaced from the working electrode by a predetermined distance, said method comprising the steps of:
(1) applying an electric potential difference between the electrodes,
(2) selecting the potential of the working electrode such that the rate of electro-oxidation of the reduced form (or electro-reduction of the oxidised form) of the species is diffusion controlled,
(3) selecting the spacing between the working electrode and the counter electrode so that reaction products from the counter electrode arrive at the working electrode,
(4) determining current as a function of time after application of the potential and prior to achievement of a steady state,
(5) estimating the magnitude of the steady state current, and
(6) obtaining from the change in current with time and the magnitude of the steady state current, a value indicative of the diffusion coefficient and/or of the concentration of the reduced form (or the oxidised form) of the species.
The concentration measured in this way is substantially independent of variation if any in the diffusion coefficient of the reduced form, and therefore is compensated for variations in temperature and viscosity. The concentration so measured is independent of variations in haematocrit and other substances which affect the diffusion coefficient of the reduced form of the redox species.
It will be appreciated that the method of the invention is equally applicable for determining the concentration of a reduced form of a redox species or an oxidized form of a redox species in the cell. In the case that the concentration of the reduced form is to be determined the potential of the working electrode must be maintained such that the rate of electro oxidation of the reduced form is diffusion controlled in step (2) and it is the concentration of the reduced form that is obtained in step (5). In the case that the concentration of oxidized form is to be determined, the potential of the working electrode must be maintained such that the rate of electro reduction of the oxidized form is diffusion controlled in step (2) and it is the concentration of the oxidized form that is obtained in step (5).
The redox species may be an analyte or may be a redox mediator.
In preferred embodiments of the method a mediator is used and the concentration of the reduced (or oxidized) form of the mediator is in turn indicative of the concentration of an analyte,and a measure of the diffusion coefficient of the reduced (or oxidized) form of the mediator is determined as a precursor to the determination of the concentration of the analyte.
For preference the cell comprises a working electrode and counter/reference electrode. If a reference electrode separate from a counter electrode is used, then the reference electrode may be in any convenient location in which it is in contact with the sample in the sensor.
In contrast to prior art, when conducting the method of the invention, the electrodes are sufficiently close that the products of electrochemical reaction at the counter electrode migrate to the working electrode during the period of the test. For example, in an enzyme ferricyanide system, the ferrocyanide produced at the counter electrode diffuses to the working electrode.
This allows a steady state concentration profile to be achieved between the electrodes leading to a steady state current. This in turn allows the diffusion coefficient and concentration of the redox species (mediator) to be measured independently of sample variations and therefore greatly improves accuracy and reliability.
The method also permits the haematocrit concentration of blood to be determined from the diffusion coefficient by use of look-up tables (or by separation of red cells from plasma and measurement of the diffusion coefficient of the red cell fraction) and the plasma fraction, and comparing the two.
According to a second aspect, the invention consists in apparatus for determining the concentration of a redox species in an electrochemical cell comprising:
an electrochemical cell having a working electrode and a counter (or counter/reference) electrode,
means for applying an electric potential difference between said electrodes, means for measuring the change in current with time,
and characterised in that the working electrode is spaced from the counter electrode by less than 500 μm.
In preferred embodiments the cell has an effective volume of 1.5 microlitres less. Apparatus for use in the invention may comprise a porous membrane, a working electrode on one side of the membrane, a counter/reference electrode on the other side, said electrodes together with a zone of the membrane therebetween defining an electrochemical cell, and wherein the membrane extends laterally from the cell to a sample deposition area spaced apart from the cell zone by a distance greater than the thickness of the membrane.
Preferably the porous membrane, the distance of the target area from the cell portion, and the membrane thickness are so selected in combination that when blood (comprising plasma and red cells) is placed on the target area a plasma front diffuses laterally towards the electrochemical cell zone in advance of the red cells.
It is thus possible to fill a thin layer electrochemical cell with plasma substantially free of haematocrit which would cause a variation in the diffusion coefficient of the redox mediator and which would affect the accuracy of the test as hereinafter explained.
In preferred embodiments of the biosensor according to the invention a second electrochemical cell zone of the membrane is defined by a second working electrode and a second counter/reference electrode on the opposite side of the membrane from the second working electrode. The second electrochemical cell zone is situated intermediate the first cell zone and the sample deposition or “target” area, or is situated on the side of the target area remote from the first electrochemical zone. In these embodiments the plasma comes into contact with enzyme in or on route to, the first electrochemical cell while plasma reaching the second cell does not. The first cell thus in use measures the concentration of reduced mediator in the presence of plasma (including electrochemically interfering substances), and enzyme while the second electrochemical cell measures it in the presence of plasma (including electrochemically interfering substances) and in the absence of enzyme. This allows determination of the concentration of the reduced interfering substances in the second cell and the concentration of reduced interfering substances plus analyte in the first cell. Subtraction of the one value from the other gives the absolute concentration of analyte.
In a highly preferred embodiment of the invention a hollow cell is employed wherein the working and reference (or counter/reference) electrodes are spaced apart by less than 500 μm and preferably by from 20–200 μm.
DESCRIPTION OF THE DRAWINGS
The invention will now be more particularly described by way of example only with reference to the accompanying drawings wherein:
FIG. 1 is a schematic drawing (not to scale) of a first embodiment according to the invention shown in side elevation.
FIG. 2 shows the embodiment of FIG. 1 in plan, viewed from above.
FIG. 3 shows the embodiment of FIG. 1 in plan, viewed from below.
FIG. 4 shows the embodiment of FIG. 1 viewed in end elevation.
FIG. 5 is a schematic drawing (not to scale) of a second embodiment according to the invention in side elevation.
FIG. 6 shows the embodiment of FIG. 5 in plan, viewed from above.
FIG. 7 is a schematic drawing (not to scale) of a third embodiment according to the invention, in side elevation.
FIG. 8 shows the embodiment of FIG. 7 in plan, viewed from above.
FIG. 9 is a schematic drawing (not to scale) according to the invention in plan view, viewed from above.
FIG. 10 shows the embodiment of FIG. 9 in end elevation.
FIG. 11 shows the embodiment of FIG. 9 in side elevation.
FIG. 12 shows a schematic drawing (not to scale) of a hollow cell embodiment according to the invention, viewed in cross section.
FIG. 13 is a graph showing a plot of current (ordinate axis) versus time (co-ordinate axis) during conduct of a method according to the invention.
FIG. 14 is a further graph of use in explaining the method of the invention.
In FIGS. 5 to 12 , components corresponding in function to components of the embodiment of FIGS. 1 to 4 are identified by identical numerals or indicia.
DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to FIGS. 1 to 4 there is shown a first embodiment of apparatus of the invention, in this case a biosensor for determining glucose in blood. The embodiment comprises a thin strip membrane 1 having upper and lower surfaces 2 , 3 and having a cell zone 4 defined between a working electrode 5 disposed on upper surface 2 and a counter electrode 6 disposed on lower surface 3 . The membrane thickness is selected so that the electrodes are separated by a distance “1” which is sufficiently close that the products of electrochemical reaction at the counter electrode migrate to the working electrode during the time of the test and a steady state diffusion profile is substantially achieved. Typically, “1” will be less than 500 μm. A sample deposition or “target” area 7 defined on upper surface 2 of membrane 1 is spaced at a distance greater than the membrane thickness from cell zone 4 . Membrane 1 has a diffusion zone 8 extending between target area 7 and cell zone 4 . A suitable reagent including a redox mediator “M”, an enzyme “E” and a pH buffer “B” are contained within cell zone 4 of the membrane and/or between cell zone 4 and target area 7 . The reagent may also include stabilisers and the like.
In some cases it is preferable to locate the enzyme and mediator and/or the buffer in different zones of the membrane. For example the mediator may be initially located within electrochemical cell zone 4 while the enzyme may be situated below target area 7 or in diffusion zone 8 .
Haemoglobin releases oxygen at low pH's, but at higher pH's it binds oxygen very firmly. Oxygen acts as a redox mediator for glucose oxidase dehydrogenase (GOD). In a glucose sensor this competes with the redox mediator leading to low estimates of glucose concentration. Therefore if desired a first pH buffer can be contained in the vicinity of target area 7 to raise the pH to such a level that all the oxygen is bound to haemoglobin. Such a pH would be non-optimal for GOD/glucose kinetics and would consequently be detrimental to the speed and sensitivity of the test. In a preferred embodiment of the invention a second pH buffer is contained as a reagent in the vicinity of the working electrode to restore the pH to kinetically optimal levels. The use of a second buffer does not cause oxygen to be released from the haemoglobin as the haemoglobin is contained within the blood cells which are retained near blood target area 7 or are retarded in diffusion in comparison with the plasma and therefore not influenced by the second buffer. In this manner oxygen interference may be greatly reduced or eliminated.
In use of the sensor a drop of blood containing a concentration of glucose to be determined is placed on target zone 7 . The blood components wick towards cell zone 4 , the plasma component diffusing more rapidly than red blood cells so that a plasma front reaches cell zone 4 in advance of blood cells.
When the plasma wicks into contact with the reagent, the reagent is dissolved and a reaction occurs that oxidises the analyte and reduces the mediator. After allowing a predetermined time to complete this reaction an electric potential difference is applied between the working electrode and the counter electrode. The potential of the working electrode is kept sufficiently anodic such that the rate of electro oxidation of the reduced form of the mediator at the working electrode is determined by the rate of diffusion of the reduced form of the mediator to the working electrode, and not by the rate of electron transfer across the electrode/solution interface.
In addition the concentration of the oxidised form of the mediator at the counter electrode is maintained at a level sufficient to ensure that when a current flows in the electrochemical cell the potential of the counter electrode, and thus also the potential of the working electrode, is not shifted so far in the cathodic direction that the potential of the working electrode is no longer in the diffusion controlled region. That is to say, the concentration of the oxidized form at the counter electrode must be sufficient to maintain diffusion controlled electro oxidation of the reduced form of the mediator at the working electrode.
The behaviour of a thin layer cell is such that if both oxidised and reduced forms of the redox couple are present, eventually a steady state concentration profile is established across the cell. This results in a steady state current. It has been found that by comparing a measure of the steady state current with the rate at which the current varies in the current transient before the steady state is achieved, the diffusion coefficient of the redox mediator can be measured as well as its concentration. This is in contrast to the Cottrell current that is measured in the prior art. By measuring the Cottrell current at known times after application of a potential to the sensor electrodes it is only possible to determine the product concentration times square root of the diffusion coefficient and therefore it is not possible to determine the concentration of the mediator independent of its diffusion coefficient.
In a cell according to the current invention, by solving the appropriate diffusion equations it can be shown that over a restricted time range a plot of ln(i/i ∞ −1) vs time (measured in seconds) is linear and has a slope (denoted by S) which is equal to −4π 2 D/I 2 , where “i” is the current at time “t”, “i ∞ ” is the steady state current, “D” is the diffusion coefficient in cm 2 /sec, “1” is the distance between the electrodes in cm and “π” is approximately 3.14159. The concentration of reduced mediator present when the potential was applied between the electrodes is given by 2π 2 i ∞ /FA1S, where “F” is Faraday's constant, A is the working electrode area and the other symbols are as given above. As this later formula uses S it includes the measured value of the diffusion coefficient.
Since 1 is a constant for a given cell, measurement of i as a function of time and i ∞ enable the value of the diffusion coefficient of the redox mediator to be calculated and the concentration of the analyte to be determined.
Moreover the determination of analyte concentration compensates for any variation to the diffusion coefficient of the species which is electro oxidised or electro reduced at the working electrode. Changes in the value of the diffusion coefficient may occur as a result of changes in the temperature and viscosity of the solution or variation of the membrane permeability. Other adjustments to the measured value of the concentration may be necessary to account for other factors such as changes to the cell geometry, changes to the enzyme chemistry or other factors which may effect the measured concentration. If the measurement is made on plasma substantially free of haematocrit (which if present causes variation in the diffusion coefficient of the redox mediator) the accuracy of the method is further improved.
Each of electrodes 5 , 6 has a predefined area In the embodiments of FIGS. 1 to 4 cell zone 4 is defined by edges 9 , 10 , 11 of the membrane which correspond with edges of electrodes 5 , 6 and by leading (with respect to target area 7 ) edges 12 , 13 of the electrodes. In the present example the electrodes are about 600 angstrom thick and are from 1 to 5 mm wide.
Optionally, both sides of the membrane are covered with the exception of the target area 7 by laminating layers 14 (omitted from plan views) which serves to prevent evaporation of water from the sample and to provide mechanical robustness to the apparatus. Evaporation of water is undesirable as it concentrates the sample, allows the electrodes to dry out, and allows the solution to cool, affecting the diffusion coefficient and slowing the enzyme kinetics, although diffusion coefficient can be estimated as above.
A second embodiment according to the invention, shown in FIGS. 5 and 6 , differs, from the first embodiment by inclusion of a second working electrode 25 and counter/reference electrode 26 defining a second cell zone 24 therebetween. These electrodes are also spaced apart by less than 500 μm in the present example. Second electrodes 25 , 26 are situated intermediate cell zone 4 and target area 7 . In this embodiment the redox mediator is contained in the membrane below or adjacent to target area 7 or intermediate target area 7 and first cell zone 4 . The enzyme is contained in the membrane in the first cell zone 4 and second cell zone 24 . The enzyme does not extend into second cell 24 . In this case when blood is added to the target area, it dissolves the redox mediator. This wicks along the membrane so that second electrochemical cell 24 contains redox mediator analyte and serum including electrochemically interfering substances. First electrochemical cell receives mediator, analyte, serum containing electrochemically interfering substances, and enzyme. Potential is now applied between both working electrodes and the counter electrode or electrodes but the change in current with time is measured separately for each pair. This allows the determination of the concentration of reduced mediator in the absence of analyte plus the concentration of electrochemically interfering substances in the second electrochemical cell and the concentration of these plus analyte in the first electrochemical cell. Subtraction of the one value from the other gives the absolute concentration of analyte.
The same benefit is achieved by a different geometry in the embodiment of FIGS. 7 and 8 in which the second working electrode and second counter/reference electrode define the second cell 24 on the side of target area 7 remote from first electrochemical cell 4 . In this case the enzyme may be contained in the membrane strip between the target area and cell 1 . The redox mediator may be in the vicinity of the target area or between the target area and each cell. The diffusion coefficient of mediator is lowered by undissolved enzyme and the arrangement of FIGS. 7 and 8 has the advantage of keeping enzyme out of the thin layer cells and allowing a faster test (as the steady state current is reached more quickly). Furthermore the diffusion constant of redox mediator is then the same in both thin layer cells allowing more accurate subtraction of interference.
Although the embodiments of FIGS. 1 to 8 are unitary sensors, it will be understood that a plurality of sensors may be formed on a single membrane as shown in the embodiment of FIGS. 9 to 11 . In this case the electrodes of one sensor are conductively connected to those of an adjacent sensor. Sensors may be used successively and severed from the strip after use.
In the embodiment of FIGS. 9 to 11 electrode dimensions are defined in the diffusion direction (indicated by arrow) by the width of the electrode in that direction. The effective dimension of the electrode in a direction transverse to diffusion direction is defined between compressed volumes 16 of the membrane in a manner more fully described in co-pending Application PCT/AU96/00210, the disclosure of which is incorporated herein by reference in its entirety. For clarity optional laminated layer 14 of FIG. 1 has been omitted from FIGS. 9 to 11 .
In the embodiment of FIG. 12 there is shown a hollow cell according to the invention wherein the electrodes 5 , 6 are supported by spaced apart polymer walls 30 to define a hollow cell. An opening 31 is provided on one side of the cell whereby a sample can be admitted into cavity 32 . In this embodiment a membrane is not used. As in previous embodiments, the electrodes are spaced apart by less than 500 μm, preferably 20–400 μm and more preferably 20–200 μm. Desirably the effective cell volume is 1.5 microlitres or less.
It will be understood that the method of the invention may be performed with a cell constructed in accord with co-pending application PCT/AU95/00207 or cells of other known design, provided these are modified to provide a sufficiently small distance between electrode faces.
The method of the invention will now be further exemplified with reference to FIGS. 13 and 14 .
EXAMPLE 1
A membrane 130 microns thick was coated on both sides with a layer of Platinum 60 nanometers thick. An area of 12.6 sq. mm was defined by compressing the membrane. 1.5 microlitres of a solution containing 0.2 Molar potassium ferricyanide and 1% by weight glucose oxidase dehydrogenase was added to the defined area of the membrane and the water allowed to evaporate.
The platinum layers were then connected to a potentiostat to be used as the working and counter/reference electrodes. 3.0 microlitres of an aqueous solution containing 5 millimolar D-glucose and 0.9 wt % NaCl was dropped on to the defined area of the membrane. After an elapse of 20 seconds a voltage of 300 millivolts was applied between the working and counter/reference electrodes and the current recorded for a further 30 seconds at intervals of 0.1 seconds.
FIG. 13 is a graph of current versus time based on the above measurements. Using a value of the steady state current of 26.9 microamps the function ln(i/26.9−1) was computed and plotted versus time. The slope of the graph ( FIG. 14 ) is −0.342 which corresponds to a diffusion coefficient of 1.5×10 −6 cm 2 per second and a corrected glucose concentration (subtracting background ferrocyanide) of 5.0 millimolar.
The steady state current is one in which no further significant current change occurs during the test. As will be understood by those skilled in the art, a minimum current may be reached after which there may be a drift due to factors such as lateral diffusion, evaporation, interfering electrochemical reactions or the like. However, in practice it is not difficult to estimate the “steady state” current (i ∞ ). One method for doing so involves approximating an initial value for i ∞ . Using the fit of the i versus t data to the theoretical curve a better estimate of i ∞ is then obtained. This is repeated reiteratively until the mewed value and approximated value converge to within an acceptable difference, thus yielding an estimated i ∞ .
In practice, the measurements of current i at time t are made between a minimum time t min and a maximum time t max after the potential is applied. The minimum and maximum time are determined by the applicability of the equations and can readily be determined by experiment of a routine nature. If desired the test may be repeated by switching off the voltage and allowing the concentration profiles of the redox species to return towards their initial states.
It is to be understood that the analysis of the current v. time curve to obtain values of the Diffusion Co-efficient and/or concentration is not limited to the method given above but could also be achieved by other methods.
For instance, the early part of the current v. time curve could be analysed by the Cottrell equation to obtain a value of D 1/2 ×Co (Co=Concentration of analyte) and the steady state current analysed to obtain a value of D×Co. These 2 values can then be compared to obtain D and C separately.
It will be understood that in practice of the invention an electrical signal is issued by the apparatus which is indicative of change in current with time. The signal may be an analogue or digital signal or may be a series of signals issued at predetermined time intervals. These signals may be processed by means of a microprocessor or other conventional circuit to perform the required calculations in accordance with stored algorithms to yield an output signal indicative of the diffusion coefficient, analyte concentration, haematocrit concentration or the like respectively. One or more such output signals may be displayed by means of an analogue or digital display.
It is also possible by suitable cell design to operate the cell as a depletion cell measuring the current required to deplete the mediator. For example in the embodiment of FIG. 5 the method of the invention may be performed using electrodes 5 , 6 , which are spaced apart by less than 500 μm. An amperometric or voltametric depletion measurement may be made using electrodes 5 and 26 which are spaced apart more than 500 μm and such that there is no interference between the redox species being amperometrically determined at electrodes 5 , 26 .
The depletion measurement may be made prior to, during or subsequent to, the measurement of diffusion coefficient by the method of the invention. This enables a substantial improvement in accuracy and reproducibility to be obtained.
In the embodiments described the membrane is preferably an asymmetric porous membrane of the kind described in U.S. Pat. Nos. 4,629,563 and 4,774,039 both of which are incorporated herein in their entirety by reference. However symmetrical porous membranes may the employed. The membrane may be in the form of a sheet, tube, hollow fibre or other suitable form.
If the membrane is symmetric the target area is preferably on the more open side of the asymmetric membrane. The uncompressed membrane desirably has a thickness of from 20 to 500 μm. The minimum thickness is selected having regard to speed, sensitivity, accuracy and cost. If desired a gel may be employed to separate haematocrit from GOD. The gel may be present between the electrodes and/or in the space between the sample application area and the electrodes.
The working electrode is of any suitable metal for example gold, silver, platinum, palladium, iridium, lead, a suitable alloy. The working electrode may be preformed or formed in situ by any suitable method for example sputtering, evaporation under partial vacuum, by electrodeless plating, electroplating, or the like. Suitable non-metal conductors may also be used for electrode construction. For example, conducting polymers such as poly(pyrrole), poly(aniline), porphyrin “wires” poly(isoprene) and poly (cis-butadiene) doped with iodine and “ladder polymers”. Other non-metal electrodes may be graphite or carbon mixed with a binder, or a carbon filled plastic. Inorganic electrodes such as In 2 O 3 or SnO 2 may also be used. The counter/reference electrode may for example be of similar construction to the working electrode. Nickel hydroxide or a silver halide may also be used to form the counter/reference electrode. Silver chloride may be employed but it will be understood that chloridisation may not be necessary and silver may be used if sufficient chloride ions are present in the blood sample. Although in the embodiments described the working electrode is shown on the upper surface of the biosensor and the counter/reference electrode is on the lower surface, these may be reversed.
It is preferable that the working electrode and counter (or counter/reference) electrodes are of substantially the same effective geometric area.
If a separate reference and counter electrode are employed, they may be of similar construction. The reference electrode can be in any suitable location.
It will be understood that the features of one embodiment hereindescribed may be combined with those of another. The invention is not limited to use with any particular combination of enzyme and mediator and combinations such as are described in EP 0351892 or elsewhere may be employed. The system may be used to determine analytes other than glucose (for example, cholesterol) by suitable adaptation of reagents and by appropriate membrane selection. The system may also be adapted for use with media other than blood. For example the method may be employed to determine the concentration of contaminants such as chlorine, iron, lead, cadmium, copper, etc., in water.
Although the cells herein described have generally planar and parallel electrodes it will be understood that other configurations may be employed, for example one electrode could be a rod or needle and the other a concentric sleeve.
It will be apparent to those skilled in the art from the disclosure hereof the invention may be embodied in other forms without departing from the inventive concept herein disclosed.
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This invention relates to a biosensor and more particularly to an electrochemical biosensor for determining the concentration of an analyte in a carrier. The invention is particularly useful for determining the concentration of glucose in blood and is described herein with reference to that use but it should be understood that the invention is applicable to other analytic determinations.
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BACKGROUND OF THE INVENTION
This invention relates to a construction of a fuel assembly spacer used for various nuclear power reactors of the type where the fuel assembly is inserted in a coolant duct and, more particularly, to a fuel assembly spacer which has a plurality of springs having a unit for spring strength and arranged around the outer periphery of the spacer so that the fuel assembly can be positioned coaxially with the coolant duct.
In the design of a nuclear power reactor, in which the heat produced from the nuclear fuel is transmitted to a coolant, as the criterion for evaluation of the soundness of the fuel at the present it is necessary to provide sufficient heat removal capacity lest burn-out of fuel should result. Considerations in this respect should also be given to the design of the spacer. The basic function of the spacer is to keep the gap between adjacent fuel rods at a prescribed value so as to prevent formation of hot spots, either thermal or radioactive. Also, it should not unduly interfere with the flow of the coolant contributing to the removal and transmission of heat from the fuel, and also it is required to have sufficient strength to reliably hold the fuel rods in their normal positions even against vibrations due to the flow force of the coolant, thermal bending due to non-uniform thermal distribution in the fuel rods and other stresses due to external loads.
However, results of recent research reveals that the performance of removal of heat from the fuel by the coolant is greatly influenced by such factor as the contour of the fuel assembly including the spacers. Particularly, where a channel tube or a pressure tube is used as an outer structure of a fuel assembly constituting a duct for the passage of a coolant, there is some tolerance in the cross-sectional demension of the coolant duct during its manufacture, and also the sectional area of the duct tends to increase due to the secular creep deformation caused by stresses produced during use of the reactor and by irradiation with neutrons. Therefore, the effects of the positional contour of the fuel assembly within the coolant duct during the thermal performance of the fuel cannot be ignored.
However, the design of the conventional spacers has been made mainly from the standpoint of the structural strength, and the aforementioned effects of the contour of the fuel assembly including the spacers during the heat removal performance have not been taken into detailed consideration.
SUMMARY OF THE INVENTION
In the light of the foregoing, an object of the invention is to provide a fuel assembly spacer for various types of nuclear power reactors where the fuel assembly is inserted in a coolant duct.
Another object of the invention is to provide a fuel assembly spacer which prevents eccentricity of the fuel assembly in the coolant duct which ordinarily would result from the combination of dimensional tolerance at the time of manufacture and secular dimensional changes, to thereby improve the removal of heat by the coolant.
A further object of the invention is to provide a fuel assembly spacer which can maintain as uniform a gap as possible between the inner wall of the coolant duct and each outermost fuel rod of the fuel assembly to maintain the symmetry of the flow of the coolant in a section perpendicular to; the coolant duct, thereby improving the thermal performance the fuel.
The invention provide a fuel assembly spacer which has a plurality of springs having uniform spring strength and arranged around its outer periphery in a symmetrical relation with respect to the periphery or axis of rotation. The above and other objects, features and advantages of the invention will become more apparent from the following description taken in conjunction iwth the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the relation between burn-out heat flux ratio and the eccentricity of a fuel assembly in a pressure tube type reactor;
FIG. 2 is a plan view showing a cluster-type fuel assembly spacer embodying the invention;
FIG. 3 is a side view of the spacer shown in FIG. 2;
FIG. 4A shows the back of a spring on the spacer;
FIG. 4B is a sectional view of the spring on the spacer shown in FIG. 4A;
FIG. 5 is a plan view showing a hexagonal fuel assembly spacer for a liquid metal cooled reactor; and
FIG. 6 is an enlarged, fragmentary, perspective view showing one side of the hexagonal outer periphery of the spacer shown in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
As described above, the removal of heat from the fuel by the coolant is greatly affected by factors related to the contour of the fuel assembly including spacers. Of these contour factors, present invention concerns the eccentricity of the fuel assembly in a coolant duct. By the term "eccentricity of the fuel assembly" is meant a deviation a transverse the center of sectional plane of the fuel assembly with respect to the transverse center of a sectional plane of a coolant duct such as channel tube or pressure tube. If this eccentricity is present, the relative flow areas of sub-channels are different from the normal values for the fuel assembly causing unfavorable effects upon the sub-channel flows of the coolant. Particularly, in case of a boiling water cooled reactor, a great deviation of steam quality by weight is produced in the sectional area of each sub-channel.
Since in a water cooled reactor the burn-out phenomenon is a linearly reducing function of the steam quality, that is, the burn-out heat flux is reduced with increase of the steam quality.
FIG. 1 shows the relation between the burn-out heat flux ratio and the eccentricity of a cluster type fuel assembly in a pressure tube of a pressure tube type reactor of the boiling water cooling type, the graph being obtained from experiments using a 14 megawatt heat transfer loop. These experiments were conducted under conditions wherein the dimensions of the inner diameter of the tested pressure tube was 117.8 mm and the outer peripheral diameter of the cluster type fuel assembly was 116.7 mm. The eccentricity was controlled by positioning the dummy fuel assembly for the burn-out test in the top enclosure of the 14 megawatt heat transfer loop. As is apparent from FIG. 1, the burn-out heat flux ratio is greatly reduced even for a slight eccentricity of the fuel assembly. Thus, it is important to hold the fuel assembly in the coolant duct in a position in which there is no eccentricity.
FIGS. 2 and 3 show an embodiment of a fuel assembly spacer according to the invention. It is a cluster type fuel assembly spacer used for a pressure tube type reactor or the like. This spacer 1 comprises an annular outer member 2, and a number of fuel rod retainer rings 3 and reinforcing rings 4, these rings being provided inside the annular outer member. Also, it comprises eight stationary projections 5 and also eight projecting springs 6, these springs being arranged around the outer periphery of the annular member 2. The individual springs 6 all have substantially uniform spring strength and are uniformly spaced around the outer periphery of the spacer.
The details of the construction of each spring 6 are shown in FIGS. 4A and 4B. As is shown, it has an outer deformable slide portion 6a having a substantially arcuate convex sectional profile and inner portions 6b folded from the opposite ends of the outer portion. The ends of the opposite inner portions are butt welded to each other, and the welded portion is welded to the inner periphery of the annular outer member 2 of the spacer. The material of the spring can be metals as Inconel and stainless steel. In addition, in a boiling water cooled reactor, niobium dispersion type zirconium alloys, which absorb less thermal neutrons and which have excellent resiliency within the reactor operation temperature range, are suitable for the spacer material.
When a fuel assembly using spacers of the above described construction is inserted in a pressure tube, the deformable slide portions 6a thereof are uniformly deformed when they can in contact with the inner wall of the pressure tube by virtue of the uniform spring strength of the springs 6. In this way, the fuel assembly and pressure tube are naturally disposed in a true coaxial relation to each other. Further, the central portion of the pressure tube, with respect to its length, at which the reactor core is positioned receives higher flux of fast neutrons than the other portion of the pressure tube in the course reactor operation, and a so-called "belly" shape is formed in the pressure tube due to eventual increase of the inner diameter of the central portion of the pressure tube compared to portions thereof adjacent to its ends. And further, in case of refuelling a belly shaped pressure tube, a fuel assembly can be easily loaded through the narrow end portion of the pressure tube, because the deformable slide portions of 6a of the spacers accommodate themselves to the small inner diameter of the pressure tube.
The invention can of course be applied to a liquid metal cooled reactor fuel assembly as well as to a boiling water cooled reactor fuel assembly as above-described. The fuel assembly used in a liquid metal cooled reactor usually has a hexagonal lattice arrangement of fuel rods having an outer diameter of 4 to 6 mm such that a hexagon is formed by the outermost fuel rods. In this case, a channel tube or wrapper tube forming the outer side structure of this fuel assembly also has a hexagonal sectional profile. Thus, as shown in FIGS. 5 and 6, the outer member 7 of the fuel assembly spacer of the aforementioned type also has a hexagonal shape. Again in this case, springs 8 having uniform spring strength are provided on the outer periphery of the outer member 7 at symmetrical positions thereof to maintain a uniform gap between the inner wall of the wrapper tube (not shown) and the outermost fuel rods 9 of the fuel assembly, whereby it is possible to improve the removal of heat for the fuel rods by the liquid metal coolant from the reasons set forth above.
In the embodiment shown in FIGS. 5 and 6, each side of the hexagonal outer periphery of the outer member 7 is provided with a spring 8 at the middle portion of the lenght of each side and two rigid projections 10 on opposite sides of the spring 8. The spring is punched out to form a deformable slide portion having a substantially arcuate convex sectional profile. The deformable slide portion 8 has two slits on either side thereof.
While the invention has been described in some detail in conjunction with its most preferred embodiments, it is apparent that various changes and modifications can be made without departing from the scope and spirit of the invention and that the invention covers any possible form of structure that falls within the scope of the annexed claims.
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A fuel assembly spacer for a nuclear reactor, the spacer having a plurality of spring with a uniform spring strength and arranged symmetrically around the outer periphery of the spacer so that the fuel assembly can be coaxially disposed with respect to a coolant duct. This spacer serves to maintain as uniform a gap as possible between the inner wall of the coolant duct and each outermost fuel rod in the fuel assembly so that the flow of the coolant keeps it symmetry in the section of the coolant duct, thereby improving the thermal performance of the fuel assembly.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of U.S. patent application Ser. No. 11/458,209, filed Jul. 18, 2006, which is a continuation-in-part of U.S. patent application Ser. No. 11/057,400 filed Feb. 11, 2005, now U.S. Pat. No. 7,553,382, incorporated herein by reference.
FIELD OF INVENTION
The present invention relates to metallic glasses and more particularly to iron based alloys and iron based glasses and more particularly to the addition of Niobium to these alloys.
BACKGROUND
Conventional steel technology is based on manipulating a solid-state transformation called a eutectoid transformation. In this process, steel alloys are heated into a single phase region (austenite) and then cooled or quenched at various cooling rates to form multiphase structures (i.e. ferrite and cementite). Depending on how the steel is cooled, a wide variety of microstructures (ie. pearlite, bainite and martensite) can be obtained with a wide range of properties.
Another approach to steel technology is called glass devitrification, producing steels with bulk nanoscale microstructures. The supersaturated solid solution precursor material is a super cooled liquid, called a metallic glass. Upon superheating, the metallic glass precursor transforms into multiple solid phases through devitrification. The devitrified steels form specific characteristic nanoscale microstructures, analogous to those formed in conventional steel technology.
It has been known for at least 30 years, since the discovery of metallic glasses, that iron based alloys could be made into metallic glasses. However, with few exceptions, these iron based glassy alloys have had very poor glass forming ability and the amorphous state could only be produced at very high cooling rates (>10 6 K/s). Thus, these alloys may be processed by techniques which give very rapid cooling such as drop impact or melt-spinning techniques.
While conventional steels have critical cooling rates for forming metallic glasses in the range of 10 9 K/s, special iron based metallic glass forming alloys have been developed having a critical cooling rate orders of magnitude lower than conventional steels. Some special alloys have been developed that may produce metallic glasses at cooling rates in the range of 10 4 to 10 5 K/s. Furthermore, some bulk glass forming alloys have critical cooling rates in the range of 10 0 to 10 2 K/s, however these alloys may employ rare or toxic alloying elements to increase glass forming ability, such as the addition of beryllium, which is highly toxic, or gallium, which is expensive. The development of glass forming alloys which are low cost and environmentally friendly has proven much more difficult.
In addition to the difficulty in developing cost effective and environmentally friendly alloys, the very high cooling rate required to produce metallic glass has limited the manufacturing techniques that are available for producing articles from metallic glass. The limited manufacturing techniques available have in turn limited the products that may be formed from metal glasses, and the applications in which metal glasses may be used. Conventional techniques for processing steels from a molten state may provide cooling rates on the order of 10 −2 to 10 0 K/s. Special alloys that are more susceptible to forming metallic glasses, i.e., having reduced critical cooling rates on the order of 10 4 to 10 5 K/s, may not be processed using conventional techniques with such slow cooling rates and still produce metallic glasses. Even bulk glass forming alloys having critical cooling rates in the range of 10 0 to 10 2 K/s, may be limited in the available processing techniques, and have the additional processing disadvantage in that they may not be processed in air but only under very high vacuum.
SUMMARY
An aspect of the present disclosure relates to an iron based alloy. The alloy may include at least 55 atomic % iron, at least one transition metal selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Al, Mn or Ni present in the range of about 7 at % to 20 at %, at least one non/metal or metalloid selected from the group consisting of B, C, N, 0, P, Si, or S present in the range of about 0.01 at % to 25 at %, and niobium present in the range of about 0.01 at % to 10 at %.
BRIEF DESCRIPTION OF DRAWINGS
The detailed description below may be better understood with reference to the accompanying figures which are provided for illustrative purposes and are not to be considered as limiting any aspect of the disclosure herein or claims appended hereto.
FIG. 1 illustrates a scanning electron image of the microstructure of Alloy LCW1 1/16 inch GMAW weld near the bottom of a single pass weld;
FIG. 2 illustrates a scanning electron image of the microstructure of Alloy LCW1 1/16 inch GMAW weld at the center of the single pass weld showing fine scale structure of the matrix;
FIG. 3 illustrates a backscattered scanning electron image of Alloy LCW1 1/16 inch GMAW weld microstructure at the center of the single pass weld;
FIG. 4 illustrates a backscattered scanning electron image of Alloy LCW1 1/16 inch GMAW weld microstructure near the top of the single pass weld;
FIGS. 5 a, b and c illustrate backscattered scanning electron images of hardness indentations into the microstructure of Alloy LCW1 1/16 GMAW weld showing that cracks be formed at the tip of the indentations either don't form or are blunted and stopped by the ductile phase matrix;
FIG. 6 illustrates a scanning electron image of hardness indentations across the Alloy LCW1 1/16 GMAW weld single pass weld interface. Point 3 of Table 5 is at the bottom of the figure within the substrate;
FIGS. 7 a and b illustrate scanning electron images of hardness indentions at point 3 (within the substrate) and point 4 (within the weld overlay) as described in Table 5 across the interface of A36 steel substrate and LCW1 1/16 GMAW weld single pass weld. FIG. 7 a is a backscattered electron micrograph image and FIG. 7 b is a secondary electron micrograph image;
FIG. 8 illustrates a backscattered scanning electron image of Vickers hardness indentations in the A36 steel substrate and the LCW1 1/16 GMAW weld single pass weld along with the distance from the boundary layer; and
FIG. 9 illustrates an optical picture of the as cast LCW1 plate.
DETAILED DESCRIPTION
The present invention relates to the addition of niobium to iron based glass forming alloys. The present alloys include an alloy design approach that may be utilized to modify and improve existing iron based glass alloys and their resulting properties and may be related to three distinct properties. First, the alloys contemplated herein may increase the hardness of iron based alloys. Second, the alloys disclosed herein may increase the wear resistance of the iron based alloys. Third, the niobium addition may allow for increased refinement of the phases exhibited by the alloys disclosed herein. These effects may not only occur in the alloy design stage but may also occur in industrial gas atomization processing of feedstock and in PTAW welding of hardfacing weld overlays.
Furthermore, the improvements may generally be applicable to a range of industrial processing methods including PTAW, welding, spray forming, MIG (GMAW) welding, laser welding, sand and investment casting and metallic sheet forming by various continuous casting techniques.
A consideration in developing nanocrystalline or even amorphous welds, is the development of alloys with low critical cooling rates for metallic glass formation in a range where the average cooling rate occurs during solidification. This may allow high undercooling to occur during solidification, which may result either in the prevention of nucleation resulting in glass formation or in nucleation being prevented so that it occurs at low temperatures where the driving force of crystallization is very high and the diffusivities are minimal. Undercooling during solidification may also result in very high nucleation frequencies with limited time for growth resulting in the achievement of nanocrystalline scaled microstructures in one step during solidification.
In developing advanced welds with reduced microstructural scales, the nanocrystalline or near nanocrystalline/submicron grain size may be maintained in the as-welded condition by preventing or minimizing grain growth. Also, the as-crystallization grain size may be reduced by slowing down the crystallization growth front which can be achieved by alloying with elements which have high solubility in the liquid/glass but limited solubility in the solid. Thus, during crystallization, the supersaturated state of the alloying elements may result in an ejection of solute in front of the growing crystallization front which may result in a dramatic refinement of the as-crystallized/as solidified phase size. This may be accomplished in multiple stages to slow down growth throughout the solidification regime.
Consistent with the present invention, the nanocrystalline materials may include iron based glass forming alloys. It will be appreciated that the present invention may suitably employ other alloys based on iron, or other metals, that may be susceptible to forming metallic glass materials. Accordingly, an exemplary alloy may include a steel composition, comprising at least 40 at % iron and at least one element selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Al, Mn, or Ni; and at least one element selected from the group consisting of B, C, N, O, P, Si and S. In a further embodiment, the alloys contemplated herein may include iron present at least 55 atomic % (at %), at least one transition metal present in the range of about 7 at % to 20 at %, at least one nonmetal/metalloids present in the range of about 0.01 at % to 25 at % and Niobium present in the range of about 0.01 at % to 10 at %, including all values and increments therein.
In a further embodiment, an exemplary alloy may include iron present at an atomic percent of greater than 55 at %, including in the range of about 55 at % to 65 at %. The alloy may also include Cr present in the range of about 7 at % to 16 at % and/or Mn present in the range of about 0.1 to 4%. The alloy may further include B present in the range of about 10 at % to 23 at %, C present in the range of about 0.1 at % to 9 at %, and/or Si present in the range of about 0.1 at % to 3 at %. Niobium may be added to the iron based alloy between 0.5-8 at % relative to the alloys and all incremental values in between, i.e. 0.5-2 at %, 2-5 at % 5-8 at % etc. More preferably, the niobium present in the alloy is 0.01-6 at % relative to the alloys. All ranges noted above may include all increments and values therein.
The alloys may be atomized by centrifugal, gas or water atomization producing powders of various sizes in the range of greater than 30 μm to less than 200 μm, including all values and increment therein. For example, powders may be available in the size range of +53 to −106 μm, +50 to −150 μm and +45 to −180 μm for use in various industrial application processes. Such powders may be used to provide hard coatings or surfaces via hardfacing technologies such as laser welding or plasma transferred arc welding.
In addition, the alloys may be provided in the form of cored wires or stick electrodes of various diameters including those in the range of 0.01 to 0.5 inches, including all increments and values therein. Such cored wires may be utilized in providing hard coatings or surfaces via hardfacing techniques including gas metal arc welding, metal inert gas welding, submerged arc welding, open arc welding, shielded metal arc welding or stick welding. Accordingly, it may be appreciated from the above that the alloys may be applied as a weld overlay via a number of processes.
The alloys may also be provided as a melt. The alloy melt may be cast into sheet or plate by various processes including single belt, twin belt, twin roll, continuous casting and other known processes. Furthermore, the alloys may be cast into ingots.
The formed alloys may exhibit a number of phases. For example, the formed alloys may include a matrix comprising iron rich phases ranging from approximately 0.1 to 5 microns in size, including all values and increments therein. The iron rich phase may be present in the range of approximately 40 to 80% by volume, including all values and increments therein. In addition, the alloys may include a chrome rich borocarbide phase ranging from approximately 1 to 50 microns in size, including all values and increments therein and present in the range of about 10 to 50% by volume, including all values and increments therein. Furthermore, the alloys may include a niobium rich borocarbide phase ranging from approximately 0.01 to 5 microns in size, including all values and increments therein and present in the range of about 1 to 10% by volume, including all values and increments therein. In addition, other complex carbide or borocarbide phases may be found in the alloys contemplated herein. It should be appreciated that the “rich” phases indicate that the iron, chrome or niobium are present at least about 30 at %.
The alloys described herein may exhibit a Vickers microhardness (HV300) in the range of about 800 to 1700 kg/mm 2 , including all values and increments therein, such as 900 to 1550 kg/mm 2 , etc. Such values may be obtained regardless of whether the alloy is cast as an ingot or a single or multiple pass overlay material. The alloys may also exhibit a Rockwell C hardness in the range of 64 to 77, including all values and increments therein. Furthermore, the alloys may exhibit a mass loss of less than 0.15 grams, such as in the range of 0.04 grams to 0.14 grams, including all values and increments therein as measured by ASTM G-65, procedure A, for first pass and second pass mass loss measurements, wherein the second pass was performed in the wear scar of the first pass. These values may also be obtained regardless of whether the alloy is cast as a plate or a single or multiple pass overlay.
In addition, where the alloys are applied as weld overlays it may be appreciated that the effects of dilution may be limited in such a manner that that full hardness of the alloys contemplated herein are attained within 250 microns from the substrate surface. Such substrates may include, for example, steel, aluminum or titanium alloys, as well as other base alloys.
EXAMPLES
The Examples herein are for purposes of illustration and are not meant to limit the disclosure herein or claims appended hereto.
Five alloys having the compositions illustrated in Table 1, below, were cast into small ingots.
TABLE 1
Alloy Compositions (atomic %)
Alloy
Fe
Cr
B
C
Si
Mn
Nb
LCW0
62.5
12.9
18.1
4.5
0.7
0.1
1.2
LCW1
61.7
12.9
18.1
4.9
0.7
0.1
1.6
LCW2
60.7
12.9
18.2
5.0
0.7
0.1
2.4
LCW3
59.6
13.0
18.3
5.0
0.8
0.1
3.2
LCW4
58.7
13.0
18.3
5.0
1.0
0.1
3.9
The ingots were metallurgically mounted and polished. Vickers harness indentations were made on the cross section of the ingots at a 300 g load. Ten hardness indentations were taken at random locations on each ingot and the results are presented in Table 2, below. As shown, the average hardness of the all the ingots were found to be over 1,000 kg/mm 2 Vickers hardness (VH).
TABLE 2
Vickers Microhardness (HV300) (kg/mm 2 ) for LCW1 Cast Ingots
Sample Number
LCW0
LCW1
LCW2
LCW3
LCW4
Indentation 1
1233
1384
995
1105
1229
Indentation 2
1200
1208
1031
1112
1206
Indentation 3
1125
1080
1210
1228
1193
Indentation 4
932
1512
1403
1046
1279
Indentation 5
960
1114
1039
1120
1138
Indentation 6
1292
1181
1175
1283
1128
Indentation 7
1040
1285
1049
1025
1314
Indentation 8
1045
1296
1090
1028
1281
Indentation 9
970
1089
1176
1067
1188
Indentation 10
1197
1287
1199
1078
1252
Average Hardness
1099
1244
1137
1109
1221
Alloy LCW1 was made into a 1.6 mm diameter cored wire. The wire was welding using a standard GMAW set up, which utilized a Miller Delta-Fab™ system. As shown in Table 3, five different welding parameters (A, B, C, D, E) were used to produce both single pass (1P) and double pass (2P) weld overlay samples. Note that welding were performed using both GMAW (gas shielded) and open-arc (no cover gas) conditions onto a 1 inch by 4 inch by 0.5 inch thick A36 base plate. The LCW1 appeared to exhibit minimal splatter and the absence of porosity, even after grinding.
TABLE 3
Parameters for LCW1 Weld Overlay Samples
Substrate Size
Sample
(inches)
Volts
ipm
Amps
Gas
LCW1-1PA
1 × 4
26
225
205
None/Open Arc
LCW1-2PA
1 × 4
26
225
205
None/Open Arc
LCW1-1PB
1 × 4
26
250
210
None/Open Arc
LCW1-2PB
1 × 4
26
250
210
None/Open Arc
LCW1-1PC
1 × 4
26
275
225
None/Open Arc
LCW1-2PC
1 × 4
26
275
225
None/Open Arc
LCW1-1PD
1 × 4
26
275
210
75% Ar- 25% Co 2
LCW1-2PD
1 × 4
26
275
210
75% Ar- 25% Co 2
LCW1-1PE
1 × 4
26
275
280
98% Ar- 2% Co 2
LCW1-2PE
1 × 4
26
275
280
98% Ar- 2% Co 2
The weld overlay samples were ground flat after welding. Ten hardness indentations were taken at random locations on the surface of the welds. The average hardness is shown in Table 4. As can be seen the hardness for the samples has a range of about 69 to 71 Rc.
Dry wheel sanding abrasion studies were performed according to Procedure A of ASTM G-65 on the surface of the ground samples in two passes of 6,000 cycles each. The results of these tests are provided in Table 4. As shown, the weld overlays exhibited a wear resistance with mass loss from 0.049 to 0.131 grams (corresponding volume loss from 6.73 to 19.9 mm 3 ).
TABLE 4
Hardness/Wear Results on LCW1 Weld Overlay Samples
Mass Loss
Volume Loss
Sample
Hardness
1 st Pass
2 nd Pass
1 st Pass
2 nd Pass
Number
(Rc)
6,000
6,000
6,000
6,000
LCW1-1PA
69.2
0.1310
0.1265
17.94
17.28
LCW1-2PA
70.0
0.0898
0.0810
12.28
11.08
LCW1-1PB
70.1
0.1058
0.0950
14.47
12.99
LCW1-2PB
70.6
0.0828
0.0787
11.33
10.76
LCW1-1PC
70.5
0.1161
0.1096
15.92
14.99
LCW1-2PC
69.5
0.0969
0.0945
13.27
12.94
LCW1-1PD
70.2
0.1154
0.1086
15.80
14.84
LCW1-2PD
70.7
0.0623
0.0513
8.52
7.02
LCW1-1PE
70.5
0.0922
0.0856
12.61
11.71
LCW1-2PE
70.9
0.0598
0.0492
8.18
6.73
LCW1-2PE
70.9
0.0906
0.0841
12.43
11.54
Scanning electron microscope (SEM) studies were performed on LCW1 GMAW samples welded under parameter D of Table 3. Representative sample SEM pictures, taken with backscattered electron micrographs are given in FIGS. 1 through 4 . The SEM studies illustrate that the weld structure exhibits a relatively refined uniform microstructure throughout the cross-section. The matrix phase consisting of iron rich ductile phases, having a gray color in the SEM micrographs, were from about 1 to 2 microns in size. The chrome rich borocarbide phases, having a black color in the micrographs, were from about 5 to 25 microns in size. The niobium rich borocarbide phases exhibiting a cubic/hexagonal structure, having a white color in the micrographs, were found to range from about 0.5 to 1.0 microns in size. The iron rich phase was estimated to be approximately 60 to 65% of the alloy by volume, the chrome rich phase was estimated to be approximately 30 to 35% of the alloy by volume and the white phase was estimated to be approximately 4 to 5% of the alloy by volume.
The weld overlay samples described above, were then tested using drop impact testing from a drop tower impacting onto a 0.75 inch toll steel anvil punch. Random samples were tested by hitting on the same spot for five impacts at 160 ft-lbs. No cracking or spallation was observed on the impacted welds, which may verify that the weld overlay sample alloys are relatively tough.
Vickers hardness indentations were made in the cross-section of a metallographically mounted and polished section of the sample welds. In a few cases, cracks were found to originate from the corners of the hardness indentions when the hardness indention hit a hard (black) borocarbide phase. See FIG. 5 . The cracks propagated a few microns and/or until hitting the grey ductile phases of the matrix and the was immediately stopped. FIG. 5 a illustrates crack “A” which is shown to propagate about 1 micron through the alloy and in particular in the chrome rich borocarbide phase. FIG. 5 b illustrates crack “A,” which is shown to propagate through the chrome rich borocarbide phase and end at the iron rich phase. Crack “B” is shown to propagate a few microns into the chrome rich borocarbide phase and terminate.
A wire of Alloy LCW 1 welded via GMAW onto an A36 steel substrate using the process parameter D of Table 3. The welded sample was cut to reveal the cross-section and was metallographically mounted and polished. A Vickers microhardness traverse at a 100 g load was done with approximately 0.005 inch spacing starting in the base metal A36 and then up through the weld to the top of the sample. The results of the microhardness testing are shown in Table 5. It is noted that hardness points 1 through 3 , were performed in the base substrate, the A36 steel, and that the remaining hardness points 4 to 25 were performed in the weld overlay alloy.
TABLE 5
Vickers Microhardness (HV100) Across Weld Overlay Sample
Hardness Point No.
Hardness
(0.005 inch spacing)
(kg/mm 2 )
1
165
2
165
3
178
4
1103
5
1194
6
1090
7
1140
8
1196
9
1280
10
1060
11
1136
12
1022
13
1059
14
1094
15
1274
16
1066
17
1086
18
1037
19
1291
20
1099
21
1094
22
1080
23
1034
24
1269
25
1105
FIG. 6 is an SEM micrograph of the substrate and weld overlay illustrating the Vickers Microhardness measurements at points 3 through 9 . FIGS. 7 a and b illustrate the Vickers Microhardness measurements at points 3 and 4 . FIG. 7 a is a backscattered scanning electron microscope image, whereas FIG. 7 b is a secondary electron micrograph image. FIG. 9 is backscattered scanning electron microscope image illustrating the distance between the substrate and hardness point 4 , which is illustrated to be 57.9 μm at measurement “A.” The boundary layer between the substrate and the weld overlay appears to be less than 10 μm at measurements “B” and “C” respectively.
In addition, the LCW 1 allow was die cast into a plate having the dimensions of 4 inches by 5 inches by 0.5 inches using a copper die. The LCW1 plate was found to be crack free and is illustrated FIG. 9 . The sides of the plate were ground to yield a plate that was 10 mm in thickness. Hardness indentations were taken across the cross-section of the plate in both horizontal and vertical directions. The 19 hardness indentations are shown in Table 6 and indicate that the cast plate exhibits a hardness in the range of about 69.7 Rc to about 70.8 Rc. From the cast plate, a 1 inch by 4 inch sample was cut out and then the surface was ground. To measure the abrasion resistance, ASTM G-65 dry wheel sand abrasion studies were done according to Procedure A and the results are given in Table 7. As shown in the table, the mass loss was found to be about 0.116 to 0.122 grams.
TABLE 6
Hardness Results LCW1 Plate
Hardness Point
Hardness (Rc)
1
70.3
2
70.2
3
70.1
4
69.8
5
69.5
6
70.1
7
70.0
8
69.9
9
70.2
10
70.3
11
70.4
12
70.8
13
70.4
14
70.8
15
70.2
16
69.9
17
70.0
18
70.1
19
69.7
TABLE 7
Wear Results on LCW1 Plate
Mass Loss (g)
Volume Loss (mm 3 )
Test Number
1 st 6,000 cycles
1 st 6,000 cycles
1
0.116
15.87
2
0.122
16.69
The foregoing description has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed, and obviously many modifications and variations are possible in light of the above teaching.
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The present invention relates to the addition of niobium to iron based glass forming alloys. More particularly, the present invention is related to changing the nature of crystallization resulting in glass formation that may remain stable at much higher temperatures, increasing the glass forming ability and increasing devitrified hardness of the nanocomposite structure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to a method and apparatus for monitoring receivers, and more particularly to methods and apparatus for determining the particular transmitting station from which program signals are received and translated by a monitored receiver and including automobile and portable receivers.
2. Description of the Prior Art
Various arrangements have been employed to determine the channel to which a radio and/or television receiver is tuned. Examples of receiver monitoring methods and apparatus for monitoring receivers are provided by U.S. Pat. Nos. 2,833,859; 3,973,206; 4,048,562, 4,425,578; 4,723,302; 4,764,808; 4,876,736; 4,930,011; 4,943,963; and 4,972,503. While these systems provide improvements over other known arrangements, a need exists for an economically effective system having flexibility to accommodate monitoring a large number of receivers including mobile receivers in a prompt and efficient manner.
SUMMARY OF THE INVENTION
Important objects of the present invention are to provide a method and apparatus for monitoring receivers that overcome many of the disadvantages of the prior art systems; to provide such method and apparatus for monitoring receivers that can be effectively and efficiently configured for monitoring mobile receivers; to provide a method and apparatus for determining a particular transmitting station from which program signals are received and translated by a monitored receiver within a test area that automates the identification of new transmitting stations.
In brief, the objects and advantages of the present invention are achieved by a method and apparatus for determining a particular transmitting station from which program signals are received and translated by a monitored receiver within a test area. A transmitter characteristic table is stored in the receiver monitor apparatus. The transmitter characteristic table includes a corresponding transmitting station identification stored with a predefined subarea of a plurality of predefined subareas within the test area for each predetermined tuned frequency of the monitored receiver. A tuned frequency of the monitored receiver is identified and the particular transmitting station corresponding to the identified tuned frequency is identified responsive to both the identified tuned frequency of the monitored receiver and the stored transmitter characteristic table. The identified transmitting station data is stored with time of occurrence data.
BRIEF DESCRIPTION OF THE DRAWING
The present invention together with the above and other objects and advantages may best be understood from the following detailed description of the embodiment of the invention illustrated in the drawings, wherein:
FIG. 1 is a block diagram of a receiver monitoring system according to the present invention;
FIG. 2 is a transmitter characteristic table illustrating transmitting stations with a corresponding transmitting frequency by predefined subareas of a geographical test area of the receiver monitoring system of FIG. 1 to perform the method of the present invention;
FIG. 3 is a block diagram illustrating a receiver monitoring apparatus of the receiver monitoring system of FIG. 1;
FIGS. 4-5 are flow charts illustrating logical steps performed by the receiver monitoring apparatus of the receiver monitoring system of FIG. 1 in accordance with methods of the present invention; and
FIG. 6 is a flow chart illustrating logical steps performed by either a central computer or the receiver monitoring apparatus in generating the transmitter characteristic table of the receiver monitoring system of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, with particular attention to FIG. 1, there is illustrated a block diagram of a new and improved receiver monitoring system according to the invention generally designated by the reference numeral 10. While the receiver monitoring system 10 is depicted and generally described herein for monitoring a mobile radio receiver, the principles of the present invention are also applicable to monitoring television receivers, video cassette recorders and other receivers and television viewing and listening habits of individual audience members or panelists of cooperating households.
Receiver monitoring system 10 includes a plurality of receiver monitors 1-N generally designated by the reference character 12 coupled to a central computer 14 via communications links generally designated by the reference character 16. Each receiver monitor 12 monitors and stores selected, monitored receiver data, for example, such as tuned transmitting station and frequency data, tune-in and tune-out events together with time of occurrence data and identified new transmitters or broadcasting stations within a geographical or test area of the receiver monitor system 10. Receiver monitor 12 does not require access to any electrical signal that is only available internally to a monitored receiver 18. Central computer 14 collects and processes the monitored data from the receiver monitors 12 to provide market research analysis and reports. Central computer 14 utilizes the collected data to update and maintain transmitter characteristic data including additional identified broadcasting stations. Central computer 14 periodically resets the real time clocks of the receiver monitor 12 to facilitate accurately time stamping of the monitored receiver data.
FIG. 1 illustrates a plurality of broadcasting stations or transmitters T1-T8 in the test area of the receiver monitor system 10. An associated transmitting frequency is shown with each of the transmitters T1-T8. As shown, transmitter T1 has a transmitting frequency f1, transmitter T2 has a transmitting frequency f2, transmitter T3 has a transmitting frequency f3, transmitter T4 has a transmitting frequency f4, transmitter T5 has a transmitting frequency f5, transmitter T6 has a transmitting frequency f6, transmitter T7 has the transmitting frequency f3 and transmitter T8 has a transmitting frequency f7.
By dividing the test area into cells or subareas based upon transmitter signal strengths, broadcasting stations or transmitters having the same transmitting frequency, such as frequency f3 for both transmitters T3 and T7, can be distinguished and uniquely identified.
FIG. 2 is a transmitter characteristic table illustrating a cluster list of the transmitter stations T1-T8 by a plurality of predefined subareas S1-S4 within the test area of the receiver monitor system 10. Referring to FIGS. 1 and 2, geographic subareas S1-S4 are determined by a unique set of the transmitters T1-T8 that can be received within acceptable signal-to-noise ratios. For example, a receiver monitor 12 located within the subarea S1 can receive acceptable transmitted frequency signals f4, f5 from transmitter stations T4 and T5, while other transmitted frequency signals f3, f2, f6, f7 and f3 from transmitter stations T3, T2, T6, T8 and T7 have a signal-to-noise ratio below a predetermined threshold value. Similarly, a receiver monitor 12 located within the subarea S2 can receive acceptable transmitted frequency signals f2, f3 and f5 from transmitter stations T2, T3 and T5. Using such predefined subareas S1-S4, a receiver monitor 12 having identified a tuned frequency f3 of its monitored receiver, determines its subarea location by tuning another frequency signal within the subareas S2, S3 or S4, for example, by tuning transmitted frequency signal f4 and comparing the detected signal-to-noise ratio to a threshold value. When the detected signal-to-noise ratio is greater than the threshold value, then subarea S3 is identified. Otherwise, another frequency signal within either subarea S2 or S4 is tuned to identify one of the subareas S2 or S4 as the current location. When subarea S3 is identified, then the associated transmitter station is T7.
Referring to FIG. 3, there is shown a block diagram representation of the receiver monitor 12 together with a monitored receiver 18 that is coupled to a receiving antenna 20. Among its primary components, receiver monitor 12 includes a frequency synthesized receiver 22 having the same frequency bands (AM and FM) of the monitored receiver 18; a microprocessor 24 for controlling the frequency synthesized receiver 22 and identifying a tuned transmitter; a correlator 26 computes a crosscorrelation of output signals of the monitored receiver 18 and the frequency synthesized receiver 22 under the control of the microprocessor 24; and a nonvolatile random access memory (RAM)/clock cartridge 28 for providing memory for storage of the transmitter characteristic table and monitored data and including a real time clock for providing time of occurrence or a time stamp of any change in channel or other desired monitored parameter. Frequency synthesized receiver 22 is connected to the receiving antenna 20 so that the same radio frequency (RF) signals are received by the receiver monitor 12 as the monitored receiver 18. Microprocessor 24 controls the frequency synthesized receiver frequency scan until a transmitting station is tuned.
An audio output signal of the monitored receiver 18 can be applied to the correlator 26 via either a direct connection or a microphone pick-up as indicated at a line labelled MONITORED RECEIVER SIGNAL. Frequency synthesized receiver 22 generates a standard audio output that is applied to the correlator 26. When the frequency synthesized receiver 22 and the monitored receiver 18 are tuned to the same frequency, the audio output signals applied to the correlator 26 are similar. A crosscorrelation output signal of the correlator 26 is applied to the microprocessor 24. Microprocessor 24 threshold compares the crosscorrelation output signal to determine whether or not the frequency synthesized receiver 22 and the monitored receiver 18 are tuned to the same frequency.
RAM/clock cartridge 28 includes a battery and advantageously functions as the communications link 16 for bidirectional communications with the central computer 14. The real time clock contained in the RAM/CLOCK cartridge 28 is periodically reset by the central computer 14 and the transmitter characteristic table is updated by the central computer 14 to include new broadcasting stations. A local oscillator detection circuit 30 receives a RF signal emitted by the monitored receiver 18 via a non-invasive, inductive probe 32. A detected local oscillator signal of the circuit 30 is applied to the microprocessor 24 to determine the tuned frequency of the monitored receiver 18.
It should be understood that various conventional arrangements can be used for the communication links 16, for example, such as, via telephone lines connected to the public switched telephone network or via mailable memory devices. Various commercially available microprocessor devices having standard capabilities can be used for the central computer 14, for example, such as a 80286 microprocessor manufactured and sold by Intel Corporation of Santa Clara, Calif.
FIGS. 4-5 are flow charts illustrating logical steps performed by the microprocessor 24 in the operation of the receiver monitoring system 10. In FIG. 4, the sequential operations begin as indicated at a block 400. Microprocessor 24 monitors the receiver status as indicated at blocks 402 and 404. When the receiver is turned on, the scanning process begins with scanning first the most often tuned frequencies, or the last tuned frequency as indicated at a block 406. The presence of the local oscillator signal is identified as indicated at a block 408. When the absence of the local oscillator signal is identified at block 408, then an alternate signal source, such as a cassette use is stored as indicated at a block 410. Otherwise when the local oscillator signal is identified at block 408, the tuned frequency is identified as indicated at a block 412. A crosscorrelation match is determined as indicated at a block 414. A lack of crosscorrelation or no match indicates an alternate signal source, such as a cassette use is stored at block 410. A monitored mobile receiver 18 is identified at a decision block 416.
Referring to FIG. 5, when a monitored mobile receiver is identified at block 416 of FIG. 4, then the sequential operations continue following entry point A by comparing the identified tuned frequency with the transmitter characteristic table as indicated at a block 500. When a tie or more than one corresponding transmitting station is identified as indicated at a decision block 502, then a scan loop is performed to determine the particular subarea location of the monitored receiver 18 as indicated at a block 504. The particular subarea is identified as indicated at a block 506 and then the particular corresponding transmitter is identified as indicated at a block 508. For a fixed monitored receiver identified at block 416 of FIG. 4, then the sequential operations continue following entry point B, to identify the particular corresponding transmitter at block 508. When a corresponding transmitter is not identified at block 508, a new transmitted frequency is indicated at a decision block 510 such as transmitter T8, shown in dotted line in FIG. 1. The new transmitted frequency is stored with the monitored data in RAM/clock cartridge 28 as indicated at block 512. The identified particular corresponding transmitter data is stored as indicated at a block 514. A status change of the monitored receiver is determined as indicated at a decision block 516 and monitoring of the identified tuned frequency continues as indicated at a block 518 until a status change is identified. Then the change data is time-stamped and stored as indicated at block 520 and the sequential operations return as indicated at block 522 and the monitoring sequence is repeated.
Referring to FIG. 6, sequential steps performed by the microprocessor 24 or the central computer 14 for defining and storing the transmitter characteristic table are illustrated. The sequential operations begin as indicated at a block 600. A first subarea S(n) S1 is identified as indicated at a block 602 and n is set to 1 as indicated at a block 604. A scan loop for the subarea S1 is performed by the microprocessor 24 located within the subarea S1 or identified from predetermined broadcast map data by the central computer 14 as indicated by a block 606. Each transmitting frequency is identified as indicated at a block 608 and the signal-to-noise signal is threshold compared as indicated at a block 610. When the detected or calculated signal-to-noise signal is greater than an acceptable threshold value T, then the transmitting frequency and transmitter station identification is stored for the subarea S1 as indicated at block 612. Otherwise, when the detected or calculated signal-to-noise signal is less than the acceptable threshold value T or after storing the subarea transmitter data at block 612, then next higher frequencies are sequentially tuned as indicated at block 616 and the sequential steps are repeated until the upper limit of the frequency band is identified at a decision 614. Then n is incremented as indicated at a block 618 and the sequential steps are repeated for a next subarea within the test area.
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A method and apparatus are provided for determining a particular transmitting station from which program signals are received and translated by a monitored receiver within a test area and including mobile receivers. A stored transmitter characteristic table includes a corresponding transmitting station identification stored with a predefined subarea of a plurality of predefined subareas within the test area for each predetermined tuned frequency of the monitored receiver. A tuned frequency of the monitored receiver is identified and the particular transmitting station corresponding to the identified tuned frequency is identified responsive to both the identified tuned frequency of the monitored receiver and the stored transmitter characteristic table. The identified transmitting station data is stored with time of occurrence data.
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This invention relates to automatic phase control (APC) circuitry which uses a controllable phase shifter to align the phase of an oscillator signal to that of a reference signal.
U.S. Pat. No. 3,911,368 entitled "Phase Interpolating Apparatus and Method", which is hereby incorporated by reference, relates to circuitry for aligning the transitions of a clock signal to those of a reference signal. In this system, a multiplicity of flip-flops and gating circuits are used to select the phase of a multi-phase clock signal which is closest to having a transition coincident with a transition in the reference signal.
The system described in the above-referenced patent is shown, in simplified form, in FIG. 1. A source of oscillatory signal 10 provides an oscillatory signal OSC which is applied to a chain of three delay elements, 14, 16 and 18. Each of these delay elements provides a time delay substantially equal to one-quarter of the period of the oscillatory signal OSC. Thus, the signal OSC and the output signals of the delay elements 14, 16 and 18 represent four different, equally spaced phases of the signal OSC. The signal OSC is applied to the input terminal, D, of a data-type flip-flop 22 and the output signals of the delay elements 14, 16 and 18 are applied to the D input terminals of the respective flip-flops 24, 26 and 28. A source of reference signal 12 provides a signal REF to the clock input terminal, CK, of each of the flip-flops 22, 24, 26 and 28.
In this configuration the flip-flops 22, 24, 26 and 28 effectively take a "snapshot" of the waveform of the signal OSC at the time that the flip-flops are clocked by the signal REF. In other words, the states of the various flip-flops 22, 24, 26 and 28 represent one period of the signal OSC sampled at time intervals determined by the delay elements 14, 16 and 18. The standard output signal, Q, and the complemented output signal, Q, of the flip-flops 22, 24, 26 and 28 are applied to respective first and second input terminals of NOR gates 40, 42, 44 and 46. These NOR gates pass one of the phases of the signal OSC, which are applied to the respective third input terminals of the NOR gates, to the OR gate 60, the output signal of which is the final output oscillatory signal OSC F .
As selected by this circuitry, the signal OSC F has a positive going transition which occurs approximately coincident with a positive-going transition of the signal REF. To understand how the circuitry aligns these signals, consider the following example. Assume that, when the flip-flops 22, 24, 26 and 28 are clocked by a positive-going transition of the signal REF, their respective states are 0, 0, 1 and 1. This set of states indicates that a negative-going transition of the signal OSC leads the positive-going transition of the signal REF by between one-quarter and one-half of a period of the signal OSC.
As set forth above, The three input terminals of the NOR gate 40 are connected to the output terminal, Q, of the flip-flop 22; the inverted output terminal, Q, of the flip-flop 24; and the output terminal of the source of oscillatory signal 10. The corresponding input terminals of the NOR gate 42 are similarly connected to the Q output terminal of the flip-flop 24, the Q output terminal of the flip-flop 26 and the output terminal of the delay element 14, respectively. The three input terminals of the NOR gate 44 are connected to the Q output terminal of the flip-flop 26, the Q output terminal of the flip flop 28 and the output terminal of the delay element 16, respectively. The NOR gate 46 is coupled so that its three input terminals are connected to the Q output terminal of the flip-flop 28, the Q output terminal of the flip-flop 22 and the output terminal of the delay element 18.
In the example set forth above, the Q output terminals of the flip-flops 22, 24, 26 and 28 provide output values of 0, 0, 1 and 1, respectively. The Q output terminals of these flip-flops provide respective output values of 1, 1, 0 and 0. Consequently, the NOR gates 40, 44 and 46 always provide logic 0 output values and the NOR gate 42 provides an output signal that is the logical inverse of the signal provided by the delay element 14. The output signals provided by the NOR gates 40, 42, 44 and 46 are applied to respectively different input terminals of the OR gate 60. In the example set forth above, the output signal of the OR gate 60 is the same as the output signal of the NOR gate 42. This signal has a positive-going transition which is approximately coincident with the positive-going transition of the signal REF. The phase of the signal OSC that is selected and then inverted by the circuits shown in FIG. 1 may change with each positive-going edge of the signal REF. However, the final selected and inverted phase will have at least one transition that is synchronized to a transition in the signal REF.
One application of the phase alignment circuitry shown in FIG. 1, is in a consumer digital television receiver which uses a sampling clock signal that is locked in phase to the horizontal line synchronizing signal component of the received video signals (i.e. a line-locked clock signal). Although the clock signal is locked in phase to the line synchronizing signal, there may be significant timing errors in the occurrence of the first pulse of the sampling clock following the occurrence of a pulse of the horizontal line synchronizing signal. These timing errors may distort the image reproduced from samples taken using this sampling clock signal. This distortion causes vertical or diagonal edges in the image to appear wavy or jagged.
The system shown in FIG. 1 could be expanded by adding delay elements and decoding stages to provide a clock signal that corrects this type of distortion. An exemplary system for use in an NTSC receiver, would have 63 serially connected delay elements, providing 63 equally timed clock phases. The time delay through all of the delay elements would be substantially equal to one period of the signal OSC. Each of the 63 delay elements would be connected to a respectively different decoding stage, including a flip-flop and a NOR gate. An expanded system of this type would produce a line-locked signal having a frequency of 910 times the frequency, f h , of the horizontal line synchronizing signal, with an accuracy of ±1 nanosecond (ns) relative to the horizontal synchronizing signal.
This system is not without problems, however. To reduce the cost of the system it would be desirable for the phase alignment circuitry to be implemented as a single integrated circuit. When the delay elements used by this system are buffer gates, implemented using standard processing techniques, the amount of time delay provided each one may vary by as much as -50% and +100% of the nominal value. Thus, if these delay elements were implemented to provide a nominal time delay value such that the sum of all of the nominal delay values equaled the period of the clock signal, the actual total delay provided may be as little as one-half of the clock period or as much as two clock periods. In the first instance, the phase alignment circuitry may not produce an output clock signal. This would occur when the values stored in the flip-flops do not include a transition of the line locked clock signal. In the second instance, signals provided by two or more of these delay elements may be selected and inverted. Due to timing differences between these two phases, their combination in the OR gate may introduce undesirable high frequency signal components in the output clock signal and may change the duty cycle of the clock signal.
It would be desirable if integrable phase alignment circuitry could be designed which does not have the problems set forth above.
SUMMARY OF THE INVENTION
The present invention is embodied in circuitry for aligning an oscillatory signal into a predetermined phase relationship with a reference signal. The circuitry includes a delay line which provides M signals representing M successively delayed phases of the oscillatory signal. The delay line provides at least one phase signal that is delayed by more than one period of the oscillatory signal relative to the undelayed oscillatory signal. The phase alignment circuitry further includes gating circuitry, coupled to the M output terminals of the delay line, for selecting one of the M signals provided by the delay line. This selected signal has a predetermined phase relationship with the reference signal and has a time delay with respect to the undelayed oscillatory signal that is less than one period of the oscillatory signal. The system further includes circuitry which inhibits the selection of ones of said M signals having greater time delays than that of the selected signal. The selected signal is the output signal of the phase alignment circuitry.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1, described above, is a block diagram showing exemplary phase alignment circuitry of the prior art.
FIG. 2 is a block diagram showing signal phase alignment circuitry which embodies the present invention.
DETAILED DESCRIPTION
The embodiment of the invention shown in FIG. 2 is in the context of a television signal processing system. This circuitry, is generally similar to the prior art circuitry described in reference to FIG. 1, but has significant structural differences which overcome the shortcomings of that prior art circuit. The circuitry shown in FIG. 2 is used to align a line-locked clock signal, CLK, with a horizontal drive signal, HDRIVE. This circuitry consists of five stages including four delay elements. If this circuitry were used in an NTSC television receiver having a clock frequency of 910 times the frequency, f H , of the horizontal line synchronizing signal, the clock signal, CLK', produced by the phase alignment circuitry would be synchronized to the horizontal drive signal with an accuracy of 1/(3×910 f H ) or 23 ns. In an actual system, accuracies of approximately 1 ns may be desirable. Signal phase alignment circuitry which achieves a ±1 ns accuracy would include at least 64 stages having 63 delay elements in the delay line. The smaller number of stages and delay elements were selected in the present embodiment to simplify the explanation of the invention. However, one skilled in the art will appreciate how to construct the 64 stage version after reading this application.
In FIG. 2, a source of line locked clock signal, 210 provides the signal CLK to a delay element 214, the first delay element in a chain of delay elements 214, 216, 218 and 220. The source 210 used in this embodiment of the invention includes a phase locked loop (PLL) circuit which produces the signal CLK having a frequency substantially equal to 910 f H and locked in phase to the horizontal line synchronizing signal component of an input composite video signal. The delay elements 214, 216, 218 and 220 used in this embodiment of the invention are conventional buffer gates. The amount of time delay provided by each of the buffer gates is the signal propagation delay through the gate circuitry.
Each of the delay elements 214, 216, 218 and 220 delays the signal applied to its input terminal by an amount of time nominally equal to one-third of a period of the signal CLK. Since these delay elements are realized as a portion of an integrated circuit, however, the amount of time delay provided by each of these delay elements 214, 216, 218 and 220 may vary by as much as -50% to +100%. Consequently, the total time delay provided by the four delay elements 214, 216, 218 and 220 may be between two-thirds of a period, and two and two thirds periods of the signal CLK.
The signal CLK provided by the source 210 is applied to the data input terminal, D, of a conventional data-type flip-flop 222. The output signals of the delay elements 214, 216, 218 and 220 are similarly applied to the D input terminals of respective data type flip-flops 224, 226, 228 and 230. Each of the flip-flops 222, 224, 226, 228 and 230 is clocked by the signal HDRIVE provided by a source of horizontal drive signal 212.
In this embodiment of the invention, the source 212 includes a PLL which produces the signal HDRIVE that is locked in phase to the horizontal line synchronizing signal component of the input composite video signal and has a frequency substantially equal to f H .
Coincident with a positive-going transition of the signal HDRIVE, each of the flip-flops 222, 224, 226, 228 and 230 loads the value of the signal applied to its D input terminal as its internal state. The flip-flops 222, 224, 226, 228 and 230 provide these state values at their respective Q output terminals and logically complemented versions of the state values at their respective Q output terminals.
The Q and Q output terminals of the flip-flops 222-230 are coupled to logic circuitry which, based on the state values stored in the flip-flops, passes either the clock signal CLK, provided by the source 210, or one of the phase shifted clock signals provided by the delay elements 214, 216, 218 or 220, as the phase aligned output clock signal CLK'.
To understand the operation of this circuitry, it is helpful to consider the flip-flops and logic gates to be configured as a chain of five interconnected stages. The state values held in respective flip-flops 222, 224, 226, 228 and 230 represent samples of respective phases of the signal CLK having successively greater delays. In addition, the state value held by the flip-flop 222 is used by the circuitry as a sample of a phase of the signal CLK that is delayed relative to the phase which produced the sample held in the flip-flop 230. As set forth above, all of these samples are taken coincident with a positive-going transition of the signal HDRIVE. The individual stages of the gating circuits compare the samples of successive clock signal phases to determine which of the clock signal phases has a positive-going transition that is approximately coincident with the positive-going transition of the signal HDRIVE.
For example, if the state of the flip-flops 222 and 224 are logic 1 and logic 0, respectively, the phase of the signal CLK, which has a positive going transition coincident with that of the signal HDRIVE is advanced in time with respect to the signal provided by the delay element 214, and delayed in time with respect to the signal CLK provided by the source 210. The Q output terminal of the flip-flop 222 and the Q output terminal of the flip-flop 224 are coupled to respectively different input terminals of an AND gate 242. The AND gate 242 is conditioned by these input signals to apply a logic 1 value to one input terminal of an AND gate 252, enabling the AND gate 252 to pass the phase of the signal CLK that is provided by the delay element 214 to the OR gate 260.
The AND gates 244 and 254 are similarly configured to pass the clock phase signal provided by the delay element 216 to the OR gate 260, when the state of the flip-flops 224 and 226 are logic 1 and logic 0, respectively. AND gates 246 and 256 pass the signal provided by the delay element 218 when the states of the flip-flops 226 and 228 are, respectively, logic 1 and logic 0, and the AND gates 248 and 258 pass the signal provided by the delay element 220 when the respective states of the flip-flops 228 and 230 are logic 1 and logic 0. The input terminals of an AND gate 240 are coupled to the Q output terminal of the flip-flop 230 and to the Q output terminal of the flip-flop 222. The AND gate 240 conditions an AND gate 250 to pass the signal CLK, provided by the source 210, to the OR gate 260 when the states of the flip-flops 230 and 222 are logic 1 and logic 0, respectively.
The AND gates 240 and 250 ensure that the phase alignment circuitry will produce an oscillatory output signal as long as the total time delay provided by the delay elements 214, 216, 218 and 220 is greater than one-half of one period of the signal CLK. When, for example, the states of the flip-flops 222-230 span a time interval that includes a negative-going transition of a phase of the signal CLK but does not include a positive-going transition, the signal CLK' provided by the OR gate 260 will be the signal CLK. Without the AND gates 240 and 250, the circuitry shown in FIG. 2 would produce a logic 0 as the output signal CLK' in the example described above.
The description of the circuits shown in FIG. 2 has, so far, ignored the effect of the OR gates 245, 247 and 249 and of the inverters 232, 234, 236 and 238. These circuit elements are included in the phase alignment circuitry to ensure that only one clock phase signal is passed to the OR gate 260 when the total time delay represented by the delay elements 214, 216, 218 and 220 is greater than one period of the signal CLK. These circuit elements act to inhibit the gating of the delayed phases of the clock signal having time delays greater than that of a selected signal. As set forth above, applying more than one clock phase signal to the OR gate 260 may introduce undesirable high frequency signal components into, and may change the duty cycle of, the phase synchronized clock signal CLK'.
This inhibiting circuitry is included in the phase alignment circuitry as described below. The output terminal of the AND gate 242 is connected to the input terminal of an inverter 234 and to one input terminal of an OR gate 245. When the AND gate 242 provides a logic 1 output value to the AND gate 252, the inverter 234 applies a logic 0 value to one input terminal of the AND gate 244, ensuring that the AND gate 244 may not enable the AND gate 254 to apply the signal provided by the delay element 216 to the OR gate 260. The OR gate 245 is further coupled to receive an input signal from the output terminal of the AND gate 244. The output terminal of the OR gate 245 is connected through the inverter 236, to one input terminal of the OR gate 247. When either the AND gate 242 or the AND gate 244 has a logic 1 output value, the inverter 236 is conditioned to apply a logic 0 value to one input terminal of the AND gate 246, preventing the AND gate 246 from applying a logic 1 value to the AND gate 256. The other input terminal of the OR gate 247 is connected to the output terminal of the AND gate 246. The output terminal of the OR gate 247 is connected to the inverter 238 which disables the AND gate 248 when any of the AND gates 242, 244 or 246 has a logic 1 output value. The output signal provided by the OR gate 247 is logically ORed with the output signal of the AND gate 248 by the OR gate 249. The output signal provided by the OR gate 249 is inverted by the inverter 232 and applied to one input terminal of the AND gate 240. The signal provided by the inverter 232 disables the AND gate 240 when any of the AND gates 242, 244, 246 or 248 provides a logic 1 output signal.
Thus, the circuitry shown in FIG. 2 uses only one phase of the signal CLK to produce the clock signal CLK'. The signal CLK is provided by this circuitry as the signal CLK' only when the total delay provided by the chain of delay elements 214-220 is less than one period of the signal CLK and does not include a positive-going transition.
It is contemplated that the inverter 234 may be eliminated and that the OR gate 249 may be changed to a NOR gate, eliminating the inverter 232, without affecting the performance of the circuitry shown in FIG. 2. Although the sources 210 and 212 are shown as being separate in the embodiment of the invention shown in FIG. 2, it is contemplated that they may be combined to provide the signals HDRIVE and CLK from a single line-locked PLL.
The circuitry shown in FIG. 2 is described in the context of a digital television receiver having a line locked clock signal, however, it is contemplated that this circuitry may be used in other applications in which a substantially stable oscillatory signal (CLK) is to be synchronized to reference signal (HDRIVE). In addition, it is contemplated that the circuitry may be expanded to include more delay elements and more stages of gating circuits by replicating, for example, the delay element 218, flip flop 228, AND gates 246 and 256, inverter 236 and OR gate 247, the desired number of times.
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Circuitry for aligning the transition of a clock signal to transitions of a horizontal line synchronizing signal includes a series of delay elements which provide a plurality of clock signal phases. The longest phase delay provided by this circuitry is greater than the period of the clock signal. The clock signal and the delayed clock signal phases are applied to circuitry which selects one clock signal phase, which has a transition occurring within a predetermined time interval of the transition in the horizontal line synchronizing signal. Other circuitry, coupled to this selection circuitry, inhibits the selection of any clock phase having a greater time delay than the selected phase. This prevents the selection of multiple clock phase signals.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 13/128,803 filed May 11, 2011, which is a National Stage Application of PCT/JP2009/070383 filed Dec. 4, 2009, which claims priority from Japanese Application No. 2008-310716 filed on Dec. 5, 2008. The entire disclosures of the prior applications are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates to a therapeutic and/or prophylactic agent for neurodegenerative diseases, diseases induced by neurological dysfunction, or diseases induced by deterioration of mitochondrial function, the agent comprising a quinolone compound or a salt thereof as an active ingredient.
BACKGROUND ART
[0003] Parkinson's disease is a chronic, progressive neurodegenerative disease that generally develops after middle age. Initial symptoms include unilateral resting tremor, akinesia and rigidity. The tremors, akinesia, and rigidity are called the three major signs of Parkinson's disease, and each of them is caused by the selective death of dopaminergic neurons projected from the substantia nigra to the striatum. The etiology of the disease is still unknown; however, accumulated evidence suggests that an impaired energy-generating system accompanied by abnormal mitochondrial function of nigrostriatal dopaminergic neurons triggers the neurodegenerative disorder of the disease. The mitochondrial dysfunction has been assumed to subsequently cause oxidative stress and failure of calcium homeostasis, thereby resulting in neurodegeneration (NPL 1).
[0004] Treatments of Parkinson's disease are roughly classified into medical management (medication) and surgical management (stereotaxic operation). Of these, medication is an established therapy and regarded as a basic treatment. In the medication, a symptomatic therapeutic agent is used to compensate for the nigrostriatal dopaminergic neuronal function denatured by Parkinson's disease. L-dopa exhibits the most remarkable therapeutic effects. It is said that no agent exceeds the effectiveness of L-dopa. Currently, L-dopa is used together with a dopa decarboxylase inhibitor to prevent the metabolism thereof in the periphery, and the desired clinical effects have been obtained.
[0005] However, L-dopa treatment has drawbacks in that, after several years of usage, there is a recurrence of movement disorders such as dyskinesia, and the sustainability and stability of the drug's effects are lost, resulting in fluctuations within each day. Moreover, side effects including digestive problems such as nausea and vomiting brought on by excessive release of dopamine, circulatory organ problems such as orthostatic hypotension, tachycardia and arrhythmia, and neurological manifestations such as hallucination, delusion and distraction have been a cause for concern.
[0006] Thus, in order to decrease the L-dopa preparation dosage and thereby reduce the side effects, multidrug therapies, in which dopamine receptor agonists, dopamine metabolism enzyme inhibitors, dopamine releasers, central anticholinergic agents and the like are used in combination, are employed. While such therapeutic advances remarkably improve prognoses, there is still no fundamental cure for Parkinson's disease and other neurodegenerative diseases. Medication must be taken for the rest of the patient's life, and the aforementioned drawbacks, i.e., decreased efficacy during long-term administration, side effects, and uncontrollable disease progression, can result from L-dopa monotherapy. In addition, it is difficult to expect dramatic effects, even with the employment of multidrug therapies.
[0007] Alzheimer's disease is a progressive neurodegenerative disease that affects various cognitive functions, primarily causing impairment of memory. Pathologically, Alzheimer's disease is characterized by the degeneration of synapses or neurons in the hippocampus and cerebral cortex, and the accumulation of two types of abnormal fibrils, i.e., senile plaques and changes in neurofibrils. Although the disease etiology is not completely understood, amyloid β protein (Aβ), which is derived from amyloid precursor protein (APP) by various mechanisms, is known to play an important role. Currently, cholinesterase inhibitors (tacrine, Aricept, rivastigmine, and galantamine) are used in the treatment of Alzheimer's disease for ameliorating symptoms, because acetylcholinergic nervous system in the brain is involved in cognitive function, and marked deficits in the acetylcholinergic system are observed in Alzheimer's disease. N-methyl-D-aspartate glutamate receptor antagonists (memantine) are also in practical use because hyperexcitability of the mechanism of glutamate neurotransmission is associated with neural degeneration or impairment. Neither monotherapy nor combination therapy using these drugs, however, has produced sufficient therapeutic effects, nor are they capable of halting the progression of the disease. Furthermore, gastrointestinal symptoms such as nausea and diarrhea are observed as side effects of cholinesterase.
[0008] With respect to ischemic neurodegenerative disorders induced by cerebral infarctions, such as atherothrombotic cerebral infarction, lacunar infarction, cardiogenic cerebral embolism, etc., the usage of very early thrombolytic therapy using tissue plasminogen activator (tPA) is rapidly increasing. This therapy, however, has many problems including a time window as short as within three hours after the onset of disease, hemorrhagic complications, etc.
[0009] In Japan, a free radical scavenger, edaravone, is used for a brain protection therapy. Although edaravone can be used concomitantly with tPA, sufficient clinical results have not been obtained.
[0010] Accordingly, there exists a strong need for a pharmaceutical agent having a novel mechanism of action, or a neuroprotectant for preventing neural degeneration or impairment from its etiologies such as abnormal mitochondrial function, etc.
[0011] PTL 1 discloses a quinolone compound or a salt thereof that is effective as an anticancer agent; however, PTL 1 does not teach that the compound or a salt thereof is effective as a therapeutic and/or prophylactic agent for neurodegenerative diseases, diseases induced by neurological dysfunction, or diseases induced by deterioration of mitochondrial function.
[0012] Additionally, PTL 2 discloses a quinolone compound that is effective for preventing intimal proliferation; however, PTL 2 but does not teach that the compound is effective as a therapeutic and/or prophylactic agent for neurodegenerative diseases, diseases induced by neurological dysfunction, or diseases induced by deterioration of mitochondrial function.
CITATION LIST
Patent Literature
[0000]
PTL 1: WO 2001/012607
PTL 2: WO 2002/022074
Non Patent Literature
[0000]
NPL 1: Ann. N.Y. Acad. Sci. 991: 111-119 (2003)
SUMMARY OF INVENTION
Technical Problem
[0016] An object of the present invention is to provide a therapeutic and/or prophylactic agent that inhibits the chronic progression of Parkinson's disease or protects dopamine neurons from the disease itself, thereby suppressing the progression of neurological dysfunction, so as to prolong the period of time until L-dopa is administered while also improving neuronal function.
[0017] Another object of the invention is to provide a pharmaceutical agent that is useful in treating diseases that induce cell death, and more specifically, to provide a pharmaceutical agent having efficacy for treating Alzheimer's disease, or improving dysfunction or neurologic deficits induced by cerebral apoplexy.
Solution to Problem
[0018] The present inventors conducted extensive research to accomplish the aforementioned object. Consequently, they succeeded in producing a compound represented by Formula (1) shown below, which protects and improves mitochondrial function, and/or protects neurons and repairs neuronal function. The present invention has been accomplished based on the above findings.
[0019] The invention provides a therapeutic and/or prophylactic agent comprising a quinolone compound and a method for treating and/or preventing diseases as set forth in the following Items 1 to 6.
[0020] Item 1. A therapeutic and/or prophylactic agent for neurodegenerative diseases, diseases induced by neurological dysfunction, or diseases induced by deterioration of mitochondrial function, the agent comprising as an active ingredient a quinolone compound represented by Formula (1):
[0000]
[0000] or a salt thereof, wherein:
[0021] R 1 represents hydrogen, lower alkyl, or cyclo C 3 -C 8 alkyl lower alkyl;
[0022] R 2 represents hydrogen or lower alkyl; and
[0023] R 3 represents phenyl, naphthyl, pyridyl, furyl, thienyl, indolyl, benzodioxolyl or benzothienyl, wherein the aromatic or heterocyclic ring represented by R 3 may be substituted with one or more substituents selected from the group consisting of the following substituents (1) to (7):
[0000] (1) lower alkyl,
(2) halogen-substituted lower alkyl,
(3) hydroxy,
(4) lower alkoxy,
(5) halogen-substituted lower alkoxy,
(6) phenyl optionally having one or more substituents selected from the group consisting of lower alkyl and lower alkoxy, and
(7) halogen;
[0024] R 4 represents hydrogen, lower alkyl, halogen-substituted lower alkyl, hydroxy, lower alkoxy, lower alkoxy lower alkyl, phenyl, cyclo C 3 -C 8 alkyl, or carbamoyl optionally having one or two lower alkyl groups;
[0025] R 5 represents hydrogen, lower alkyl, halogen, lower alkoxy, benzoylamino, or imidazolyl,
[0026] R 6 represents hydrogen, halogen, lower alkyl, hydroxy, or lower alkoxy; and
[0027] R 7 represents any of the following groups (1) to (19):
[0000] (1) hydrogen,
(2) hydroxy,
(3) lower alkyl,
(4) lower alkoxy,
(5) phenoxy,
(6) cyclo C 3 -C 8 alkyloxy,
(7) halogen,
(8) lower alkylthio,
(9) amino optionally having one or two substituents selected from the group consisting of lower alkyl, lower alkoxy lower alkyl, and cyclo C 3 -C 8 alkyl,
(10) carbamoyl optionally having one or two lower alkyl groups,
(11) pyrrolidinyl,
(12) azepanyl,
(13) morpholinyl,
(14) piperazinyl optionally having one or two lower alkyl groups,
(15) imidazolyl optionally having one or two lower alkyl groups,
(16) furyl,
(17) thienyl,
(18) benzothienyl, and
(19) pyrrolidinylcarbonyl.
[0028] Item 2. A therapeutic and/or prophylactic agent according to Item 1, wherein the neurodegenerative disease is selected from the group consisting of Parkinson's disease, Parkinson's syndrome, juvenile parkinsonism, striatonigral degeneration, progressive supranuclear palsy, pure akinesia, Alzheimer's disease, Pick's disease, prion disease, corticobasal degeneration, diffuse Lewy body disease, Huntington's disease, chorea-acanthocytosis, benign hereditary chorea, paroxysmal choreoathetosis, essential tremor, essential myoclonus, Gilles de la Tourette's syndrome, Rett's syndrome, degenerative ballism, dystonia musculorum deformans, athetosis, spasmodic torticollis, Meige syndrome, cerebral palsy, Wilson's disease, Segawa's disease, Hallervorden-Spatz syndrome, neuroaxonal dystrophy, pallidal atrophy, spinocerebellar degeneration, cerebral cortical atrophy, Holmes-type cerebellar atrophy, olivopontocerebellar atrophy, hereditary olivopontocerebellar atrophy, Joseph disease, dentatorubropallidoluysian atrophy, Gerstmann-Straussler-Scheinker disease, Friedreich's ataxia, Roussy-Levy syndrome, May-White syndrome, congenital cerebellar ataxia, hereditary episodic ataxia, ataxia telangiectasia, amyotrophic lateral sclerosis, progressive bulbar palsy, spinal progressive muscular atrophy, spinobulbar muscular atrophy, Werdnig-Hoffmann disease, Kugelberg-Welander disease, hereditary spastic paraparesis, syringomyelia, syringobulbia, Arnold-Chiari malformation, Stiff-man syndrome, Klippel-Feil syndrome, Fazio-Londe syndrome, lower myelopathy, Dandy-Walker syndrome, spina bifida, Sjogren-Larsson syndrome, radiation myelopathy, age-related macular degeneration, and cerebral apoplexy selected from the group consisting of cerebral infarction and cerebral hemorrhage and/or associated dysfunction or neurologic deficits.
[0029] Item 3. A therapeutic and/or prophylactic agent according to Item 1, wherein the disease induced by neurological dysfunction is selected from the group consisting of spinal cord injury, chemotherapy-induced neuropathy, diabetic neuropathy, radiation damage, and a demyelinating disease selected from the group consisting of multiple sclerosis, acute disseminated encephalomyelitis, transverse myelitis, progressive multifocal leukoencephalopathy, subacute sclerosing panencephalitis, chronic inflammatory demyelinating polyneuropathy, and Guillain-Barre syndrome.
[0030] Item 4. A therapeutic and/or prophylactic agent according to Item 1, wherein the disease induced by deterioration of mitochondrial function is selected from the group consisting of Pearson's syndrome, diabetes, deafness, malignant migraine, Leber's disease, MELAS, MERRF, MERRF/MELAS overlap syndrome, NARP, pure myopathy, mitochondrial cardiomyopathy, myopathy, dementia, gastrointestinal ataxia, acquired sideroblastic anemia, aminoglycoside-induced hearing loss, complex III deficiency due to inherited variants of cytochrome b, multiple symmetric lipomatosis, ataxia, myoclonus, retinopathy, MNGIE, ANT1 disease, Twinkle disease, POLG disease, recurrent myoglobinuria, SANDO, ARCO, complex I deficiency, complex II deficiency, optic nerve atrophy, fatal infantile complex IV deficiency, mitochondrial DNA deficiency syndrome, Leigh's encephalomyelopathy, chronic progressive external ophthalmoplegia syndrome (CPEO), Kearns-Sayre syndrome, encephalopathy, lactacidemia, myoglobinuria, drug-induced mitochondrial diseases, schizophrenia, major depression disorder, bipolar I disorder, bipolar II disorder, mixed episode, dysthymic disorders, atypical depression, seasonal affective disorders, postpartum depression, minor depression, recurrent brief depressive disorder, intractable depression, chronic depression, double depression, and acute renal failure.
[0031] Item 5. A therapeutic and/or prophylactic agent comprising as an active ingredient a quinolone compound represented by Formula (1) of Item 1 or a salt thereof, the agent being used for treating or preventing ischemic heart diseases and/or associated dysfunction, cardiac failure, myocardosis, aortic dissection, immunodeficiency, autoimmune diseases, pancreatic insufficiency, diabetes, atheroembolic renal disease, polycystic kidney, medullary cystic disease, renal cortical necrosis, malignant nephrosclerosis, renal failure, hepatic encephalopathy, liver failure, chronic obstructive pulmonary disease, pulmonary embolism, bronchiectasis, silicosis, black lung, idiopathic pulmonary fibrosis, Stevens-Johnson syndrome, toxic epidermal necrolysis, muscular dystrophy, clostridial myonecrosis, and femoral condyle necrosis.
[0032] Item 6. A method for treating and/or preventing neurodegenerative diseases, diseases induced by neurological dysfunction, or diseases induced by deterioration of mitochondrial function, the method comprising administering a quinolone compound represented by Formula (1) of Item 1 or a salt thereof to a human or an animal.
[0033] Each group in Formula (1) is specifically described below.
[0034] The term “lower” refers to a group having 1 to 6 carbons (preferably 1 to 4 carbons), unless otherwise specified.
[0035] Examples of lower alkyl groups include straight or branched C 1-6 (preferably C 1-4 ) alkyl groups such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, sec-butyl, n-pentyl, 1-ethylpropyl, isopentyl, neopentyl, n-hexyl, 1,2,2-trimethylpropyl, 3,3-dimethylbutyl, 2-ethylbutyl, isohexyl, 3-methylpentyl, etc.
[0036] Examples of cyclo C 3 -C 8 alkyl groups include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, etc.
[0037] Examples of cyclo C 3 -C 8 alkyl lower alkyl groups include the lower alkyl groups having one to three (preferably one) cyclo C 3 -C 8 alkyl group(s) described above.
[0038] Examples of lower alkoxy groups include straight or branched C 1-6 (preferably C 1-4 ) alkoxy groups such as methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, tert-butoxy, sec-butoxy, n-pentyloxy, isopentyloxy, neopentyloxy, n-hexyloxy, isohexyloxy, 3-methylpentyloxy, etc.
[0039] Examples of lower alkoxy lower alkyl groups include the lower alkyl groups having one to three (preferably one) lower alkoxy group(s) described above.
[0040] Examples of halogen atoms include fluorine, chlorine, bromine, and iodine.
[0041] Examples of halogen-substituted lower alkyl groups include the lower alkyl groups having one to seven halogen atom(s), preferably one to three halogen atom(s). Examples thereof include fluoromethyl, difluoromethyl, trifluoromethyl, chloromethyl, dichloromethyl, trichloromethyl, bromomethyl, dibromomethyl, dichlorofluoromethyl, 2,2-difluoroethyl, 2,2,2-trifluoroethyl, pentafluoroethyl, 2-fluoroethyl, 2-chloroethyl, 3.3.3-trifluoropropyl, heptafluoropropyl, 2,2,3,3,3-pentafluoropropyl, heptafluoroisopropyl, 3-chloropropyl, 2-chloropropyl, 3-bromopropyl, 4,4,4-trifluorobutyl, 4,4,4,3,3-pentafluorobutyl, 4-chlorobutyl, 4-bromobutyl, 2-chlorobutyl, 5,5,5-trifluoropentyl, 5-chloropentyl, 6,6,6-trifluorohexyl, 6-chlorohexyl, perfluorohexyl, etc.
[0042] Examples of halogen-substituted lower alkoxy groups include the lower alkoxy groups having one to seven halogen atom(s), preferably one to three halogen atom(s). Examples thereof include fluoromethoxy, difluoromethoxy, trifluoromethoxy, chloromethoxy, dichloromethoxy, trichloromethoxy, bromomethoxy, dibromomethoxy, dichlorofluoromethoxy, 2,2,2-trifluoroethoxy, pentafluoroethoxy, 2-chloroethoxy, 3,3,3-trifluoropropoxy, heptafluoropropoxy, heptafluoroisopropoxy, 3-chloropropoxy, 2-chloropropoxy, 3-bromopropoxy, 4,4,4-trifluorobutoxy, 4,4,4,3,3-pentafluorobutoxy, 4-chlorobutoxy, 4-bromobutoxy, 2-chlorobutoxy, 5,5,5-trifluoropentoxy, 5-chloropentoxy, 6,6,6-trifluorohexyloxy, 6-chlorohexyloxy, etc.
[0043] Examples of lower alkylthio groups include alkylthio groups wherein the alkyl moiety is the lower alkyl group mentioned above.
[0044] Examples of phenyl groups optionally having one or more substituents selected from the group consisting of lower alkyl and lower alkoxy include phenyl groups optionally having one to three (preferably one or two) group(s) selected from the group consisting of the lower alkyl groups and the lower alkoxy groups described above.
[0045] Examples of carbamoyl groups optionally having one or more lower alkyl groups include carbamoyl groups optionally having one or two lower alkyl groups described above.
[0046] Examples of amino groups optionally having one or two substituents selected from the group consisting of lower alkyl groups, lower alkoxy lower alkyl groups, and cyclo C 3 -C 8 alkyl groups include amino groups optionally having one or two groups selected from the group consisting of the lower alkyl groups, the lower alkoxy lower alkyl groups, and the cyclo C 3 -C 8 alkyl groups described above.
[0047] Examples of piperazinyl groups optionally having one or two lower alkyl groups include piperazinyl groups optionally having one or two (preferably one) lower alkyl group(s) described above.
[0048] Examples of imidazolyl groups optionally having one or two lower alkyl groups include imidazolyl groups optionally having one or two (preferably one) lower alkyl group(s) described above.
[0049] Examples of lower alkoxy lower alkyl groups include the lower alkyl groups having one to three (preferably one) lower alkoxy group(s) described above.
[0050] Examples of cyclo C 3 -C 8 alkyloxy groups include groups in which the cyclo C 3 -C 8 alkyl groups described above are bonded to an oxygen atom.
[0051] The process of producing the compound of the invention is described below in detail.
[0052] The quinolone compound represented by Formula (1) (hereinafter also referred to as Compound (I)) can be produced by various methods; for example, by a method according to the following Reaction Scheme 1.
[0000]
[0053] wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , and R 7 are as defined above, and R 8 represents a lower alkoxy group.
[0054] The lower alkoxy group represented by R 8 in Formula (3) has the same definition as described above.
[0055] The compound represented by Formula (2) is reacted with the compound represented by Formula (3) in an inert solvent or without using any solvents, in the presence or absence of an acid catalyst, thereby giving an intermediate compound represented by Formula (4). Then, the resulting compound is cyclized to produce the compound represented by Formula (1).
[0056] Examples of inert solvents include water; ethers such as dioxane, tetrahydrofuran, diethyl ether, 1,2-dimethoxyethane, diethylene glycol dimethyl ether, and ethylene glycol dimethyl ether; aromatic hydrocarbons such as benzene, toluene, and xylene; lower alcohols such as methanol, ethanol, and isopropanol; and polar solvents such as N,N-dimethylformamide (DMF), dimethyl sulfoxide (DMSO), hexamethylphosphoric triamide, and acetonitrile. These inert solvents can be used singly or in combinations of two or more.
[0057] Various kinds of known acid catalysts can be used, including toluenesulfonic acid, methanesulfonic acid, xylene sulfonic acid, sulfuric acid, glacial acetic acid, boron trifluoride, acidic ion exchangers, etc. These acid catalysts can be used singly or in combinations of two or more.
[0058] Among such acids, acidic ion exchangers are preferably used. Examples of acidic ion exchangers include polymeric cation exchangers available from the market such as Lewatit 5100, Zeo-karb 225, Dowex 50, Amberlite IR120, or Amberlyst 15 and like styrene sulfonic acid polymers; Lewatit PN, Zeo-karb 215 or 315, and like polysulfonic acid condensates; Lewatit CNO, Duolite CS100, and like m-phenolic carboxylic acid resins; or Permutit C, Zeo-karb 226 or Amberlite IRC 50, and like polyacrylates. Of these, Amberlyst 15 is particularly preferred.
[0059] An acid catalyst is usually used in an amount of 0.0001 to 100 moles, preferably 0.5 to 6 moles, per mole of the compound of Formula (2).
[0060] In Reaction Scheme 1, the compound of Formula (3) is usually used in an amount of at least about 1 mole, preferably about 1 to about 5 moles, per mole of the compound of Formula (2).
[0061] The reaction can be conducted under normal pressure, under inert gas atmospheres including nitrogen, argon, etc., or under increased pressure.
[0062] The reaction proceeds usually at room temperature to 200° C., and preferably at room temperature to 150° C. During the reaction, azeotropic removal of water is conducted until the reaction water generation is completed. The reaction is usually finished in about 1 to about 30 hours.
[0063] The process of producing the compound of Formula (1) via a cyclization reaction of the intermediate compound represented by Formula (4) can be carried out by heating the compound in a solvent such as diphenyl ether, or by heating the compound in the absence of a solvent. The reaction is conducted at 150 to 300° C. for 5 minutes to 2 hours.
[0064] The compound represented by Formula (2), used as a starting material in Reaction Scheme 1, is a known compound or can be produced easily using a known compound. The compound represented by Formula (3) includes a novel compound, and the compound is manufactured in accordance with, for example, the method shown in Reaction Scheme 2 described below.
[0000]
[0065] wherein R 2 , R 3 , and R 8 are as defined above, and R 9 represents a lower alkoxy group.
[0066] The lower alkoxy group represented by R 9 in Formula (6) has the same definition as described above.
[0067] The compound represented by Formula (3) can be produced by the reaction of the compound represented by Formula (5) with the compound represented by Formula (6) in an inert solvent or without using any solvents, in the presence or absence of a basic compound.
[0068] Examples of inert solvents include water; ethers such as dioxane, tetrahydrofuran, diethyl ether, 1,2-dimethoxyethane, diethylene glycol dimethyl ether, and ethylene glycol dimethyl ether; aromatic hydrocarbons such as benzene, toluene, and xylene; lower alcohols such as methanol, ethanol, and isopropanol; ketones such as acetone and methyl ethyl ketone; and polar solvents such as N,N-dimethylformamide (DMF), dimethyl sulfoxide (DMSO), hexamethylphosphoric triamide, and acetonitrile. These inert solvents can be used singly or in combinations of two or more.
[0069] As a basic compound, various known inorganic bases and organic bases can be used.
[0070] Inorganic bases include, for example, alkali metal hydroxides such as sodium hydroxide, potassium hydroxide, cesium hydroxide, and lithium hydroxide; alkali metal carbonates such as sodium carbonate, potassium carbonate, cesium carbonate, and lithium carbonate; alkali metal hydrogen carbonates such as lithium hydrogen carbonate, sodium hydrogen carbonate, and potassium hydrogen carbonate; alkali metals such as sodium and potassium; amides such as sodium amide; and alkali metal hydrides such as sodium hydride and potassium hydride.
[0071] Organic bases include, for example, alkali metal lower alkoxides such as sodium methoxide, sodium ethoxide, sodium t-butoxide, potassium methoxide, potassium ethoxide, and potassium t-butoxide; and amines such as triethylamine, tripropylamine, pyridine, quinoline, piperidine, imidazole, N-ethyl diisopropylamine, dimethylaminopyridine, trimethylamine, dimethylaniline, N-methylmorpholine, 1,5-diazabicyclo[4.3.0]non-5-ene (DBN), 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), 1,4-diazabicyclo[2.2.2]octane (DABCO), etc.
[0072] Such basic compounds can be used singly or in combinations of two or more. More preferable basic compounds used in the reaction include inorganic bases such as sodium hydride and potassium hydride.
[0073] A basic compound is usually used in an amount of 1 to 10 moles, preferably 1 to 6 moles, per mole of the compound of Formula (5).
[0074] In Reaction Scheme 2, the compound of Formula (6) is usually used in an amount of at least about 1 mole, preferably 1 to about 5 moles, per mole of the compound of Formula (5).
[0075] The reaction can be conducted under normal pressure, under inert gas atmospheres including nitrogen, argon, etc., or under increased pressure.
[0076] The reaction proceeds usually at room temperature to 200° C., and preferably at room temperature to 150° C., and is usually completed in about 1 to about 30 hours.
[0077] The compounds represented by Formulae (5) and (6), which are used as starting materials in Reaction Scheme 2, are easily available known compounds.
[0078] The raw material compounds used in each of the reaction schemes described above may include suitable salts, and the objective compounds obtained via each of the reactions may form suitable salts. These preferable salts include the following preferable salts of Compound (I).
[0079] Suitable salts of Compound (I) are pharmacologically allowable salts including, for example, salts of inorganic bases such as metal salts including alkali metal salts (e.g., sodium salts, potassium salts, etc.) and alkaline earth metal salts (e.g., calcium salts, magnesium salts, etc.), ammonium salts, alkali metal carbonates (e.g., lithium carbonate, potassium carbonate, sodium carbonate, cesium carbonate, etc.), alkali metal hydrogencarbonates (e.g., lithium hydrogencarbonate, sodium hydrogencarbonate, potassium hydrogencarbonate, etc.), and alkali metal hydroxides (e.g., lithium hydroxide, sodium hydroxide, potassium hydroxide, cesium hydroxide, etc.); salts of organic bases such as tri(lower)alkylamine (e.g., trimethylamine, triethylamine, N-ethyldiisopropylamine, etc.), pyridine, quinoline, piperidine, imidazole, picoline, dimethylaminopyridine, dimethylaniline, N-(lower)alkyl-morpholine (e.g., N-methylmorpholine, etc.), 1,5-diazabicyclo[4.3.0]non-5-ene (DBN), 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), and 1,4-diazabicyclo[2.2.2]octane (DABCO); inorganic acid salts such as hydrochloride, hydrobromide, hydroiodide, sulfate, nitrate, and phosphate; and organic acid salts such as formate, acetate, propionate, oxalate, malonate, succinate, fumarate, maleate, lactate, malate, citrate, tartrate, carbonate, picrate, methanesulfonate, ethanesulfonate, p-toluenesulfonate, and glutamate.
[0080] In addition, compounds in a form in which a solvate (for example, hydrate, ethanolate, etc.) was added to the starting materials and the objective compound shown in each of the reaction schemes are also included in each of the general formulae. Hydrate can be mentioned as a preferable solvate.
[0081] Each of the objective compounds obtained according to the above reaction schemes can be isolated and purified from the reaction mixture by, for example, cooling the reaction mixture, first, performing an isolation procedure such as filtration, concentration, extraction, etc., to separate a crude reaction product, and then subjecting the crude reaction product to a usual purification procedure such as column chromatography, recrystallization, etc.
[0082] The compound represented by Formula (1) according to the present invention naturally includes geometrical isomers, stereoisomers, optical isomers, and like isomers.
[0083] The following points should be noted regarding the compound of Formula (1) shown above. Specifically, when R 1 of Formula (1) represents a hydrogen atom, the compound includes a tautomer of the quinolone ring. That is, in the quinolone compound of Formula (1), when R 1 represents a hydrogen atom (1′),
[0000]
[0084] wherein R 2 , R 3 , R 4 , R 5 , R 6 , and R 7 are as defined above, the compound of the tautomer can be represented by Formula (1″),
[0000]
[0085] wherein R 2 , R 3 , R 4 , R 5 , R 6 , and R 7 are as defined above. That is, both of the compounds represented by Formulae (1′) and (1″) are in the tautomeric equilibrium state represented by the following balance formula.
[0000]
[0086] wherein R 2 , R 3 , R 4 , R 5 , R 6 , and R 7 are as defined above.
[0087] Such tautomerism between a 4-quinolone compound and a 4-hydroxyquinoline compound is technically known, and it is obvious for a person skilled in the art that both of the above-described tautomers are balanced and mutually exchangeable.
[0088] Therefore, the compound represented by Formula (1) of the present invention naturally includes the tautomers as mentioned above.
[0089] In the specification, the constitutional formula of a 4-quinolone compound is suitably used as a constitutional formula of the objective or starting material including compounds of such tautomers.
[0090] The present invention also includes isotopically labeled compounds that are identical to the compounds represented by Formula (1), except that one or more atoms are replaced by one or more atoms having specific atomic mass or mass numbers. Examples of isotopes that can be incorporated into the compounds of the present invention include hydrogen, carbon, nitrogen, oxygen, sulfur, fluorine, and chlorine, such as 2 H, 3 H, 13 C, 14 c, 15 N, 18 O, 17 O, 18 F, and 36 Cl. Certain isotopically labeled compounds of the present invention, which include the above-described isotopes and/or other isotopes of other atoms, for example, those into which radioisotopes such as 3 H and 14 C are incorporated, are useful in drug and/or substrate tissue distribution assay. Tritiated (i.e., 3 H), and carbon-14 (i.e., 14 C) isotopes are particularly preferred for their ease of preparation and detectability. Further, substitution with heavier isotopes such as deuterium (i.e., 2 H) can afford certain therapeutic advantages resulting from greater metabolic stability, for example, an increased in vivo half-life or reduced dosage requirements. The isotopically labeled compounds of the present invention can generally be prepared by substituting a readily available, isotopically labeled reagent for a non-isotopically labeled reagent according to the method disclosed in the schemes above and/or in the Examples below.
[0091] The compound of Formula (1) and the salt thereof are used in the form of general pharmaceutical preparations. The preparations are obtained using typically employed diluents or excipients such as fillers, extenders, binders, wetting agents, disintegrators, surfactants, lubricants, etc. The form of such pharmaceutical preparations can be selected according to the purpose of the therapy. Typical examples include tablets, pills, powders, solutions, suspensions, emulsions, granules, capsules, suppositories, injections (solutions, suspensions, etc.), and the like.
[0092] To form tablets, any of various carriers conventionally known in this field can be used. Examples thereof include lactose, white sugar, sodium chloride, glucose, urea, starch, calcium carbonate, kaolin, crystalline cellulose, silicic acid, and other excipients; water, ethanol, propanol, simple syrup, glucose solutions, starch solutions, gelatin solutions, carboxymethylcellulose, shellac, methylcellulose, potassium phosphate, polyvinylpyrrolidone, and other binders; dry starch, sodium alginate, agar powder, laminarin powder, sodium hydrogen carbonate, calcium carbonate, fatty acid esters of polyoxyethylene sorbitan, sodium lauryl sulfate, stearic acid monoglycerides, starch, lactose, and other disintegrators; white sugar, stearin, cacao butter, hydrogenated oils, and other disintegration inhibitors; quaternary ammonium bases, sodium lauryl sulfate, and other absorption promoters; glycerol, starch, and other wetting agents; starch, lactose, kaolin, bentonite, colloidal silicic acid, and other adsorbents; purified talc, stearates, boric acid powder, polyethylene glycol, and other lubricants; etc. Further, such tablets may be coated with typical coating materials as required, to prepare, for example, sugar-coated tablets, gelatin-coated tablets, enteric-coated tablets, film-coated tablets, double- or multi-layered tablets, etc.
[0093] To form pills, any of various carriers conventionally known in this field can be used. Examples thereof include glucose, lactose, starch, cacao butter, hydrogenated vegetable oils, kaolin, talc, and other excipients; gum arabic powder, tragacanth powder, gelatin, ethanol, and other binders; laminarin, agar, and other disintegrators; etc.
[0094] To form suppositories, any of various carriers conventionally known in this field can be used. Examples thereof include polyethylene glycol, cacao butter, higher alcohols, esters of higher alcohols, gelatin, semi synthetic glycerides, etc.
[0095] Capsules can be prepared by mixing the active principal compound with the above-mentioned carriers to enclose the former in a hard gelatin capsule, soft gelatin capsule or the like.
[0096] To form an injection, a solution, emulsion or suspension is sterilized and preferably made isotonic to blood. Any of the diluents widely used for such forms in this field can be employed to form the injection. Examples of such diluents include water, ethyl alcohol, macrogol, propylene glycol, ethoxylated isostearyl alcohol, polyoxylated isostearyl alcohol, fatty acid esters of polyoxyethylene sorbitan, etc.
[0097] In this case, the pharmaceutical preparation may contain sodium chloride, glucose or glycerol in an amount sufficient to prepare an isotonic solution, and may contain typical solubilizers, buffers, analgesic agents, etc. Further, if necessary, the pharmaceutical preparation may contain coloring agents, preservatives, flavors, sweetening agents, etc., and/or other medicines.
[0098] The amount of the compound represented by Formula (1) and the salt thereof included in the pharmaceutical preparation of the present invention is not limited, and can be suitably selected from a wide range. The proportion is generally about 0.1 to about 70 wt. %, preferably about 0.1 to about 30 wt. % of the pharmaceutical preparation.
[0099] The route of administration of the pharmaceutical preparation of the present invention is not particularly limited, and the preparation is administered by a route suitable to the form of the preparation, patient's age, sex and other conditions, and severity of the disease. For example, tablets, pills, solutions, suspensions, emulsions, granules and capsules are administered orally. Injections are intravenously administered singly or as mixed with typical injection transfusions such as glucose solutions, amino acid solutions or the like, or singly administered intramuscularly, intracutaneously, subcutaneously or intraperitoneally, as required. Suppositories are administered intrarectally.
[0100] The dosage of the pharmaceutical preparation of the invention is suitably selected according to the method of use, patient's age, sex and other conditions, and severity of the disease. The amount of active principal compound is usually about 0.1 to about 10 mg/kg body weight/day. Further, it is desirable that the pharmaceutical preparation in each unit of the administration form contains the active principal compound in an amount of about 1 to about 200 mg.
[0101] The use of the compound of the present invention in combination with L-dopa preparations, dopamine receptor agonists, dopamine metabolism enzyme inhibitors, dopamine release-rate-promoting preparations, central anticholinergic agents, and the like can achieve effects such as dosage reduction, improvement of side effects, increased therapeutic efficacy, etc., which were not attained by known therapies.
Advantageous Effect of Invention
[0102] The compound of the present invention protect and improve mitochondrial function and/or protect neurons and repair neuronal function, and hence are effective in the treatment and/or prevention of neurodegenerative diseases, diseases induced by neurological dysfunction, and diseases induced by deterioration of mitochondrial function.
[0103] Examples of neurodegenerative diseases include Parkinson's disease, Parkinson's syndrome, juvenile parkinsonism, striatonigral degeneration, progressive supranuclear palsy, pure akinesia, Alzheimer's disease, Pick's disease, prion disease, corticobasal degeneration, diffuse Lewy body disease, Huntington's disease, chorea-acanthocytosis, benign hereditary chorea, paroxysmal choreoathetosis, essential tremor, essential myoclonus, Gilles de la Tourette's syndrome, Rett syndrome, degenerative ballism, dystonia musculorum deformans, athetosis, spasmodic torticollis, Meige syndrome, cerebral palsy, Wilson's disease, Segawa's disease, Hallervorden-Spatz syndrome, neuroaxonal dystrophy, pallidal atrophy, spino-cerebellar degeneration, cerebral cortical atrophy, Holmes-type cerebellar atrophy, olivopontocerebellar atrophy, hereditary olivopontocerebellar atrophy, Joseph disease, dentatorubropallidoluysian atrophy, Gerstmann-Straussler-Scheinker disease, Friedreich's ataxia, Roussy-Levy syndrome, May-White syndrome, congenital cerebellar ataxia, hereditary episodic ataxia, ataxia telangiectasia, amyotrophic lateral sclerosis, progressive bulbar palsy, progressive spinal muscular atrophy, spinobulbar muscular atrophy, Werdnig-Hoffmann disease, Kugelberg-Welander disease, hereditary spastic paraparesis, syringomyelia, syringobulbia, Arnold-Chiari malformation, Stiff-man syndrome, Klippel-Feil syndrome, Fazio-Londe syndrome, lower myelopathy, Dandy-Walker syndrome, spina bifida, Sjogren-Larsson syndrome, radiation myelopathy, age-related macular degeneration, and cerebral apoplexy (e.g., cerebral infarction and cerebral hemorrhage) and/or dysfunction or neurologic deficits associated with cerebral apoplexy.
[0104] Examples of diseases induced by neurological dysfunction include spinal cord injury, chemotherapy-induced neuropathy, diabetic neuropathy, radiation damage, and demyelinating diseases (e.g., multiple sclerosis, acute disseminated encephalomyelitis, transverse myelitis, progressive multifocal leucoencephalopathy, subacute sclerosing panencephalitis, chronic inflammatory demyelinating polyneuropathy, and Guillain-Barre syndrome).
[0105] Examples of diseases induced by deterioration of mitochondrial function include Pearson's syndrome, diabetes, deafness, malignant migraine, Leber's disease, MELAS, MERRF, MERRF/MELAS overlap syndrome, NARP, pure myopathy, mitochondrial cardiomyopathy, myopathy, dementia, gastrointestinal ataxia, acquired sideroblastic anemia, aminoglycoside-induced hearing loss, complex III deficiency due to inherited variants of cytochrome b, multiple symmetrical lipomatosis, ataxia, myoclonus, retinopathy, MNGIE, ANT1 disease, Twinkle disease, POLG disease, recurrent myoglobinuria, SANDO, ARCO, complex I deficiency, complex II deficiency, optic nerve atrophy, fatal infantile complex IV deficiency, mitochondrial DNA deficiency syndrome, Leigh's encephalomyelopathy, chronic-progressive-external-ophthalmoplegia syndrome (CPEO), Kearns-Sayre syndrome, encephalopathy, lactacidemia, myoglobinuria, drug-induced mitochondrial diseases, schizophrenia, major depression disorder, bipolar I disorder, bipolar II disorder, mixed episode, dysthymic disorders, atypical depression, seasonal affective disorders, postpartum depression, minor depression, recurrent brief depressive disorder, intractable depression, chronic depression, double depression, and acute renal failure.
[0106] Furthermore, the compound of the present invention is effective in the prevention and/or treatment of ischemic heart diseases and/or associated dysfunction, cardiac failure, myocardosis, aortic dissection, immunodeficiency, autoimmune diseases, pancreatic insufficiency, diabetes, atheroembolic renal disease, polycystic kidney disease, medullary cystic disease, renal cortical necrosis, malignant nephrosclerosis, renal failure, hepatic encephalopathy, liver failure, chronic obstructive pulmonary disease, pulmonary embolism, bronchiectasis, silicosis, black lung, idiopathic pulmonary fibrosis, Stevens-Johnson syndrome, toxic epidermal necrolysis, muscular dystrophy, clostridial muscle necrosis, and femoral condyle necrosis.
[0107] The compound of the present invention can achieve effects heretofore unattained by known therapies, such as reduced dose, reduced side effects, and potentiated therapeutic effects, when it is administered in combination with L-dopa preparations, dopamine receptor agonists, dopamine metabolism enzyme inhibitors, dopamine release-rate-promoting preparations, central anticholinergic agents, cholinesterase inhibitors, N-methyl-D-aspartate glutamate receptor antagonists, or other agents used in thrombolytic therapy, cerebral edema therapy, brain protection therapy, antithrombotic therapy, and blood plasma dilution therapy.
DESCRIPTION OF EMBODIMENTS
[0108] Hereinafter, the present invention is described in more detail with reference to Reference Examples, Examples, and Pharmacological Test Examples.
Reference Example 1
4-Methyl-2-nitro-1-propoxybenzene
[0109] A DMF solution (4 ml) of potassium carbonate (5.21 g, 37.7 mmol) and 1-iodopropane (5.80 g, 34.1 mmol) was added to a N,N-dimethylformamide (DMF) solution (10 ml) of 4-methyl-2-nitrophenol (4.0 g, 26.1 mmol), and the mixture was stirred at room temperature for 48 hours. Water was added to the reaction mixture, and the resulting mixture was extracted with ethyl acetate. The organic layer was washed with a saturated saline solution twice and concentrated under reduced pressure. The residue was purified using silica gel column chromatography (n-hexane:ethyl acetate=9:1). The purified product was concentrated under reduced pressure to thereby obtain 4.23 g of pale-yellow oily 4-methyl-2-nitro-1-propoxybenzene (yield: 83%).
[0110] 1 H-NMR (CDCl 3 ) δ ppm: 1.05 (3H, t, J=7.4 Hz), 1.80-1.86 (2H, m), 2.33 (3H, s), 4.02 (2H, t, J=6.4 Hz), 6.95 (1H, d, J=8.5 Hz), 7.29 (1H, d, J=8.5 Hz), 7.62 (1H, s).
Reference Example 2
5-Methyl-2-propoxyaniline
[0111] 4-Methyl-2-nitro-1-propoxybenzene (2.0 g, 10.2 mmol) and 5% palladium carbon (700 mg) were added to ethanol (30 ml), followed by conduction of catalytic reduction at room temperature under ordinary pressure. The catalyst was removed by Celite filtration, and the filtrate was concentrated under reduced pressure. The residue was dissolved in dichloromethane and dried over anhydrous magnesium sulfate. The resultant dry substance was concentrated under reduced pressure to thereby obtain 1.49 g of reddish-brown oily 5-methyl-2-propoxyaniline (yield: 89%).
[0112] 1 H-NMR (CDCl 3 ) δ ppm: 1.05 (3H, t, J=7.4 Hz), 1.76-1.86 (2H, m), 2.21 (3H, s), 3.73 (2H, brs), 3.91 (2H, t, J=6.5 Hz), 6.49-6.50 (1H, m), 6.54 (1H, s), 6.66 (1H, d, J=8.0 Hz).
Reference Example 3
Ethyl α-(hydroxymethylene)-4-methoxyphenyl acetate
[0113] Sodium hydride (60% in oil) (467 mg, 11.7 mmol) was added to a benzene solution (10 ml) of ethyl 4-methoxyphenyl acetate (2.0 g, 10.3 mmol), while being cooled with ice. The mixture was stirred at room temperature for 5 minutes. The stirred mixture was cooled with ice again; ethyl formate (1.02 ml, 12.6 mmol) was added thereto and stirred at room temperature for 3 hours. While being cooled with ice, water and ethyl acetate were added to the reaction mixture, and then 2N hydrochloric acid (6 ml) was added to separate the reaction mixture into two layers. The organic layer was concentrated under reduced pressure, and the residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=4:1). The purified product was concentrated under reduced pressure to thereby obtain 1.97 g of slightly reddish-brown oily ethyl α-(hydroxymethylene)-4-methoxyphenyl acetate (yield: 86%). The resulting object was purged with nitrogen and stored in a freezer.
[0114] 1 H-NMR (CDCl 3 ) δ ppm: 1.28 (3H, t, J=7.1 Hz), 3.81 (3H, s), 4.28 (2H, q, J=7.1 Hz), 6.87 (2H, d, J=8.8 Hz), 7.16-7.26 (3H, m), 12.02 (1H, d, J=12.5 Hz).
Example 1
[0115]
3-(4-Methoxyphenyl)-5-methyl-8-propoxy-1H-quinolin-4-one
[0116] 270 mg of Amberlyst 15 (produced by Sigma-Aldrich Corporation) was added to a benzene solution (50 ml) of 5-methyl-2-propoxyaniline (1.49 g, 9.0 mmol) and ethyl α-(hydroxymethylene)-4-methoxyphenyl acetate (2.00 g, 9.0 mmol). The resulting mixture was heated under reflux for 6 hours using a Dean-Stark trap. The reaction mixture was then cooled to room temperature and filtered to remove resin. The filtrate was concentrated under reduced pressure. Diphenyl ether (2.5 ml) was added to the residue, and the mixture was then heated with a mantle heater and stirred for 50 minutes under reflux. The reaction mixture was cooled to room temperature, and then directly purified using silica gel column chromatography (dichloromethane:methanol=80:1→60:1). The purified product was concentrated under reduced pressure to recrystallize the residue from ethyl acetate, thereby giving 600 mg of pale-yellow scaly crystal 3-(4-methoxyphenyl)-5-methyl-8-propoxy-1H-quinolin-4-one (yield: 21%).
[0117] Melting point: 192° C.-193° C.
[0118] Using appropriate starting materials, Examples 2 to 109 were prepared in the same manner as in Example 1.
Example 2
[0119]
1-Ethyl-7-methoxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
White Powder
[0120] Melting point: 129° C.-131° C.
Example 3
[0121]
3-(4-Methoxyphenyl)-8-propoxy-1H-quinolin-4-one
Yellow Powder
[0122] Melting point: 231° C.-233° C.
Example 4
[0123]
1-Ethyl-7-hydroxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
Pale-Brown Powder
[0124] 1 H-NMR (DMSO-d 6 ) δ ppm: 1.35 (3H, t, J=6.8 Hz), 3.76 (3H, s), 4.23 (2H, q, J=6.9 Hz), 6.84-6.96 (4H, m), 7.64 (2H, d, J=8.6 Hz), 8.09 (1H, s), 8.11 (1H, d, J=8.8 Hz), 10.33 (1H, s).
Example 5
[0125]
5,6,7-Trimethoxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
Pale-Yellow Powder
[0126] 1 H-NMR (DMSO-d 6 ) δ ppm: 3.70 (3H, s), 3.76 (3H, s), 3.86 (3H, s), 3.93 (3H, s), 6.48 (1H, s), 6.95 (2H, d, J=8.8 Hz), 7.59 (2H, d, J=8.8 Hz), 8.22 (1H, s) 11.40 (1H, brs).
Example 6
[0127]
8-Butyl-3-(4-methoxyphenyl)-1H-quinolin-4-one
Pale-Brown Powder
[0128] 1 H-NMR (DMSO-d 6 ) δ ppm: 0.90 (3H, t, J=7.2 Hz), 1.34-1.39 (2H, m), 1.55-1.59 (2H, m), 2.86 (2H, t, J=7.5 Hz), 3.76 (3H, s), 6.95 (2H, d, J=8.5 Hz), 7.25 (1H, t, J=7.7 Hz), 7.46 (1H, d, J=6.9 Hz), 7.62 (2H, d, J=8.5 Hz), 7.92 (1H, s), 8.08 (1H, d, J=8.0 Hz), 11.39 (1H, brs).
Example 7
[0129]
3-(4-Methoxyphenyl)-8-propyl-1H-quinolin-4-one
White Powder
[0130] 1 H-NMR (DMSO-d 6 ) δ ppm: 0.94 (3H, t, J=7.2 Hz), 1.59-1.64 (2H, m), 2.83 (2H, t, J=7.5 Hz), 3.75 (3H, s), 6.93-6.95 (2H, m), 7.25 (1H, t, J=7.8 Hz), 7.46 (1H, d, J=6.0 Hz), 7.60-7.61 (2H, m), 7.92 (1H, s), 8.07-8.09 (1H, m), 11.40 (1H, brs).
Example 8
[0131]
8-Propyl-3-(4-trifluoromethoxyphenyl)-1H-quinolin-4-one
Pale-Yellow Powder
[0132] 1 H-NMR (DMSO-d 6 ) δ ppm: 0.96 (3H, t, J=7.2 Hz), 1.59-1.66 (2H, m), 2.85 (2H, t, J=7.6 Hz), 7.27 (1H, t, J=7.9 Hz), 7.36 (2H, d, J=8.7 Hz), 7.49 (1H, d, J=7.0 Hz), 7.83 (2H, d, J=8.7 Hz), 8.02 (1H, s), 8.09-8.10 (1H, m), 11.47 (1H, brs).
Example 9
[0133]
3-(4-Bromophenyl)-8-propyl-1H-quinolin-4-one
White Powder
[0134] 1 H-NMR (DMSO-d 6 ) δ ppm: 0.95 (3H, t, J=7.2 Hz), 1.58-1.65 (2H, m), 2.84 (2H, t, J=7.6 Hz), 7.27 (1H, d, J=7.9 Hz), 7.48 (1H, d, J=7.1 Hz), 7.55 (2H, d, J=8.5 Hz), 7.67 (2H, d, J=8.5 Hz), 8.00 (1H, s), 8.08-8.09 (1H, m), 11.46 (1H, brs).
Example 10
[0135]
3-(4T-Methoxybiphenyl-4-yl)-8-propyl-1H-quinolin-4-one
Pale-Brown Powder
[0136] 1 H-NMR (DMSO-d 6 ) δ ppm: 0.95 (3H, t, J=7.2 Hz), 1.59-1.66 (2H, m), 2.85 (2H, t, J=7.6 Hz), 3.81 (3H, s), 7.00 (2H, d, J=8.7 Hz), 7.28 (1H, t, J=8.5 Hz), 7.48 (1H, d, J=7.1 Hz), 7.60-7.64 (4H, m), 7.76 (2H, d, J=8.2 Hz), 8.02 (1H, s), 8.11 (1H, d, J=8.1 Hz), 11.45 (1H, brs).
Example 11
[0137]
3-(4-Bromophenyl)-1-ethyl-7-methoxy-1H-quinolin-4-one
White Powder
[0138] 1 H-NMR (DMSO-d 6 ) δ ppm: 1.37 (3H, t, J=6.9 Hz), 3.91 (3H, s), 4.34 (2H, q, J=7.0 Hz), 7.01-7.04 (2H, m), 7.54 (2H, d, J=8.4 Hz), 7.69 (2H, d, J=8.4 Hz), 8.20 (1H, d, J=8.8 Hz), 8.24 (1H, s).
Example 12
[0139]
3-Biphenyl-4-yl-1-ethyl-7-methoxy-1H-quinolin-4-one
White Powder
[0140] 1 H-NMR (DMSO-d 6 ) δ ppm: 1.38 (3H, t, J=7.0 Hz), 3.91 (3H, s), 4.35 (2H, q, J=7.0 Hz), 7.01-7.05 (2H, m), 7.34 (1H, t, J=7.4 Hz), 7.45 (2H, t, J=7.6 Hz), 7.65-7.68 (4H, m), 7.81 (2H, d, J=8.3 Hz), 8.22-8.25 (2H, m).
Example 13
[0141]
5-Methoxy-3-(4-methoxyphenyl)-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0142] Melting point: 223° C.-224° C.
Example 14
[0143]
3-(3,4-Dimethoxyphenyl)-8-propoxy-1H-quinolin-4-one
[0144] Pale-Yellow Powder
[0145] Melting point: 210° C.-211° C.
Example 15
[0146]
8-Propoxy-3-pylidine-4-yl-1H-quinolin-4-one
Pale-Brown Powder
[0147] Melting point: 259° C.-260° C.
Example 16
[0148]
3-(2,4-Dimethoxyphenyl)-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0149] Melting point: 231° C.-232° C.
Example 17
[0150]
8-Propoxy-3-(3,4,5-trimethoxyphenyl)-1H-quinolin-4-one
Pale-Brown Amorphous Product
[0151] 1 H-NMR (DMSO-d 6 ) δ ppm: 1.04 (3H, t, J=7.3 Hz), 1.78-1.90 (2H, m), 3.67 (3H, s), 3.84 (6H, s), 4.12 (2H, t, J=6.4 Hz), 7.00 (2H, s), 7.17-7.26 (2H, m), 7.74 (1H, d, J=6.7 Hz), 7.99 (1H, d, J=6.3 Hz), 11.47 (1H, d, J=6.2 Hz).
Example 18
[0152]
3-(4-Methoxyphenyl)-8-phenoxy-1H-quinolin-4-one
Pale-Brown Powder
[0153] Melting point: 250° C.-251° C.
Example 19
[0154]
3-(4-Methoxy-2-methylphenyl)-8-propoxy-1H-quinolin-4-one
[0155] Pale-Yellow Powder
[0156] Melting point: 214° C.-215° C.
Example 20
[0157]
3-(2,4-Dimethoxyphenyl)-5-methyl-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0158] Melting point: 193° C.-194° C.
Example 21
[0159]
3-(2,4-Dimethoxyphenyl)-5-methoxy-8-propoxy-1H-quinolin-4-one
Pale-Gray Powder
[0160] Melting point: 113° C.-114° C.
Example 22
[0161]
3-(4-Methoxyphenyl)-5-phenyl-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0162] Melting point: 186° C.-187° C.
Example 23
[0163]
3-(4-Methoxyphenyl)-5,7-dimethyl-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0164] Melting point: 174° C.-175° C.
Example 24
[0165]
3-(4-Methoxyphenyl)-8-propoxy-5-trifluoromethyl-1H-quinolin-4-one
[0166] Pale-Yellow Powder
[0167] Melting point: 220° C.-221° C.
Example 25
[0168]
5,8-Diethoxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
Pale-Yellow Powder
[0169] Melting point: 182° C.-183° C.
Example 26
[0170]
5,8-Dimethoxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
Pale-Yellow Powder
[0171] Melting point: 159° C.-160° C.
Example 27
[0172]
3-(2,4-Dichlorophenyl)-8-propoxy-1H-quinolin-4-one
Green Powder
[0173] Melting point: 189° C.
Example 28
[0174]
3-(2,6-Dichlorophenyl)-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0175] Melting point: 193° C.
Example 29
[0176]
3-(2-Chloro-4-fluorophenyl)-8-propoxy-1H-quinolin-4-one
Pale-Orange Powder
[0177] Melting point: 230° C.
Example 30
[0178]
3-(2-Chloro-6-fluorophenyl)-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0179] Melting point: 250° C.
Example 31
[0180]
3-(2,5-Dimethoxyphenyl)-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0181] Melting point: 175° C.
Example 32
[0182]
8-Propoxy-3-(2-trofluoromethylphenyl)-1H-quinolin-4-one
White Powder
[0183] Melting point: 224° C.
Example 33
[0184]
3-Pentafluorophenyl-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0185] Melting point: 160° C.
Example 34
[0186]
6-Fluoro-3-(4-methoxyphenyl)-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0187] Melting point: 153° C.-154° C.
Example 35
[0188]
N-[5,8-Diethoxy-3-(4-methoxyphenyl)-4-oxo-1,4-dihydroquinolin-6-yl]-benzamide
Pale-Brown Powder
[0189] Melting point: 120° C.-121° C.
Example 36
[0190]
3-(4-Methoxyphenyl)-6-methyl-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0191] Melting point: 161° C.-162° C.
Example 37
[0192]
7-Methoxy-3-(4-methoxyphenyl)-5-methyl-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0193] Melting point: 195° C.-196° C.
Example 38
[0194]
3-(2,4-Dichlorophenyl)-5-methoxy-8-propoxy-1H-quinolin-4-one
White Powder
[0195] Melting point: 125° C.
Example 39
[0196]
3-(2-Methoxyphenyl)-8-propoxy-1H-quinolin-4-one
White Powder
[0197] Melting point: 218° C.-220° C.
Example 40
[0198]
5-Methoxy-3-(2-methoxyphenyl)-8-propoxy-1H-quinolin-4-one
White Powder
[0199] Melting point: 239° C.-241° C.
Example 41
[0200]
3-(2,3-Dimethoxyphenyl)-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0201] Melting point: 253° C.-255° C.
Example 42
[0202]
3-(2,3-Dimethoxyphenyl)-5-methoxy-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0203] Melting point: 145° C.-148° C.
Example 43
[0204]
3-(2,5-Dimethoxyphenyl)-5-methoxy-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0205] Melting point: 179° C.-180° C.
Example 44
[0206]
3-Naphthalen-1-yl-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0207] Melting point: 255° C.-256° C.
Example 45
[0208]
8-Ethoxy-5-methoxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
Pale-Yellow Powder
[0209] Melting point: 117° C.-119° C.
Example 46
[0210]
8-Isopropoxy-5-methoxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
Pale-Yellow Powder
[0211] Melting point: 213° C.-214° C.
Example 47
[0212]
8-Isobutoxy-5-methoxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
Pale-Yellow Powder
[0213] Melting point: 242° C.-244° C.
Example 48
[0214]
7-Fluoro-3-(4-methoxyphenyl)-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0215] Melting point: 160° C.-161° C.
Example 49
[0216]
5-Ethyl-3-(4-methoxyphenyl)-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0217] Melting point: 169° C.-170° C.
Example 50
[0218]
5-Methyl-8-propoxy-3-o-tolyl-1H-quinolin-4-one
Pale-Yellow Powder
[0219] Melting point: 201° C.-202° C.
Example 51
[0220]
5-Methoxy-3-naphthalen-1-yl-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0221] Melting point: 130° C.-133° C.
Example 52
[0222]
3-(2-Methoxyphenyl)-5-methyl-8-propoxy-1H-quinolin-4-one
White Powder
[0223] Melting point: 221° C.-223° C.
Example 53
[0224]
3-(2,3-Dimethoxyphenyl)-5-methyl-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0225] Melting point: 170° C.-171° C.
Example 54
[0226]
3-(2-Bromophenyl)-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0227] Melting point: 200° C.-203° C.
Example 55
[0228]
3-(3-Bromophenyl)-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0229] Melting point: 107° C.-108° C.
Example 56
[0230]
3-(2′,4′-Dimethoxybiphenyl-3-yl)-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0231] Melting point: 81° C.-84° C.
Example 57
[0232]
3-(2,4-Dichlorophenyl)-5-methyl-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0233] Melting point: 103° C.-106° C.
Example 58
[0234]
5-Methyl-8-propoxy-3-thiophen-3-yl-1H-quinolin-4-one
Pale-Brown Powder
[0235] Melting point: 104° C.-107° C.
Example 59
[0236]
3-(4′-Methylbiphenyl-3-yl)-8-propoxy-1H-quinolin-4-one
Pale-Orange Powder
[0237] Melting point: 189° C.-193° C.
Example 60
[0238]
3-Benzo[1,3]dioxol-5-yl-5-methyl-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0239] Melting point: 110° C.-115° C.
Example 61
[0240]
5-Methyl-8-propoxy-3-thiophen-2-yl-1H-quinolin-4-one
Light-Green Powder
[0241] Melting point: 104° C.-105° C.
Example 62
[0242]
5-Methyl-3-(1-methyl-1H-indol-3-yl)-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0243] Melting point: 106° C.-109° C.
Example 63
[0244]
3-Benzo[b]thiophen-3-yl-5-methyl-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0245] Melting point: 80° C.-82° C.
Example 64
[0246]
5-Methoxymethyl-3-(4-methoxyphenyl)-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0247] Melting point: 81° C.-83° C.
Example 65
[0248]
5-Cyclopropyl-3-(4-methoxyphenyl)-8-propoxy-1H-quinolin-4-one
White Powder
[0249] Melting point: 168° C.-170° C.
Example 66
[0250]
5-Methyl-3-(3-methylbenzo[b]thiophen-2-yl)-8-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0251] Melting point: 90° C.-92° C.
Example 67
[0252]
8-Imidazol-1-yl-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
Pale-Yellow Powder
[0253] Melting point: 196° C.-198° C.
Example 68
[0254]
3-(4-Methoxyphenyl)-5-methyl-8-pyrrolidin-1-yl-1H-quinolin-4-one
Pale-Yellow Powder
[0255] Melting point: 177° C.-178° C.
Example 69
[0256]
8-Cyclopropylmethoxy-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
White Powder
[0257] Melting point: 182° C.-183° C.
Example 70
[0258]
3-(4-Methoxyphenyl)-5-methyl-8-propylsulfanyl-1H-quinolin-4-one
Pale-Yellow Powder
[0259] Melting point: 132° C.-135° C.
Example 71
[0260]
8-(2-Ethylimidazol-1-yl)-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
Pale-Yellow Powder
[0261] Melting point: 258° C.-260° C.
Example 72
[0262]
3-(4-Methoxyphenyl)-5-methyl-8-(methyl-propyl-amino)-1H-quinolin-4-one
White Powder
[0263] Melting point: 159° C.-161° C.
Example 73
[0264]
3-(4-Methoxyphenyl)-5-methyl-8-morpholin-4-yl-1H-quinolin-4-one
Pale-Brown Powder
[0265] Melting point: 260° C.-263° C.
Example 74
[0266]
3-(4-Hydroxyphenyl)-5-methyl-8-propoxy-1H-quinolin-4-one
White Powder
[0267] Melting point: 265° C.-267° C.
Example 75
[0268]
8-Hydroxy-3-(4-hydroxyphenyl)-5-methyl-1H-quinolin-4-one
Pale-Yellow Powder
[0269] Melting point: 270° C.-275° C. (decomposition)
Example 76
[0270]
8-Butyl-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
Pale-Yellow Powder
[0271] Melting point: 186° C.-188° C.
Example 77
[0272]
3-(4-Methoxyphenyl)-5-methyl-8-(4-methylpiperazin-1-yl)-1H-quinolin-4-one
Pale-Brown Powder
[0273] Melting point: 214° C.-215° C.
Example 78
[0274]
3-(2-Ethoxy-4-methoxyphenyl)-5-methyl-8-propoxy-1H-quinolin-4-one
White Powder
[0275] Melting point: 191° C.-192° C.
Example 79
[0276]
8-Cyclopropylmethoxy-3-(2-fluoro-4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
White Powder
[0277] Melting point: 198° C.-199° C.
Example 80
[0278]
3-(4-Methoxyphenyl)-8-methyl-5-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0279] Melting point: 156° C.-158° C.
Example 81
[0280]
8-Chloro-3-(4-methoxyphenyl)-5-propoxy-1H-quinolin-4-one
Pale-Yellow Powder
[0281] Melting point: 145° C.-147° C.
Example 82
[0282]
8-Butyl-3-(4-methoxyphenyl)-4-oxo-1,4-dihydroquinolin-5-carboxylic acid dimethylamide
Pale-Yellow Powder
[0283] Melting point: 198° C.-200° C.
Example 83
[0284]
8-Cyclopropylmethoxy-3-(4-methoxyphenyl)-5,6-dimethyl-1H-quinolin-4-one
Pale-Brown Powder
[0285] Melting point: 99° C.-101° C.
Example 84
[0286]
8-Azepan-1-yl-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
Yellow Powder
[0287] Melting point: 249° C.-250° C.
Example 85
[0288]
6-Imidazol-1-yl-3-(4-methoxyphenyl)-8-propoxy-1H-quinolin-4-one
Pale-Brown Powder
[0289] Melting point: 236° C.-237° C.
Example 86
[0290]
8-Bromo-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
Pale-Yellow Powder
[0291] Melting point: 185° C.-186° C.
Example 87
[0292]
3-(4-Methoxyphenyl)-4-oxo-8-propoxy-1,4-dihydroquinolin-5-carboxylic acid dimethylamide
Pale-Gray Powder
[0293] Melting point: 218° C.-220° C.
Example 88
[0294]
8-Cyclopropylmethoxy-5-methoxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
Pale-Brown Powder
[0295] Melting point: 212° C.-214° C.
Example 89
[0296]
3-(4-Methoxyphenyl)-5-methyl-4-oxo-1,4-dihydroquinolin-8-carboxylic acid dimethylamide
Yellow Powder
[0297] Melting point: 158° C.-160° C.
Example 90
[0298]
3-(4-Methoxyphenyl)-5-methyl-8-(pyrrolidine-1-carbonyl)-1H-quinolin-4-one
Pale-Brown Powder
[0299] Melting point: 193° C.-195° C.
Example 91
[0300]
8-Cyclopentyloxy-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
Pale-Yellow Powder
[0301] Melting point: 237° C.-239° C.
Example 92
[0302]
1-Cyclopropylmethyl-3-(4-methoxyphenyl)-5-methyl-8-propoxy-1H-quinolin-4-one
White Powder
[0303] Melting point: 100° C.-101° C.
Example 93
[0304]
8-Cyclopentyloxy-5-methoxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
Yellow Green Powder
[0305] Melting point: 213° C.-215° C.
Example 94
[0306]
5,8-Diethoxy-3-(4-fluorophenyl)-1H-quinolin-4-one
Pale-Yellow Powder
[0307] Melting point: 232° C.-234° C.
Example 95
[0308]
5-Methyl-8-propoxy-3-pyridin-4-yl-1H-quinolin-4-one
Pale-Orange Powder
[0309] Melting point: 112° C.-113° C.
Example 96
[0310]
8-Furan-2-yl-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
Pale-Yellow Powder
[0311] Melting point: 129° C.-131° C.
Example 97
[0312]
3-(4-Methoxyphenyl)-5-methyl-8-thiophen-3-yl-1H-quinolin-4-one
White Powder
[0313] Melting point: 189° C.-190° C.
Example 98
[0314]
8-Benzo[b]thiophen-2-yl-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
White Powder
[0315] Melting point: 229° C.-231° C.
Example 99
[0316]
8-(N-Cyclohexyl-N-methylamino)-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
White Powder
[0317] Melting point: 186° C.-187° C.
Example 100
[0318]
3-(4-Methoxyphenyl)-5-methyl-8-thiophen-2-yl-1H-quinolin-4-one
Orange Powder
[0319] Melting point: 197° C.-199° C.
Example 101
[0320]
8-[(2-Methoxyethyl)methyl-amino]-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one hydrochloride
Pale-Yellow Powder
[0321] Melting point: 90° C.-93° C.
Example 102
[0322]
8-(N-Isobutyl-N-methyl-amino)-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
White Powder
[0323] Melting point: 111° C.-113° C.
Example 103
[0324]
8-(N-Isopropyl-N-methylamino)-3-(4-methoxyphenyl)-5-methyl-1H-quinolin-4-one
White Powder
[0325] Melting point: 186° C.-187° C.
Example 104
[0326]
8-Cyclopentyloxy-3-(2,4-dichlorophenyl)-5-methoxy-1H-quinolin-4-one
White Powder
[0327] Melting point: 266° C.-268° C.
Example 105
[0328]
8-Cyclopropylmethoxy-3-(2,4-dichlorophenyl)-5-methoxy-1H-quinolin-4-one
Pale-Brown Powder
[0329] Melting point: 254° C.-256° C.
Example 106
[0330]
8-Cyclopentyloxy-3-(2,4-dichlorophenyl)-5-hydroxy-1H-quinolin-4-one
Yellow Powder
[0331] Melting point: 154° C.-155° C.
Example 107
[0332]
8-Cyclopropylmethoxy-3-(2,4-dichlorophenyl)-5-hydroxy-1H-quinolin-4-one
Yellow Powder
[0333] Melting point: 163° C.-165° C.
Example 108
[0334]
8-Cyclopentyloxy-5-ethoxy-3-(4-methoxyphenyl)-1H-quinolin-4-one
Pale-Yellow Powder
[0335] Melting point: 204° C.-206° C.
Example 109
[0336]
8-Cyclopropylmethoxy-3-furan-2-yl-5-methoxy-2-methyl-1H-quinolin-4-one
Pale-Yellow Powder
[0337] Melting point: 189° C.-190° C.
Pharmacological Test 1
Evaluation of improvement of mitochondrial function using human neuroblastoma cell lines SH-SY5Y treated with 1-methyl-4-phenylpyridinium (MPP′)
[0338] In human neuroblastoma cell lines SH-SY5Y in which mitochondrial function was damaged by MPP + treatment (Bollimuntha S. et al., J Biol Chem, 280, 2132-2140 (2005) and Shang T. et al., J Biol Chem, 280, 34644-34653 (2005)), the improvement of mitochondrial function was evaluated on the basis of the measurement value for mitochondrial oxidation reduction activity using Alamar Blue fluorescent dye after the compound addition (Nakai M. et al, Exp Neurol, 179, 103-110 (2003)).
[0339] The human neuroblastoma cell lines SH-SY5Y were cultured in Dulbecco's Modified Eagle's Medium containing 10% fetal bovine serum (DMEM containing 50 units/ml penicillin and 50 μg/ml streptomycin as antibiotics) at 37° C. in the presence of 5% carbon dioxide. Cells were scattered on a poly-D-lysine-coated 96-well black plate at a concentration of 3−6×10 4 cells/cm 2 (medium amount: 100 μl/well) and cultured in the medium for two days. Further, the medium was changed to DMEM containing a 1% N2 supplement (N2-DMEM) or to a medium (100 μl/well) in which 1.5 mM MPP + was dissolved. The cells were cultured therein for 39 to 48 hours, and then subjected to a mitochondrial oxidation reduction activity measurement system. A sample compound that had been previously dissolved in dimethyl sulfoxide (DMSO) was diluted with N2-DMEM and added in a volume of 10 μl/well 24 hours before the activity measurement (final compound concentration: 0.01 to 1 μg/ml).
[0340] After removal of the medium by suction, a balanced salt solution containing 10% Alamar Blue (154 mM sodium chloride, 5.6 mM potassium chloride, 2.3 mM calcium chloride, 1.0 mM magnesium chloride, 3.6 mM sodium hydrogen carbonate, 5 mM glucose, 5 mM HEPES, pH 7.2) was added in a volume of 100 μl/well, and reacted in an incubator at 37° C. for 1 hour. The fluorescent intensity was detected using a fluorescence detector (a product of Hamamatsu Photonics K.K., excitation wavelength: 530 nm, measurement wavelength: 580 nm) to thereby measure the mitochondrial oxidation reduction activity.
[0341] The fluorescent intensity of the well of the cells cultured in a medium containing MPP + and each of the sample compounds was relatively evaluated based on the 100% fluorescent intensity of the well of the cells cultured in a medium containing DMSO alone (final concentration: 0.1%). When the MPP + -induced cell group exhibited higher florescent intensity than the cell group cultured in DMSO alone, the test compound was judged to have improved the mitochondrial function.
[0000]
TABLE 1
Improvement of mitochondrial function using human neuroblastoma
cell lines SH-SY5Y treated with 1-methyl-4-phenylpyridinium (MPP + )
Fluorescence Intensity (%)
Concentration (μg/ml)
Test Compound
0
0.01
0.03
0.1
0.3
1
Compound of Example 1
51
58
68
73
66
46
Compound of Example 2
54
71
73
74
77
81
Compound of Example 3
49
68
77
77
83
67
Compound of Example 13
48
56
65
74
69
62
Compound of Example 18
28
29
45
44
47
30
Compound of Example 20
52
65
67
74
78
77
Compound of Example 21
54
65
68
77
82
84
Compound of Example 23
44
51
63
67
68
59
Compound of Example 24
42
50
57
64
63
36
Compound of Example 32
45
49
53
54
57
61
Compound of Example 34
42
47
53
53
63
53
Compound of Example 37
43
47
54
55
60
59
Compound of Example 38
39
47
54
67
75
65
Compound of Example 51
34
37
45
54
65
49
Compound of Example 58
39
42
53
60
61
55
Compound of Example 60
48
52
65
75
70
44
Compound of Example 63
33
40
48
57
43
21
Compound of Example 64
44
51
56
63
53
38
Compound of Example 65
45
59
73
78
66
20
Compound of Example 67
40
45
54
61
57
42
Compound of Example 68
42
49
56
62
57
33
Compound of Example 70
42
48
56
61
50
22
Compound of Example 82
53
63
62
62
69
81
Compound of Example 83
54
65
70
67
62
29
Compound of Example 86
53
60
65
65
65
52
Compound of Example 87
55
57
57
60
65
66
Compound of Example 95
46
51
56
57
61
47
Compound of Example 96
51
54
64
68
60
23
Compound of Example 109
47
49
62
65
82
73
Pharmacological Test 2
Evaluation of dopaminergic neuronal protective activity using C57BL/6 mouse treated with 1-methyl-4-phenyl1,2,3,6-tetrahydro pyridine (MPTP)
[0342] Using a mouse having MPTP-induced dopaminergic neurons (Chan P. et al., J Neurochem, 57, 348-351 (1991)), the dopaminergic neuronal protective activity was evaluated based on the protein levels of tyrosine hydroxylase (TH) and dopamine transporter (DAT), which are dopaminergic neuronal marker proteins, and a dopamine content in the brain corpus striatum region after the compound administration (Mori A. et al., Neurosci Res, 51, 265-274 (2005)).
[0343] A male C57BL/6 mouse (provided by Japan Charles River Inc., 10 to 12 weeks) was used as a test animal. MPTP was dissolved in a physiological salt solution so that the concentration was 4 mg/ml, and then administered to the mouse subcutaneously in a volume of 10 ml/kg. A test compound was suspended in a 5% gum arabic/physiological salt solution (w/v) so that the concentration was 1 mg/ml. Each of the test compounds or solvents thereof was orally administered to the mouse after 30 minutes, 24 hours, and 48 hours of the MPTP administration. The mouse was decapitated after 72 hours of the MPTP administration, the brain was removed, and each side of the striatum was dissected.
[0344] The left striatum was used as a sample to detect the protein level by Western blot analysis. Each tissue was homogenized in a HEPES buffer sucrose solution (0.32 M sucrose, 4 μg/ml pepstatin, 5 μg/ml aprotinin, 20 μg/ml trypsin inhibitor, 4 μg/ml leupeptin, 0.2 mM phenylmethanesulfonyl fluoride, 2 mM ethylenediaminetetraacetic acid (EDTA), 2 mM ethylene glycol bis(β aminoethyl ether) tetraacetic acid, 20 mM HEPES, pH 7.2), and assayed for protein using a bicinchoninic acid kit for protein assay (provided by Pierce Corporation). Each homogenized sample, having an equal amount of protein that had been dissolved in a Laemmli sample buffer solution, was subjected to electrophoresis through a sodium dodecyl sulfate polyacrylamide gel. The protein separated by electrophoresis was electrically transferred to polyvinylidene fluoride membrane. The membrane was reacted with a specific primary antibody for TH, DAT, and housekeeping proteins, i.e., α1 subunit of Na + /K + -ATPase and actin (Na + /K + -ATPase is a product of UpState Biotechnology Inc.; others are products of Chemi-Con Corporation). Subsequently, a horseradish peroxidase-labeled secondary antibody (a product of Amersham K.K.) for each primary antibody was fixed, and the chemiluminescence associated with enzyme activity of peroxidase was detected using a X-ray film. The density of the protein band on the film was analyzed using a densitometer (a product of Bio-rad Laboratories Inc.) to obtain the TH value relative to Na + /K + -ATPase and the DAT value relative to actin.
[0345] The right striatum, the tissue weight of which was measured immediately after dissection, was used as an analysis sample for determining the dopamine content. Each tissue was homogenized in a 0.1 N perchloric acid solution containing isoproterenol as an internal standard substance of the measurement, using an ultrasonic homogenizer while being cooled with ice. The supernatant obtained from 20,000 g of homogenate that had been centrifuged at 4° C. for 15 minutes was subjected to a high-performance liquid chromatography with a reversed phase column (a product of Eicom Corporation). A mobile phase 15% methanol 0.1 M citric acid/0.1 M sodium acetate buffer solution (containing 190 mg/L 1-sodium octane sulfonate and 5 mg/L EDTA, pH 3.5) was flowed at a rate of 0.5 ml/min, and the dopamine peak of each sample was detected using an electrochemical detector (applied voltage: +750 mV vs. Ag/AgCl, a product of Eicom Corporation). With reference to the identified dopamine peak, the dopamine content per tissue weight was calculated in each sample using analysis software (a product of Gilson Inc.).
[0346] In both analyses, the value of the sample derived from the MPTP-induced mouse in which only the test compound or the solvent was administered was expressed relative to the value of the sample derived from the mouse without MPTP treatment (100%). Values were analyzed statistically using a nonclinical statistical analysis system, and values of significance probability less than 0.05 were defined as significant. In the MPTP-induced mouse, when the test drug group showed an increase in protein level compared to the solvent group, and a significant difference was observed between these groups in the t-assay, the test drug was judged to have dopamine neuroprotective activity.
[0000]
TABLE 2
Protein level of tyrosine hydroxylase (TH) in
the brain corpus striatum region (% of control)
Test Compound
(% of Control)
Dosage
0 mg/kg
10 mg/kg
Compound of Example 1
51.6
86.2
Compound of Example 65
50.2
65.2
Compound of Example 67
57.7
77.9
Compound of Example 70
49.5
90.2
[0000]
TABLE 3
Protein level of dopamine transporter (DAT) in
the brain corpus striatum region (% of control)
Test Compound
(% of Control)
Dosage
0 mg/kg
10 mg/kg
Compound of Example 1
29.5
84.7
Compound of Example 65
43.1
73.0
Compound of Example 67
38.4
50.9
Compound of Example 70
39.6
64.1
[0000]
TABLE 4
Dopamine content in the brain corpus
striatum region (% of control)
Test Compound
(% of Control)
Dosage
0 mg/kg
10 mg/kg
Compound of Example 1
4.8
39.6
Compound of Example 65
4.0
31.2
Compound of Example 67
12.0
26.7
Compound of Example 70
8.9
26.5
|
The present invention provides a pharmaceutical agent that inhibits the chronic progression of Parkinson's disease or protects dopamine neurons from disease etiology, thereby suppressing the progression of neurological dysfunction, so as to prolong the period of time until L-dopa is administered while also improving neuronal function; the pharmaceutical agent of the invention comprising as an active ingredient a quinolone compound represented by Formula (1):
or a salt thereof, wherein:
R 1 represents hydrogen or the like; R 2 represents hydrogen or the like; R 3 represents substituted or unsubstituted phenyl or the like; R 4 represents hydrogen or the like; R 5 represents hydrogen or the like; R 6 represents hydrogen or the like; and R 7 represents hydroxy or the like.
| 2
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BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for detecting and regulating a focused condition of an electron beam emitted from an electron gun of an electron beam welding apparatus and directed onto a workpiece, and, more particularly, to a method and apparatus for detecting and regulating a focus point on the workpiece prior to commencing a welding operation.
It has been usual that the focusing of an electron beam is detected and regulated by directing an electron beam onto a dummy block of a material such as tungsten or copper and regulating the current flowing through an electromagnetic lens coil while observing the spot of the electron beam or a melt pond on the surface of the workpiece or the dummy block. Such a conventional method is disadvantageous in that the detection and regulation of the electron beam depend upon the operator's eyes.
Particularly, in an actual welding operation, the focus position of the electron beam on the workpiece affects the profile of the weld portion. FIGS. 1A through 3A illustrate the focus position of electron beams and FIGS. 1B through 3B corresponding profiles of weld portions.
In FIGS. 1A and 1B, when the electron beam EB is focused exactly on the surface of the worpiece WK, the welding is made to a certain depth with a small diameter. On the other hand, when the focus point is inside the workpiece WK, as shown in FIGS. 2A and 2B, the welding depth becomes much smaller than in the case shown in FIGS. 1A and 1B, but with a larger diameter. If the focus point is above the workpiece surface, as shown in FIGS. 3A and 3B, the weld profile becomes similar to a shape of a short and thick nail. The weld profiles shown in FIGS. 2B and 3B are not acceptable.
In order to resolve this problem, Japanese Laid-Open Patent Application No. 48-339 proposes a technique according to which light produced by an electron beam and reflected from the portion of a surface of a workpiece onto which the electron beam is directed is sensed by an indicator and focusing regulation is performed accordingly. This technique is more effective than visual observance of the melt pond. However, the energy of the electron beam used for regulation is much smaller than that of the electron beam used to weld the workpiece, and thus it is necessary to increase the electron beam energy after regulation has been completed. Moreover, possible variation of the focusing position due to an increase of the electron beam energy is not taken into account. Further, although the precision of the focusing position regulation may be higher than that obtainable by visual observance, the technique is still disadvantageous since the precision depends on the skill of the operator. Eggers et al. propose in their article "Automatic Focusing in High Power Electron Beam Welding", IIW-Doc. No. IV/57/71, April 1971, a technique in which electrons emitted from a workpiece irradiated with an electron beam is utilized to detect the focus position while the focus position is changed. A pair of electron collectors are used to detect the focus position. Since this technique uses the welding beam directly, it is necessary to use complicated electronics circuits in order to avoid undesirable welding conditions.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method and apparatus for detecting and regulating a focusing position of an electron beam on a workpiece precisely without the accuracy being affected by the skill of the operator.
Another object of the prevent invention is to provide a method and apparatus for automatically detecting and regulating the focusing position of an electron beam precisely within a short period of time.
These and other objects are achieved, according to the present invention, by moving a focusing position of a pilot electron beam by changing an electric current flowing through an electromagnetic condenser lens while irradiating a workpiece with the pilot electron beam, detecting either electrons or other radiation emitted from the workpiece due to the pilot electron beam irradiation thereof, and detecting the focusing position of the pilot beam on the basis of the detected electrons or other radiation. According to this method, compensation for variation of the focusing position due to a difference in energy between the pilot electron beam and the actual electron beam is performed by using predetermined correction data. According to another aspect of the present invention, the electrons or other radiation produced from the workpiece are detected by a collector composed of a plurality of segments each maintained at a different potential, and signals from the segments are used to focus the electron beam on the workpiece surface such that the diameter of the electron beam spot on the workpiece surface is minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A to 3B illustrate relations between focusing positions of an electron beam on a workpiece and pond profiles of a portion of the workpiece welded by the electron beam;
FIG. 4 is a block diagram showing an embodiment of a device for practicing the present invention;
FIG. 5 illustrates the generation of secondary electrons and X-rays on the workpiece surface as a result of irradiation thereof with the electron beam;
FIG. 6 shows an example of coil current variation of an electromagnetic condenser lens due to focusing position regulation;
FIG. 7 shows an example of variation of the secondary electron beam intensity;
FIG. 8 shows an example of the relation between the electron beam current and the coil current of a condenser lens;
FIG. 9 shows an example of the relation between the electron beam current and focal length;
FIG. 10 shows an example of variation of the X-ray intensity;
FIG. 11 shows another example of variation of the X-ray intensity;
FIG. 12 illustrates an electron collector;
FIG. 13 is a graph showing a relation of the electron collector potential and the detected radiation of an electron beam from the workpiece;
FIG. 14 is a graph showing energy distributions of various electrons emitted from the workpiece;
FIG. 15 is a graph similar to that of FIG. 7, showing another example of a local peak configuration; and
FIG. 16 shows another embodiment of an electron collector.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 4 and 5, a pilot electron beam EB emitted from an electron gun 10 is directed to a workpiece WK. In the path of the electron beam EB, an electromagnetic condenser lens and an electron collector 14 are provided. The condenser lens 12 is composed of a coil with which the degree of condensing of the electron beam is regulated by controlling a current flowing through the coil. In this embodiment, the current in the lens coil is varied with time as shown in FIG. 6. The current variation is set such that the electron beam EB is focused on the workpiece WK in a working chamber (not shown) regardless of the position thereof in the chamber. The focusing position regulation is performed with an electron beam having an energy smaller than that necessary to do work, namely, to perform an actual welding operation.
An electron collector 14 detects the reflected electron beam, and an X-ray sensor 16 is disposed in the vicinity of the focus point of the electron beam EB on the workpiece WK to detect X-rays emitted therefrom. Either of the electron collector 14 or X-ray sensor 16 may be omitted if desired.
A collector power source 18 is connected between the electron collector 14 and the workpiece WK. The collector power source 18 is adapted to apply a potential to the electron collector 14 which is positive or negative with respect to the potential of the workpiece WK. When the workpiece WK is irradiated with the electron beam EB, a radiation electron beam (RB) and X-rays (RX) are produced therefrom. The radiation electron beam RB includes reflected electrons, secondary electrons and thermal electrons. The energies of these electrons are related as follows:
reflected electron energy>secondary electron energy
reflected electron energy>thermal electron energy
Therefore, if a negative potential is applied to the electron collector 14 by the collector power source 18, only the reflected electrons reach the electron collector 14, while if the potential of the electron collector 14 is positive, secondary electrons and thermal electrons reach the electron collector 14 in addition to the reflected electrons. The collector 14 and/or X-ray sensor 16 provide electric signals indicative of the presence of the radiation electron beam RB and the X-ray beam RX thereat. These signals vary with the amount of displacement of the focusing point of the electron beam EB.
The electron collector 14 is connected to a waveform storing device 20 and the X-ray sensor 16 is connected through an amplifier 22 to the waveform storing device 20, which temporarily stores the waveforms of the signals supplied thereto. The amplifier 22 is used to amplify the output signal of the X-ray sensor 16.
The output of the waveform storing device 20 is connected to a computer processing unit 24, which analyzes the signal waveforms stored in the waveform storing device and provides a control signal according to correction data (described below) and a result of analysis.
The computer processing unit 24 is connected to a control device 26, which in turn is connected to the electron gun 10 and the condenser lens 12. The electron gun 10 and the condenser lens 12 are controlled by control signals derived from the computer processing unit 24 under the control of the control device 26.
In operation, when the focus position is being detected and regulated by the radiation electron beam RB, the electron collector 14 is used as a detector. The electron beam EB, at a reduced energy, is directed to the workpiece WK. Then, the current flowing through the condensing lens 12 is increased linearly as shown in FIG. 6.
A curve A in FIG. 7 shows the intensity of the radiation electron beam RB, i.e., the magnitude of the output of the electron collector 14, when the current in the condenser lens 12 is increased as shown in FIG. 6, with the potential of the collector 14 being positive with respect to the workpiece WK, and a curve B shows the same with the potential being negative.
As discussed above, all of the reflected electrons, secondary electrons and thermal electrons are received by the electron collector 14 when the potential thereof is positive. In this case, when the beam RB is focused on the surface of the workpiece WK, if the condenser lens coil current is increased linearly, the temperature of the latter will increase, and therefore the rate of thermal electron production increases. Thus, the radiation electron beam intensity is increased locally, as shown by the curve A in FIG. 7. The value i of the condenser lens current at the time t at which the peak intensity is obtained corresponds to the focused position, as shown in FIG. 6.
When the potential of the electron collector 14 is negative, only reflected electrons reach the electron collector 14. In this case, the diameter of the electron beam spot on the surface of the workpiece WK decreases with an increase of the condenser lens coil current, becoming a minimum at the time t, after which it decreases with a further increase of the current. That is, the electron beam is focused on the workpiece surface at which the beam density becomes high enough to melt and evaporate the focused portion of the surface, thus lowering the actual surface level of that portion which causes the radiation electron intensity to be reduced locally, as shown by the curve B in FIG. 7. The current i flowing through the condenser lens 12 at the time t of the local reduction of the radiation electron beam strength in FIG. 6 corresponds to the focus position.
The output waveforms of the electron collector 14 shown by the curves A and B in FIG. 7 are stored temporarily in the waveform storing device 20.
The computer processing unit 24 stores correction curves, one of which is shown in FIG. 8, one of which is shown in FIG. 9, and provides a control signal in accordance with data obtained from these correction curves, which is sent to the control device 26.
In a case where control is performed on the basis of the correction data obtained from FIG. 8, which is a curve from among a set of curves each indicating the coil current of the condenser lens 12 for a fixed focus position while the electron beam current is varied, the data includes a plurality of correction curves each for various distances (work distances) between the condenser lens 12 and the workpiece WK.
In the computer processing unit 24, the time t at which the waveforms stored in the waveform storing unit 20 show a local value (FIG. 7) is obtained, and then the current of the condenser lens coil corresponding to the time t is obtained from FIG. 6. Thereafter, one of the correction curves corresponding to a specific work distance is selected in the processing unit 24. For example, when the current of the condenser lens coil obtained in the processing unit 24 is IC1 and the electron beam current is IE1, the correction curve to be selected is as shown in FIG. 8. That is, the correction curve corresponding to a specific selected work distance is one which passes through a point of intersection of the current of the condenser lens coil and the electron beam current IE1.
Using the correction curve selected as above, the current IC2 of the condenser lens 12 corresponding to the work current IE2 of the electron beam EB can be obtained as shown in FIG. 8. According to these data values, a control signal is produced and sent to the control device 26 which controls the electron gun 10 and the condenser lens 12 so that the electron beam current is set at IE2 and the current of the condenser lens 12 is again regulated to IC2.
When control is to be performed on the basis of the correction data obtained from FIG. 9, which is a curve among a set of curves indicating the relation of the focal distance to the electron beam current, the computer processing unit 24 determines the current of the coil of the condenser lens 12 when the focus is regulated in the same manner as mentioned before. Then, the correction curve shown in FIG. 9 is selected corresponding to the current value of the coil of the condenser lens 12. In this regard, if the electron beam current during the focus regulation operation is IE3, the position of the workpiece WK, and hence the focal distance during the focus regulation operation, is LF1. From this, the focal distance LF2 corresponding to the electron beam work current IE4 during machining operations can be obtained. The control signal is prepared in response to these data values, i.e., LF1, LF2, IE4, and sent to the control device 26. The control device 26, in response to the control signal, controls the electron gun 10 and a table (not shown) on which the workpiece WK is mounted. That is, the control device 26 controls the electron gun 10 such that the electron beam current becomes IE4 and the table such that the focal distance is changed from LF1 to LF2.
As is clear from the foregoing, when the correction data is obtained from the correction curves in FIG. 8, the current of the coil of the condenser lens 12 is regulated while the position of the workpiece WK is unchanged. On the contrary, when the correction data is obtained from the correction curves in FIG. 9, the position of the workpiece WK is regulated while the current of the coil of the condenser lens 12 is unchanged.
In a case where the detection and regulation of the focus position is performed with X-rays (RX), the X-ray sensor 16 is used. In this case, the workpiece WK is irradiated with an electron beam as in the previous case. Then, the current of the coil of the condenser lens 12 is changed as shown in FIG. 6. The resulting variation of the X-ray intensity, i.e., the output of the X-ray sensor 16, is shown in FIG. 10, which corresponds to the curve B in FIG. 7 when the electron collector 14 is at a negative potential. That is, when the electron beam EB is focused on the surface of the workpiece WK, the electron beam density is increased and a minute portion thereof is melted and evaporated, causing the actual surface level of that portion of the workpiece WK to be lowered. Thus, the intensity of X-rays therefrom is locally decreased.
The signal shown in FIG. 10 is amplified by the amplifier 22 and stored in the waveform storage device 20. Subsequent operations are the same as those described with respect to the previous embodiments.
In some of the above-described embodiments, focus regulation is performed by irradiating the workpiece directly with an electron beam. However, it is also possible to use a suitable member positioned on the workpiece and irradiate it with an electron beam. The latter case may be beneficial when small defects on the workpiece surface should be avoided.
According to the present invention, it is possible to detect the focus position exactly and to regulate it with high precision, independent of the skill of the operator. Further, since the variation of the focus position resulting from the difference in beam current between the focus detection period and the actual working period is corrected on the basis of the preliminarily obtained correction data, the time period required to regulate the focus position is shortened, and it is possible to perform focus position regulation automatically.
FIG. 11 shows another embodiment of the present invention, which differs from the embodiment of FIG. 4 in that the current waveform of the condenser lens 12 and the output waveform of the electron collector 14 are stored temporarily in the waveform storing device 20, in that there is no control device 26, and in that the electron collector 14 is constituted with a pair of coaxially arranged members A and B, as shown in FIG. 12. A power source 18 connected between the coaxial members A and B and the workpiece WK provides a potential difference therebetween.
FIG. 13 shows the relation between the potential of the electron collector 14 and the intensity of the electron beam RB detected thereby, in which the electron intensity is abruptly changed at around the zero point of the potential. The latter change depends upon the energy distribution of the three electron beams, as shown in FIG. 14.
In FIG. 14, the energy distributions A, B and C correspond to thermal electrons, secondary electrons and reflected electrons, respectively. As can be readily understood therefrom, only the reflected high energy electrons of the radiated electron beam RB reach one of the members of the collector 14 to which a negative potential is applied. The other member, to which a positive potential is applied, receives secondary electrons and thermal electrons, which are of low energy. The electron collector 14 provides an electric signal corresponding thereto. Therefore, the output signal from the electron collector 14 varies with the focussing condition of the electron beam EB.
In operation, the electron beam EB is directed to the workpiece WK, and then the current of the coil of the condenser lens 12 is increased, as shown in FIG. 6. In this case, the spot diameter of the electron beam EB on the workpiece WK decreases with time to a minimum value at which the beam EB is focussed on the surface and then increases. At the time at which the spot diameter of the beam EB becomes minimum, the portion of the workpiece surface on which the beam falls is melted and evaporated and the output of the electron collector 14 becomes as shown in FIG. 7, as mentioned previously.
When the current value of the electron beam EB for the focussing detection is small, the amount of the workpiece portion which is melted and evaporated thereby is small. Also, the variation of the signal produced by the reflected electron beam is small, and thus it becomes difficult to detect focussing by means of the peak value of the curve B in FIG. 7. Moreover, if the beam caused by the thermal electrons is broadened, it is difficult to detect focussing exactly.
According to this embodiment, the output signals from the members of the electron collector 14 are stored in the waveform storage device 20 together with the current curve of the coil of the condenser lens 12. The computer processing unit 24 processes this stored data to determine the condenser lens coil current value at which the electron beam EB is focussed on the workpiece WK. This arrangement is also effective when the peaks are not simple in waveform as shown in FIG. 7 but relatively complex such as shown in FIG. 15.
The electron collector 14 is shown in FIG. 12 as being constituted with two coaxially arranged members A and B. As an alternative, the members of the coaxial members may be three or more with different potentials being applied thereto. Alternatively, the electron collector 14 may take the form of a plurality of sectors, as shown FIG. 16. With this electron collector, various kinds of electrons emitted from the workpiece can be collected separately.
The current of the coil of the condenser lens 12 may be reduced differently from that shown in FIG. 6, so long as it is done linearly.
|
A method and apparatus for detecting and regulating a focused condition of an electron beam emitted from an electron gun of an electron beam welding apparatus. An electron beam of a low intensity is first directed onto the workpiece. The coil current of an electromagnetic condenser lens used to focus the electron beam is then varied linearly. The resulting electrons and other radiation produced from the workpiece as a result of this irradiation is then sensed and a signal corresponding to the intensity thereof is produced. The focus position of the electron beam is determined in accordance with variations in this signal.
| 1
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